3D Printing Reduces Supply Chain Constraints
Technology Overview
What is it?
3D Printing is a proven technology that allows people and businesses the ability to create three-dimensional objects. They can do this by printing several layers over the top of each other to form physical objects. It is not a new technology, but one that has expanded into different methods based on varying materials and applications. 3D Printing has been widely used in prototyping space, however, it is quickly expanding in the pandemic world as a mitigation tool for constrained supply chains.
How does it work?
The majority of 3D Printing is done with plastics and metals because they are easy materials to work with. It allows printed creations to be detailed and produced in a short amount of time. To accomplish this, multiple layers of materials are adhered to each other by melting methods to create 3D shapes that can be used as parts and models. Some of the more advanced printers can now create thousands of micro layers which results in even more detailed products.
3D Printing has also advanced its capabilities to use much more complex materials. For example, bio-printing allows skin, bone and organ tissue to be printed using stem cells. Therefore, printed products can spread a wide range, from athletic cleats, jet engines and jewelry.
What are the features and benefits?
3D Printing has been widely leveraged across the automotive markets, for industrial products and often times in healthcare. 3D Printing is a great tool to create custom parts that result in quicker prototyping and development cycles. In current settings, many people and businesses leverage 3D Printing when work volumes are lower, for example, across 1 to 50 parts. However, there is unlocked potential in the ability to scale the capabilities. This has led to a handful of newer 3D Printing types in the manufacturing sector.
Stereolithography (SLA) is considered the original 3D printing process and it was used to create parts for the newer 3D Printing types. It has led to the development of at least five other plastic printing methods. It has also improved the process for working with metal materials. One newer type uses laser beams to adhere the metal pieces together which is called Direct Metal Laser Sintering (DMLS).
The end result of these new achievements is a much shorter value chain for businesses. 3D Printing, regardless of material, is usually only three steps. In comparison, manufacturing for standard products can be easily 8–10 steps with much longer lead times.
With 3D Printing, people and businesses can cast or mold the materials to create the usable material. Then the process can quickly start printing and adhering the materials together. Finally, the finishing cuts can be established, turning the finished good.
Who are the producers/developers of the technology?
An inventor named, Charles Hull, patented and commercialized 3D Printing back in the 1980’s. He engineered the idea of using a beam of light to activate liquid photopolymer into a solid form. This process was repeated to create physical objects used in direct manufacturing.
Today, the top company using 3D Printing is HP. Their CEO recently noted, “COVID-19 highlighted how 3D Printing has the potential of transforming the manufacturing industry as products are needed onsite in a critical timeframe”. It is important to note the top 3 companies using this technology all have revenues in the billions, so it is “big business”.
MIT has recently developed a 3D Printer that performs 10x faster than most commercial printers. It is capable of producing a product that usually takes one hour in a few minutes. In its current form, it only processes plastic materials. However, they are working to advance the high-speed printers ability to process composite materials and polymers that can be used to create furniture and other large items in minutes.
Technology in Context
What is the current and forecasted adoption/usage?
People and companies around the world have changed their 3D printing plans due to COVID-19. This technology was a critical driver in producing more PPE and ventilators when resources were scarce. 3D Printing was a great substitute for the broken supply chains. The value of 3D Printing at scale has been proven and the costs will continue to decrease as it becomes more mainstream.
3D Printing will permanently transform supply chains, accelerate creativity and design, realign ecosystems and progress values. People and companies will continue to look at cutting out the middleman as risk mitigation strategies for healthcare crises and economic and political volatility to name a few.
What are the opportunities for expanded or new usage?
The metal portion of printing has a lot of room to scale in the next ten years, and according to a McKinsey study, it will grow to over $10 billion dollars! It will improve the value chain and reduce lead times because it eliminates assembly steps and waste. It will allow people and companies the ability to be less dependent on overseas suppliers and other resources needed to complete the standard tooling processes. In addition, there seems to be no limit to what 3D Printing can produce as a finished product which leads the way for endless industry expansion.
What could be the potential magnitude of impact?
While the impact for the direct users of 3D Printing will be improved products in shorter time frames, there are in fact some impacts to small manufacturing businesses. For example, when goods can be produced in-house, it eliminates the business need for intermediate suppliers and wholesalers, along with manpower.
To put size in perspective, the manufacturing industry is worth over $12 trillion, globally. Small businesses that produce lower volume custom parts will need to find ways to adopt and retrain workers to maintain their financial health. Innovation is usually good, but the downfall of efficiency gains is that less people and companies are needed to do the same amount of work.
What are the essential requirements for successful implementation?
There are five main considerations for people and businesses to consider before incorporating 3D Printing.
- Budget
- Mechanical Requirements
- Cosmetic Appearance
- Material Selection
- Geometry
The answers to these five categories will help determine which type of 3D Printing is the best fit. Selecting the right process comes down to weighing the pros and cons. However, using 3D Printing at any point in product development will lessen design risk and improve quality of the final product. It really comes down to what needs to be produced and how many are needed.
Are there a few assumptions, uncertainties, or missing information to think about?
As with any technology, it is only a matter of time before a new technology is developed, making the old one obsolete. Since 3D Printing has been around for over 20 years, one needs to examine the risks for replacement if speed of adaption slows in the coming years.
The other thing to think about is if consumers will demand physical products. For example, with the gains in virtual environments, it may be possible virtual reality replaces some tangible goods. Think about how physical photo was replaced by the digital photo.
Ethics and Regulations
What are the associated risks relative to this technology?
It may become difficult to police the Intellectual Property (IP) issues created by 3D Printing. Businesses can recreate a physical product but it would be extremely challenging and costly to enforce it. Similar to the challenges faced with digital music, the designs could be pirated.
Another issue with 3D Printing includes product liability concerns. Think about a printed safety product, for example, a helmet. If someone has an accident and the helmet fails due to a printing defect, it would be hard to determine liability. For example, is the printer manufacture to blame or the owner of the helmet?
Furthermore, how far do the ethical bounds stretch? It would need to be determined if it is ethical to print human tissues and organs for the medical world. Also, is it alright to print firearms at home? Policing public safety could become a lot more challenging.
What are the potential unintended impacts?
If businesses do not operate their 3D Printers in the proper environments they can create somewhat harmful side effects. For example, if a plastic material is being used, the heating process can create very fine particles which are spread in the air. However, these concerns can be easily mitigated by their user through well-ventilated environments and using the lower temperature settings for the recommended ranges.
Are there relevant existing, proposed, or recommended regulations?
Today, 3D Printing is not heavily regulated. That could all change because the products created from this technology can span a wide range. As mentioned above, firearms can be printed and they can create real harm in society. It becomes challenging to regulate the creativity that can be used for better or worse.
Overall, the innovation and improved products are well worth the potential risk of 3D Printing being used in a less than desirable fashion. Legal systems may need some time to adopt to the speed of the technology, but they should be able to put control points in place over time.
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