In the vast manufacturing landscape, 3D printing has emerged as a revolutionary force, transforming how we conceive and create objects. Although considered a newcomer compared to traditional methods like injection moulding and CNC machining, the history of 3D printing dates further back than many might imagine.
The Pioneering Years: 1945 to 1981
The origins of 3D printing can be traced back as far as the 1940’s/50’s coming from the minds of science fiction writers such as Murray Leinster’s “Things Pass By” and Raymond F. Jones’ article in the 50s titled “Tools of the Trade” whereby he first described the process of 3D printing.
It wasn’t until 1981 that imagination became reality, with Hideo Kodama’s patent for the XYZ platter. A crucial turning point in history. Kodama’s project may have ended up abandoned, but it started a surge of innovation in the early 80s resulting in Chuck Hull patenting the first ever 3D printer to produce using the Stereolithography process in 1984.
The Decade of Innovation: 1980s
The 80s were a pivotal era for 3D printing, the years following saw the birth of Carl Deckard’s Selective Laser Sintering in 1986 and Scott Crump’s Fused Deposition Modelling (FDM) in 1989, laying the foundation for companies such as Stratasys.
Diverse Printing Techniques
The realm of 3D printing is vast, encompassing a wide range of techniques and technologies. Let’s explore some of the more prominent categories and technologies.
VAT Polymerisation
- SL / SLA (Stereolithography) patented by Chuck Hull in 1984 – The process employed a digital light projector to cure resin, layer by layer.
- DLP (Direct Light Processing) Larry Hornbeck’s innovation came a few years after in 1987. Similar to SLA but utilising a DLP projector for faster printing.
- Carbon DLS (Digital Light Synthesis) one of the newer processes on the list, originating from 2015. This method uses an oxygen-permeable membrane for continuous liquid interface production.
- LCD (Liquid Crystal Display) Similar to DLP, however, this technique uses an LCD screen to cure the resin, solidifying the printed layers.
Powder Bed Fusion (PBF)
- SLS (Selective Laser Sintering) developed by Carl Deckard and Dr. Joe Beaman in 1986. Uses a laser to fuse powdered material.
- DMLS (Direct Metal Laser Sintering) EOS GmbH’s creation in 1995, they adapted the SLS process for metals, using a laser to fuse the metal powder particles together.
- Multi Jet Fusion another newcomer to the scene. HP’s 2016 invention involves depositing agents on a powder bed and fusing areas to solidify the part.
Material Jetting
- Polyjet developed in 2000 by Hanan Gothait, Ramo Bonen, and Gershon Miller, this method uses inkjet printing to deposit and cure the photopolymer droplets by layer.
- MJP (MultiJet Printing) Introduced by 3D Systems in 1996, deposits liquid photopolymer layer by layer, followed by a UV cure.
- Nano Particle Jetting another newbie to the 3D printing scene, XJet’s 2016 innovation combines inkjet printing with metal nanoparticles, suspended in a liquid binder for detailed, dense, metal parts.
Binder Jetting
- Metal Binder Jetting was developed in 1993 by Ely Sachs and Mike Cima, it involves depositing a liquid binder onto layers of metal powder.
- Bioprinting Organovo’s 2002 approach, not strictly binder jetting, it uses inkjet-like methods to deposit bio-inks layer by layer for tissue-like structures.
Material Extrusion
- FDM (Fused Deposition Modelling) Invented in 1988 by Scott Crump, one of the earliest forms of 3D printing. Thermoplastic filament is melted and deposited layer by layer.
- CFF (Composite Fibre Fabrication) A relative newcomer to the scene, founded in 2014 by Markforged, the method combines material extrusion with continuous fibre reinforcement for enhanced strength.
- Pellet Extrusion another relative newcomer, Josef Prusa’s 2013/14 innovation, using pellets melted and extruded to form layers.
Directed Energy Deposition (DED)
- LENS (Laser Engineered Net Shaping) Optomec’s 1997 creation, uses a high-power laser to melt and fuse metal powder or wire.
- EBAM (Electron Beam Additive Manufacturing) Sciaky’s relatively recently 2009 method uses an electron beam for the melting and fusing of metal powder.
- DMD (Direct Metal Deposition) developed by the University of Michigan’s POM group in 1998, using a laser or electron beam to metal and fuse metal powder or wire.
Sheet Lamination
- LOM (Laminated Object Manufacturing) Helisys’ 1991 method, which involves cutting or scribing shapes onto sheets and bonding them by layer.
- UAM (Ultrasonic Additive Manufacturing) Dawn White’s 1999 invention, uses ultrasonic vibrations to bond thin metal foils together by layer.
Conclusion: A Dynamic Future
The Journey of 3D printing from its speculative origins to its wide range of applications in today’s world showcases the innovativeness and dynamism of 3D printing, a process that is still evolving. With the continuous advancement of the technology, we can expect even more groundbreaking developments in the future that will shape the future of manufacturing and redefine what is possible with 3D printing.