BFB RapMan is Manufacturing Parts

Commissioned to find and write a compelling case study on the BFB RapMan, I knew it would not be a hard brief, in that uptake is pretty rapid at the moment. However, what I was not expecting, was to come across a user that is employing the kit form of the RapMan machine to manufacture end-use components! I was staggered, I have to say. This is immense. An additive technology, under £1,000, is producing plastic components for a finished product. Granted, the volumes are not huge — yet. But, the potential is there.

I am currently waiting for approval to get this story out there into the public domain, but just as soon as I do, I will be posting it here, as well as sending it as far and wide as possible.

The Transition Period

As a long term advocate of additive technologies I have been through the peaks and troughs associated with an emerging sector. However, I have never before been witness to the growing momentum behind these technologies that exists today.

It is not possible to point to one single factor, which is probably why there is strength behind the momentum as opposed to 'hype'. Rather, it is now possible to identify a cumulative range of events and circumstances that are contributing to this escalating energy behind both 3D printing and additive manufacturing.

As the world tentatively heads out of recession, albeit teetering on the brink with economic commentators uncertain about which way the cards will fall as of yet, the vendors of additive technology platforms have fared pretty well. Some better than others, as would be expected, but what it very telling is that none have gone into administration. All of them have managed to keep their heads above water. Stratasys recently released its end of year results for 2009, and the general pattern is probably similar across the board, in that unit sales were down on the previous year, but still healthy enough. Cost cutting and belt tightening helped to buoy up the figures some, and overall the rhetoric was positive. An industry that can demonstrate positive results after a devastating year — economically speaking — only points to further significant growth at a faster rate as global circumstances improve.

Awareness is another significant factor in this building momentum. It's been a slow process (akin to wading through treacle at times) but it is now spreading at an exciting rate. There is much more talk, debate and understanding of the additive manufacturing concept. From a personal perspective, I am finding that I rarely have to explain the concept itself anymore, as most people that I speak to have heard about it and grasp the basic idea. Rather it is a case of explaining the different processes and the range of capabilities. This is progress!

A further significant pointer that I became aware of yesterday is that a large retail outlet that has picked up on the technology. PC World posted an article on its website: http://www.pcworld.com/article/189880/affordable_3d_printers.html. It refers directly to HP's interest in 3D printers and I imagine this is what brought it to the company's attention. Also, the article talks about 3DP and AM as a technology of the future, but it is talking, and more to the point, it is taking the message wider. Just think of the number of people that would never come across a manufacturing or technology website but will visit the PC World website. There could be many more 'Eureka' moments as a result!

Many of the blogs relating to 3DP and AM are also becoming much, much more prolific with their posts. A great many of them distinguish between the industrial strength processes (Stratasys, 3D Systems, Objet, ZCorp et al) and the 'hobbyist' platforms (RepRap, Fab@Home, Makerbot and BfB RapMan etc). The hobbyist platforms being those 3D printers that come in kit form. I am not sure if the 'hobbyist' label works for me, I don't think it conveys the full potential of these machines, but I get the point and the differentiation.

As of today, I think the sector is mid transition — somewhere between niche and mainstream — and moving faster than it ever has before!

The Press is Starting to Pick up on 3DP/AM

The chatter about whether or not 3D printing and/or AM is or will become mainstream has been centre stage again of late. Is it mainstream now? No, of course it isn't! That said, the mainstream press here in the UK are starting to pick up on just what these technologies can do. Indeed, just today, two articles on the subject have gone live.

Stateside there has been more mainstream press visibility with articles in some of the major daily titles, and the Jay Leno effect has had positive repercussions with increasing profile.

Today, the Daily Telegraph ran an article in its print edition outlining the impressive ALM capability at Airbus / EADS in Filton and how these companies are driving innovation and research with additive manufacturing applications that are currently undergoing the lengthy testing necessary for flight.

The Times Live also ran an online opinion piece of journalism, with a slightly tonge in cheek tone, but one that easily captures the imagination of people not familiar with 3D printing. They might need some ST knowledge though!!

http://www.timeslive.co.za/opinion/columnists/article293024.ece

The Optomec Position

Today Optomec will introduce its Aerosol Jet Display Lab System to the American market at the FlexTech 2010 Conference in Phoenix, Arizona, USA. The system has been designed and developed for the production of next generation touch screen and display applications.

Optomec is a company that intrigues me. Its proprietary LENS additive process has been around for many years and is well established and utilised among savvy clients in advanced sectors such as aerospace and defence. The applications for the LENS process have proved diverse — manufacturing and repairing high value metal components from aircraft engine parts to medical implants. However, the company often seems to fly below general radar levels, quietly going about its business.

The Aerosol Jet Display Lab goes a step further than LENS, it is an advanced additive platform that utilises Optomec’s patented Aerosol Jet technology, which in turn enables high resolution deposition of a wide variety of materials including conductive nano-particle inks, insulators, dielectrics, polymers, adhesives and other advanced materials. The system can print onto a wide variety of flexible and rigid substrates.

Despite the US launch today, a number of customers in Asia, including a leading industrial electronics research institute and a leading touch screen company, have already purchased and taken delivery of their Aerosol Jet Display Lab systems, which are being used to develop applications such as bridge/jumper circuits for bus lines on ITO/Glass, edge circuits for handheld displays, and fully printed Thin Film Transistors.

According to Optomec, the benefits of the Aerosol Jet Direct Write technology are the multi-material, fine line (<10 um) printing capability which eliminates many process steps/costs associated with current photolithographic and vacuum based display manufacturing processes. Also, the Aerosol Jet Print Engine can be integrated into automation platforms to meet high volume display production requirements. Multi-nozzle dispensing heads can be configured to meet specific end-user throughput needs. The additive process employed by Aerosol Jet technology reduces environmental impact by minimizing waste and chemicals that are prevalent in traditional electronics’ manufacturing processes.

The company has released a huge amount of information — with very little fanfare — all of which has even greater implications for future development.

The things that really stand out for me are:

• the high resolution deposition of nano-particles
• companies in the middle East are already using the systems
• multi-material deposition
• < 10 µm printing capability.
• and last, but by no means least, the system was developed for a specific application, and Optomec launch direct to its target market at FlexTech, an event dedicated to flexible technology for electronics and displays.

Basically, when a company bylines itself as "the world-leading provider of additive manufacturing systems for high-performance applications" my instinctive response is, 'yeah, yeah, you and every other AM vendor'. In this instance though, with a significant and very noticeable lack of hype around the company, I am inclined to agree that Optomec is making huge strides that are ahead of the game.


[NB: I have absolutely no commercial / financial interests in Optomec or associated companies.]

Advocating Additive Technology and Change is on the Horizon

As the Editor of the TCT Magazine I was a 100% advocate of additive layer technology. Partly because it was my remit and partly because I caught the bug. Now, it is wholly through choice, although often more tempered by cynicism. I have been wondering of late where this cynicism has come from.

By nature I am an optimist, so can I be optimistic and cynical at the same time? The answer is yes I can. I am cynical about some of the predictions and claims about 3D Printing (3DP) and Additive Manufacturing (AM), these days. I now have a tendency to reserve judgement until I see proof, or establish a strong belief system, before I start waxing lyrical. That said, I am very optimistic about the future of additive technology.

A couple of posts back I positioned myself on middle ground, with a good view. That has brought with it an accusation of sitting on the proverbial fence and acquiring splinters in uncomfortable places. In view of this coming close on the heels of a very exciting meeting I had recently, I am going to vocalise some of my optimism and go on the record with a couple of predictions of my own.

I am not at liberty to disclose any of the contents of my meeting — yet — suffice to say, it prompted this post.

IMHO:

The current additive technology field will diversify, it's already started and it will become much more defined. It will go in two directions with two clearly identified markets — prototyping (3DP) and production (AM). I am not quite so bold as to put a precise date on this, but within the next 5 years. Sooner if Stratasys/HP make good on their promises and the price of concept modellers goes into freefall with the other 3DP vendors scrabbling to compete with RapMan, Solido and Makerbot and regain some of the market share that they will surely lose in the short term.

Things are going to change, and they are going to change in a big way, for AM; and the changes are going to come from left of field. Currently AM activities are viewed as a fringe activity, a process for OEM's with deep pockets or artistic types to 'play' with. As of today, this is a misguided perception, with a host of real applications that one can point to and say, "No, the capabilities of AM technologies are real and they make a real difference." The one that stands out for me is the use of titanium human implants built using the DMLS process from EOS, but there are many more. The problem is, there is no one application that makes enough people sit up and take notice. The applications do not make a 'big enough' difference. Volumes and infrastructure are key limitations.

However, this WILL be turned on its head in the mid-term. I am absolutely, positively convinced of it. Around the year 2013 I fully expect to point people back to this post and say I believed!

All optimistic and cynical comments welcome ....