Trends in 3D printing development
(1) Data aspect
3D printing technology is a digital manufacturing process, with data development trends reflected in two areas:
Firstly, the evolution of stratification methods. Early digital layering techniques and path planning directly determine the efficiency and accuracy of subsequent physical layering.
Currently, 3D printing mainly employs simple plane slicing, but universities such as the University of Dayton and Stanford University have conducted research on data processing with a focus on layering methods, trying to transition from traditional two-dimensional plane slicing to slicing. shaped curved surface.
In China, this research plan was included in the “Major Special Projects on Additive Manufacturing and Laser Manufacturing” of the Ministry of Science and Technology in 2018.
Second, the diversification of data sources. 3D models for printing can be obtained through 3D modeling or reverse engineering methods, even using data from computed tomography scans and digital cameras to reconstruct models, increasingly used in 3D printing. However, there is some data distortion and more research is needed.
(2) Material Aspect
The advancement of 3D printing is increasingly dependent on the development of materials, with two important trends:
Firstly, tissue engineering materials. Based on vascular and cell-laden biomaterials, the construction of living tissues and organs is the most crucial direction for the development of 3D printing materials and the most anticipated field of application.
Secondly, special functional materials. Materials with specific electrical and magnetic properties, such as superconductors and magnetic storage media, as well as gradient functional materials, are also the focus of materials research and development in 3D printing and represent cutting-edge applications in the industrial field.
(3) Structural Aspect
The mechanical structure of 3D printers is also essential, determining the precision, efficiency and range of applications, with two important development trends:
Firstly, upsizing. Limitation on print size has always been a weak point of 3D printing equipment.
Increasing the size of the mechanical structure of 3D printers while maintaining precision can increase the overall manufacturing capacity, avoid model segmentation to improve printing efficiency, and significantly expand the field of application. An analysis of major companies' product lines in recent years reveals a trend toward larger production sizes.
Further investigation shows that the maximum print size of various types of 3D printers from these companies is restricted to 1 meter. Some companies in China are trying to develop printers on a large scale and have already received favorable responses from the market.
Secondly, integration with traditional production methods. This includes effective and deep integration with traditional methods such as molding, casting, forging and electrochemical precision machining.
The Ministry of Science and Technology's “Major Special Projects on Additive Manufacturing and Laser Manufacturing” in 2018 included these research projects, aiming to promote the enabling development of 3D printing in the traditional manufacturing industry and expand the applications of printing itself 3D.
(4) Manufacturing Models
Firstly, the emergence of “distributed manufacturing” models. As 3D printing becomes more affordable and technologically accessible, it is headed towards widespread adoption, with the potential for every household to own and use a 3D printer, making it a tool and platform for social innovation, crowdfunding and crowdsourcing. This is leading to a new form of social behavior and the advent of “distributed manufacturing”.
In essence, distributed production reimagines the entire production process, profoundly altering the supply and demand chain, including consumption patterns.
Second, a “function-first” design philosophy is emerging. Traditional manufacturing, limited by part complexity, required designers to consider feasibility and cost. However, 3D printing design can ignore product complexity and focus only on necessary functions, leading to the creation of previously unimaginable industrial products.
As they accumulate, they will revolutionize production, especially of complex and precise components in industries such as aerospace, shipbuilding and automobiles.
The “function first” design philosophy for 3D printing expands the creative and innovative possibilities for product designers, freed from traditional manufacturing processes and resources, and pursues unlimited creation under the paradigm that “design equals production” and “design equals product”.
Therefore, ideal structural designs can be employed without worrying about machining problems, solving manufacturing challenges for sophisticated, complex and precision components. Due to the high integration of digital design, manufacturing and analysis in 3D printing, this philosophy also significantly shortens the new product development cycle and reduces R&D costs, enabling “design today, product tomorrow”.
Thirdly, “micro and nano manufacturing” is heavily promoted. As 3D printing applications extend from macro to micro and nano manufacturing, this form of manufacturing will play a significant role. Currently, the microelectronic processes used to manufacture sensors require the production of molds and wafer processing, which means an investment of billions, if not tens of billions, of dollars for a production line.
For custom sensors with only a few hundred units required, such a large initial investment makes small-scale production unfeasible. 3D printing can fully meet the demands of this micro and nano manufacturing. Researchers at Western University in Canada have developed an implantable device that monitors patients' heart conditions, made using 3D printing technology.
This wireless implantable system integrates a blood pressure sensor and a cardiovascular pressure monitor (including a stent), with a volume of just 2,475 cm³ and a weight of just over 4 grams.
(5) Self-Evolution
In the future, 3D printing will evolve into 4D and 5D printing. Based on 3D printing, these methods account for changes over time, allowing models to gradually alter form and function, leading to what is known as 4D and 5D printing.
Firstly, 4D printing allows printed models to change shape over time. Normally, the model may be flat when printed, but it will gradually deform under the influence of temperature, magnetic fields and other environmental factors. Advantages include simplifying the 3D printing process and easily integrating printed models into devices.
Second, 5D printing allows models to change both function and form over time after being printed. Experiments with 5D printed bones have already been successful in animals. If this technology matures and becomes widespread, its social impact will be much greater than that of intelligent production, 3D printing or 4D printing.
(6) Application prospects
It is clear that 3D printing has greater potential for fully customized or small-batch applications.
First, the field of biomedicine is an excellent example of personalized applications. In 2016, the Guidance on Promoting the Healthy Development of the Pharmaceutical Industry issued by the General Secretariat of the State Council highlighted the need to promote the application of bioprinting technologies and data chips in implantable products.
The “13th Five-Year Plan” for the National Strategic Development of Emerging Industries, released by the State Council, highlighted the use of additive manufacturing (3D printing) and other new technologies to accelerate innovation and industrialization in tissue and organ repair, as well as as in implantable medicine. devices.
On February 9, 2021, the Ministry of Industry and Information Technology issued a draft Medical Equipment Industry Development Plan (2021-2025), which encourages the development of new “3D Printing + Medical Healthcare” products. Advocates for the advancement of personalized customization in medical devices, rehabilitation equipment, implants and soft tissue repair and emphasizes the application of 3D printing technology in diverse sectors.
The plan also calls for the application of advanced materials and 3D printing technologies to improve the biocompatibility and mechanical properties of products such as vascular stents, orthopedic implants and dental implants.
Supports cross-industry collaboration, integrating traditional medical equipment with new technologies such as 5G, artificial intelligence, industrial internet, cloud computing and 3D printing to promote the development of original intelligent medical equipment and promote intelligent cloud medical and healthcare services.
This shows that from the perspective of national policy, “3D Printing + Medicine” is an important research topic in recent years, receiving significant attention and support and demonstrating immense development potential. It also reflects China's commitment to the health and well-being of its people.
Secondly, the aerospace industry represents small batch production. Aerospace components are typically produced in smaller quantities than commercial products and tend to have complex structures made from expensive, high-strength, and difficult-to-process alloys.
Clearly, 3D printing is poised to have a considerable impact on this sector. Both nationally and internationally, there are high expectations for 3D printing in these two fields, as clearly demonstrated in the research plan “Main Special Projects on Additive Manufacturing and Laser Manufacturing” implemented during the “13th Five-Year Plan” period.
(7) Fundamental Science
Clearly, based on the basic principles of additive manufacturing, fundamental theoretical research continues to drive the development of 3D printing technology. The following five scientific areas are gradually attracting widespread attention from academics, both nationally and internationally.
The first is the study of strong non-equilibrium solidification in metal forming. The interaction time between the material and the energy source is extremely short during the 3D printing process, leading to instantaneous melting-solidification cycles.
For metallic materials, such non-equilibrium solidification mechanisms cannot be fully explained by traditional equilibrium solidification theories, therefore, establishing a theory of metallic solidification under strong non-equilibrium conditions is an important scientific question to be addressed in the field of printing. 3D.
Second is the development of new mechanisms for 3D printing under extreme conditions. As humanity's urgent need to explore outer space continues to grow, 3D printing technology is increasingly applied in the field of space exploration.
There is even a desire to achieve in-situ 3D printing in outer space, making it especially important to study the mechanisms of 3D printing under such extreme conditions and the lifespan and failure mechanisms of components in these service environments.
The third is the mechanism for 3D printing gradient materials and structures. 3D printing is a manufacturing technology that integrates structure and function, enabling continuous gradient changes in material composition and the combination of multiple structures within the same component. Carrying out such projects poses challenges for material mechanics and structural mechanics.
Fourth, personalized 3D printing of tissues and organs and the principles of functional regeneration. Whether it is maintaining the vitality of living entities during the manufacturing process or studying the mechanisms to recreate the functions of organs during their use, this research is still in its infancy and requires the collective efforts of experts and scholars across multiple disciplines. and fields.
Fifth, 3D printing control mechanisms integrated shape and property. 3D printing is transitioning from shape-controlled manufacturing to integrated manufacturing with controlled shapes and properties. For example, in printing metal parts, not only can the shape of the parts be printed, but the complex internal structures can be controlled with high precision and strength, approaching or exceeding forged parts.
In the future, printing blades for aircraft engines could lead to the formation of columnar crystals, which are stacked in a direction predetermined by designers, resulting in a final product with superior overall performance compared to forging.
In summary, the future role of 3D printing is expected to undergo significant changes, evolving from a supplementary form in production to a backbone of smart production. It will redefine manufacturing processes, pushing professionals to reevaluate existing practices in the field with a 3D printing mindset.
While the volume of parts produced by 3D printing may not match that of mold making and CNC machining, the value it creates can far surpass these traditional methods. Therefore, the trends and application prospects of 3D printing are very promising.
