An introduction of early 3D printing technologies.

1. History of early 3D printing
technologies

2. Stereolithography
Charles Hull invented
Stereolithography. He later
funded 3D Systems in 1986/
1983
Selective Laser Sintering
Carl Deckard, who was
working at the University of
Texas, filed a patent in the US
for the Selective Laser
Sintering (SLS) RP process. He
co-founded Desk Top
Manufacturing (DTM) Corp. in
1987 which was acquired by
3D systems in 2001.
1987
The early stages of the SLS
machine, Betsy
Carl Deckard The intermediate parts that
Deckard created with Betsy
Charles W. Hull Charles Hull demonstrates
Stereolithography

3. Fused Deposition Modeling
Scott Crump invents Fused
Deposition Modeling (FDM)
FDM. He later co-funded
Stratasys in 1989.
1988
MIT developed Three Dimensional
Printing process (3DP). 3DP
involves spreading a thin layer of
powdered material (originally
ceramic) on a flat bed, solidifying
successive layers with fine jets of
binding agent. Z Corporation
obtained an exclusive license from
MIT in 1995 and was later acquired
by 2012.
MIT Alpha Machine Printed part emerging from powder
1992
S. Scott Crump
FDM Patent Document
Three Dimensional Printing process

4. Categories of Additive Manufacturing
American Society for Testing and Materials (ASTM) group “ASTM
F42 – Additive Manufacturing” classified the range of Additive
Manufacturing processes into 7 categories in 2012
• Material Extrusion
• Vat Photopolymerization
• Sheet Lamination
• Material Jetting
• Binder Jetting
• Powder Bed Fusion
• Direct Energy Deposition

5. Material Extrusion
• Process Characteristics
• A heated thermoplastic
filament is extruded from a
capillary die
• Thin layers are formed
between the die face and
previous layer(s)
• Parts chamber is heated to
minimize stresses and
deformation

6. • Process Characteristics
• Build platform is submersed in
liquid photopolymer
• Surface polymer is cured using an
UV laser to create each layer
• Part built between the previous
layer and the surface of the
photopolymer
• Plate descends into the vat of
polymer to create each new layer
• Parts are then rinsed in solvent
and cured in an UV oven.
Vat Photopolymerization

7. Sheet Lamination
• Process Characteristics
• Laser cuts thin sheets of
material into desired cross-
sections
• Process is tuned to precisely
cut to sheet thickness
• Material is thermally fused to
the previous layer using a
heated roller
• Diced material is removed to
uncover completed parts

8. Material Jetting
• Process Characteristics
• Array of inkjet print heads to
deposit build and support
material to form each layer
• Material is cured by a UV
lamp after each layer is
deposited

9. Binder Jetting
• Process Characteristics
• Liquid bonding agent is
selectively deposited through
inkjet print head to join
powder material in powder
bed
• The difference to Material
jetting is the dispensed
material is not build material

10. Powder Bed Fusion
• Process Characteristics
• PBF includes
Direct metal laser sintering (DMLS)
Electron beam melting (EBM)
Selective laser melting (SLM)
Selective laser sintering (SLS)
• A thin layer of material is
spread over the build platform
• Energy source fuses the layer
or the cross section of the
model
• Further layers or cross sections
are fused and added

11. Direct Energy Deposition
• Process Characteristics
• A nozzle delivers metal
powder or wire on a surface
• Energy sources (Laser,
Electron beam, Plasma) melt
the material to build a solid
object
• Can form multi-material
parts and graded material
interfaces by varying powder
composition

12. Technologies
Plastic
Vat
Polymerization
Material
Jetting
Binder Jetting
Material
Extrusion
Direct Energy
Deposition
Power Bed
Fusion
Sheet
Lamination
Ceramic
Metal
Wax
Material Selection
Materials

13. 0.0
200.0
400.0
600.0
800.0
1,000.0
1,200.0
1,400.0
1,600.0
1,800.0
2,000.0
2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023
Millions
SUMMARY FORECAST FOR THE 3DP
AUTOMOTIVE INDUSTRY
Source: SmarTech’s Annual Market Findings
The automotive industry’s adoption of 3D printing is projected to increase
from $365.4M in 2015 to $1.8B in 2023, attaining a 19.51% CAGR
3D Printing Automotive Market

14. Automotive Industry Application
• Accelerating the product design phase of new product
development
• Customized fabrication of jig and fixture

15. • Complex structure designs that drive weight reduction and
fuel efficiency
Automotive Industry Application
Titanium F1 gearbox by CRP Group using
rapid casting
A F1 car safety hoop/air intake produced in
titanium using 3D printing – saving 2kg of weight
Energy absorption with 3D printed structure

16. Automotive Industry Application

17. 0.0
500.0
1,000.0
1,500.0
2,000.0
2,500.0
3,000.0
3,500.0
4,000.0
2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023
Millions
SUMMARY FORECAST FOR THE 3DP
AEROSPACE INDUSTRY
Source: SmarTech’s Annual Market Findings
3D Printing Aerospace Market
The aerospace industry’s adoption of 3D printing solutions is projected to
increase from $723M in 2015 to $3.45B in 2023, attaining an 18.97% CAGR

18. GE additively manufactured single part fuel nozzles, which were formerly
composed of 20 different parts. Used in GE’s LEAP engines, these nozzles
are five times more durable than those produced with conventional
methods. It is also the first FAA approved 3D printed component in jet
engine.
Aerospace Industry Application

19. Aerospace Industry Application
Airbus Defense and Space 3D printed a space-qualified satellite
bracket. The team was able to transform a bracket made up of four
main parts and 44 rivets into a single, laser-melted piece that is 40%
stiffer and 35% lighter than its predecessor.

20. Aerospace Industry Application
SpaceX successfully printed and fired a SuperDraco engine chamber using
Inconel, a high performance superalloy. The printed chamber resulted in a
order of magnitude reduction in lead-time – 3 Month from initial concept to
first hot fire.

21. NASA tested 3D printed rocket engine injector. Using traditional
manufacturing methods, 163 individual parts would be made and then
assembled. But with 3D printing technology, only two parts were required.
Aerospace Industry Application

22. Future of 3D Printing
Models
PrototypesMater Patterns
Plastic Aircraft Parts Consumer Products
Mold Inserts Medical Implants
Printing in
outer space
Custom
Prosthetics
Metal Aircraft
Parts
Batteries and
Electronics
Clothing Food Products
Living TissuesIntegrated
Electronics
Smart
Structures
Human Organ
Unimaginable
Applications
Source: WOHLERS ASSOCIATES

23. Future State of 3D Printing
Development
Source: CSC

24. Future State of 3D Printing
Source: Stratasys
Applications

25. Materials
Respondents were asked which materials they’d like
to see further developed for AM in the future. Metals is
the clear leader.
Processes
Current vs. anticipated future usage of several
AM processes among respondent companies.
Future State of 3D Printing
Source: Stratasys

26. Source: WOHLERS ASSOCIATES
Future 3D Printing Worldwide
Revenue