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TECH: 3D Printers
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Many of us have spent time watching science fiction shows on TV such as Star Trek, where the advanced technology is far beyond ourcurrent capabilities. However, over the last few years have you begun to notice that these amazing technologies are fast becoming a reality? For instance, the iPad bears a striking resemblance in both design and utilisation to Star Trek's PADD (Personal Access Display Device) and Siri is evolving into something similar to the ship's computer. For now, warp drive and transporter technology eludes us, but replicator technology could be upon us very soon!

The 3D printer, whilst in its infancy, is basically a replicator, the device which creates food and objects from patterns/designs at the touch of a button on Star Trek. Obviously this technology could hold great value to our civilization as it is developed, but also could pose a very real threat to some industries. This article will discuss these issues after we learn a bit more about the technology.

 

History

For many, the patriarch of this technology is Charles W. Hull , the co-founder of 3D systems which is a major company in the rapid prototyping world. The process creates a prototype quickly and accurately, without worrying about mass production costs. With more than 60 industry related patents to his name, he coined the term "Stereolithography ". This is the process of printing thin layers on top of one another to build layer-by-layer an object from a 3D computer design. This utilises a computer driven machine squirting a molten plastic into place using a UV (ultraviolet) light, bonding the layers together.

As the technology became more plausible throughout the eighties the process became known as ‘additive manufacturing’, whereby the end product started as nothing and is created by adding matter to it, not taking material away. This is contrary to the way most manufacturing is done: a subtractive method is employed, whereby the end product is created by stripping/whittling away material from a larger whole. Subtractive manufacturing is historically the main manufacturing method as it offers greater accuracy and cost effectiveness than was previously possible – which could be described as additive (forging together metal, etc.). In fact, it was so prominent until Stereolithography was popularised that it was just known as "manufacturing". The term ‘subtractive manufacturing’ was created as a retronym to differentiate it from additive manufacturing.   

Now, 3D printing technology has become available to everyone. There is an extremely lively DIY community championing the open source nature of this technology. Many of the printers for sale, can self replicate their own components for creating another printer or replacement parts, should the printer malfunction. Your home PC controls the printer using open source software. This means it is free to use and you can freely utilize the code however you see fit, without fear of breach of copyright/patent law. This CAD (computer aided design) program creates the designs/patterns of the object you wish to print. The programme uses a 3D digital model, either downloaded or designed by yourself, which it slices horizontally into layers which are then printed.  These images are formatted as .STL files , named due to STereoLithography and also Standard Tessellation Language. 

The online community has created a database of objects for users to download to use or tweak. Databases like "Thingiverse " and "Cubify " offer free and paid for tutorials, designs and accessories to get you started.

 

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Basic Principles

Whilst the basic principles of 3D printing remain true for most machines, it's worth remembering that the devices vary greatly. Some machines print using molten plastic, as described earlier, some use paper (office paper or specialised with a laminate sprayed on afterwards) and some can even print metal. The basic principles of 3D printing comprise three key aspects :

Modelling/Designing - A design of the desired object must be created. This can be downloaded from a database as discussed earlier. These designs are known as "Open Source Hardware" as they can be used freely and the copyright is not enforced. If you have a background in CAD or animation you can use digital models created in 3D modelling software like "Blender" or "MAYA ", or other open source software freely available.

Printing - The printing process can take a few hours. Factors in the speed of printing include: machine quality, complexity of the model and size of the model. The printer guided by the CAD software uses coordinates to move a print-head and deposit layers upon layers. The measurements used to describe the X-Y resolution of this process is expressed in DPI  (dots per inch). The object is completed once all the cross-sections of the digital model are printed. Printers can print in a variety of colours depending on the machine.

Refinement - Not all printers have the same resolution. The better the resolution the print-head is capable of, the more accurate the model will be. Printers with worse resolutions will have more jagged edges and be rougher, as the printer cannot produce the intricate detail needed to create a smooth edge or complex pattern. In this case you may have to sand the edges smooth, and, if colours are required, paint and gloss the finished object.

 

Problems in Design

There are a few design problems with 3D printers. Firstly, the size of objects created is limited by the size of your printer. Small printers can only print small size objects, however you could design your object to be made up of parts that fit together to make a bigger whole. Secondly, objects with overhanging structures or unstable shapes will fall victim to gravity. To combat this, supports need to be added, these can be removed after printing. Lastly, there is a limitation on colours. Most printers only print one or maybe two colours at a time, this means you will have to re-colour your objects after printing.

These devices are made by very technically minded people. These people also wrote the instruction manuals, which makes the learning curve on these machines rather steep. This will no doubt alienate users, especially those who aren't used to working with technical machinery.

 

Global Impact

This technology has its origins in rapid prototyping. This benefited industry as it allowed prototypes to be built quickly. These were then analysed and a faster cheaper way of manufacturing was derived. However, as these devices are now relatively cheap and readily available, it could be possible to offset the initial costs of purchasing the machine by downloading and printing everyday objects for use around the home. This could lead to ‘reverse capitalism’ and cause chaos in some industrial sectors as people begin to download items instead of purchasing household products made by companies. The open source nature of the devices, such as their self replication abilities, seems to promote sharing knowledge over making money.

As far as using the technology for traditional retail purposes, it could be used to print your purchases off as opposed to buying them online. This would mean that you no longer have to wait for your items in the post; you could instantly print them off after purchase. 3D printing encourages the selling of intellectual property over the actual product and therefore allows people with good ideas to make money without the manufacturing capabilities of a large company. Also, due to the lack of the physical retail stage, it would decrease shrinkage due to theft as it's printed in the buyer's home. Damages made during transit wouldn't be a problem either.

Additive manufacturing has the benefit of making things from few raw materials, meaning that it is suitable for places in isolation where getting supplies would be hard. For instance, in a remote expedition or space. Tools for maintenance could be printed on-demand when needed, instead of taking every conceivable tool you may need. This could save on space and fuel, as only a finite amount of raw material would need to be taken and you would not need to take unnecessary items. It would also inevitably decrease waste.

All that is needed is a 3D scan of an object to create a digital model. You can use a 3D printer to replicate an item which may be too fragile or important to be duplicated in traditional methods (vacuum forming). For instance, an artefact or bone fragment from an archaeological dig, a historical object of importance or religious significance could be replicated without touching the original.

Medical applications for this technology include a prosthetic jaw being constructed, with continued research into whether this technology can be used to promote bone growth.  By printing with living cells, it is feasible that working organs could one day be created.

There are of course some people with concerns about the new technology, but with it being so open source it is hard to govern the content. There have been incidents of people printing firearms, with the plans being readily available on the internet.  Knives and other weapons could be easily designed and made, this would mean that weapons are readily available for anyone that wouldn't have to be imported and thus would be impossible to trace.

 

Conclusionalt

It is safe to say that this technology is one to watch. Its potential impact on our personal lives and industry could be astronomical. While still in its infancy, this technology is very impressive. When fully imagined, it could be one of the most important technological innovations of this century. The medical potential alone warrants further research. The possibility of printing tissue and organs for transplant patients would save countless lives. 
 

By Stephen P. Ashton
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