When I first heard of additive manufacturing and Industry 4.0, I did not have a clue what either meant. Now I do. Thanks to the MSc program.https://thespearking.com/week-beginning-28th-of-the-october/
Additive manufacturing and 3D printing are interchangeable words and will be used as such within this post.
The first assessment for my MSc program was to write an essay on ‘3D printing/additive manufacturing in an industrial context’. https://thespearking.com/wp-admin/post.php?post=102&action=edit. It was an almighty headache?. I dislike essay writing because you have to conform to the mark scheme. Meaning I can’t go off a tangent and write about what I like. Hence my new found love for blogging. It’s my choice what I write about?. Also, I hadn’t written an essay in a while and the thought of writing one was not pleasant.
In writing the essay, I had to do a literature search. This enabled my understanding of the subject. Industry 4.0 involves automation, computer, and digital manufacturing technology united in a complex but flexible system.
At the heart of the 4th industrial revolution are core concepts as in the diagram above. It is easy to see how this has become relevant and had influenced various industries in today’s world.
3D Printing and The Sports Industry
Zweilkampf
Zweilkampf, an Austrian sportswear manufacturer now uses 3D printing (Additive manufacturing) in the manufacture of shin pads instead of injection moulding technique. As a result, they were able to increase volume, strength, better fit and it’s customizable. https://3dprint.com/131193/3d-systems-zweikampf/.
Under Armour
Under Armour, also sportswear manufacturer is using 3D printing (additive manufacturing) for its sports shoes which are suited for clients taking part in more than one sport.https://3dprint.com/123064/under-armour-3d-printed-shoe/
Red Bull
3D printing has found its way into water sports as well. Red Bull in conjunction with a business outfit called Proto3000 is manufacturing 3D printed surf boards.https://3dprint.com/176817/proto3000-red-bull-surfboard/. On the other hand, Imperial College London is using plastic bottles as raw materials to 3D print surfboards which are printed in sections. Its sustainability cannot be questioned as it is made from readily available waste. https://3dprint.com/186018/3d-printed-surfboard-recycled/
3D Printing and The Automotive industry
The automotive industry is where 3D printing (Additive manufacturing) has its highest benefit. About 20 percent of its market is in 3D printing.
Mclaren
In formula 1 racing, McLaren has 3 arms: Racing, automotive and applied technologies. Its cars have numerous 3D printed parts. In the applied technology arm, 3D printing is used in the manufacture of wearable armor. One of its drivers sustained an injury to his chest region. His rib cage was compromised after surgery. The company set up ‘Project invincible’ to build a shield for his chest. Measurements and 3D scans were taken of the client’s chest. Following this, a chest plate was designed to fit, and 3D printed. https://3dprint.com/188689/mclaren-3d-printing-body-armor/
BMW
Another automotive company using 3D printing, for the past 25 years and has reached its 1 millionth 3D printed car part is BMW. In the BMW i8 Roadster, the window guide rail is 3D printed as well as part of the convertible soft-top attachment. BMW is investing in 3D technology by building a 3D manufacturing campus. https://all3dp.com/4/bmw-reaches-milestone-of-one-million-3d-printed-parts/
Buggati
Most recently Buggati has produced the worlds first 3D printed brake caliper made out of titanium. https://www.facebook.com/UNILADTech/videos/3539775899390063/
3D Printing and The Healthcare Industry
Visors
COVID pandemic has seen the rise of 3D printing (additive manufacturing) in the health care setting providing much-needed exposure. Most visors are now manufactured using 3D printers. https://www.youtube.com/watch?v=MsqQ5a1AChw. To increase numbers, injection moulding is in use as well. https://www.linkedin.com/pulse/update-face-visors-3d-printing-injection-moulding-power-nick-godfrey/
The use of 3D Printing in the manufacture of visors is not the most exciting. Keep on scrolling….
Implants
The additive manufacturing of implants, as shown in the image above, is the most exciting. Implants are medical tools that are manufactured from biomaterials. It can be placed partially or totally, within the body either permanently or temporarily. It can be manufactured using synthetic materials or from soft tissue. Examples are hip prosthesis, ribs (image below) and blood vessel grafts. https://doi.org/10.1016/j.matdes.2020.108940
Prosthesis
The use of 3D tech for Prosthesis is way cooler than all others!! Only because ‘ROBERT’ is involved?. Don’t know who ‘ROBERT’ is? See the video below or use this link https://www.youtube.com/watch?v=oEx5lmbCKtY&feature=emb_logo
The use of 3D printed prosthesis has enabled the customization of the prosthesis to the patient’s needs. Prints can be generated at the point of care within the hospitals and speed up recovery time. The image below shows a 3D print of an ear, just fantastic!!
3D Printing and The Aircraft Industry
In aircraft manufacturing, there is pressure to make aircraft lighter in weight to make it more efficient and reduce carbon footprint.
Airbus
With the use of generative design (A design technique that keeps function but reduces the weight of the part), Airbus in collaboration with Autodesk was able to redesign an existing A320 cabin partition. This a part of the plane that separates the passenger compartment from the galley.
The aim of the design was to reduce the weight, support the weight of the flight attendants on takeoff and landing. Also, it should attach to the plane in 4 locations. This resulted in a design that was 45% lighter and 95% less raw material. On the whole, there was a saving of about 3000kg of fuel per partition every year. These partitions were manufactured with 3D printing.
Conclusion
Industry 4.0 is here to stay and I am looking forward to technological advancements. One day, all the tech we see in the Star Trek movies will be a reality.
Take home message: There is a 3D printed part in your car. Maybe not in your present car but definitely in your future one?!!
