3D printing is the construction of a three-dimensional object from a digital 3D model – for example, using computer-aided design (CAD) models. It is typically done in a process in which material is deposited, joined, or solidified under computer control.
Sometimes the term “additive manufacturing” is considered synonymous with 3D printing, but this term is more correctly applied to manufacturing that involves 3D printing plus other technologies.
One of the key advantages of 3D printing is the ability to produce complex shapes that would not otherwise be feasible to construct by hand.
The first patent describing 3D printing is dated 1971 and described a continuous inkjet metal material device to form a removable metal fabrication on a reusable surface for immediate use.
In the early stages of the technology in the 1980s, 3D printing was considered suitable only for the production of functional prototypes – what used to be called rapid prototyping. It wasn’t until about 2020 that these processes were considered viable as production technology.
3D printing has revolutionized the way businesses approach prototyping and product development. As the technology advances, industries such as mining, construction, and manufacturing are leveraging their capabilities to create faster, more cost-effective prototypes. However, while 3D printing offers numerous benefits, it also comes with limitations. In this blog, we explore the advantages and challenges of integrating 3D printing into the product development process.
The pros of 3D printing in prototyping and product development:
- Speed and Efficiency:
Traditional prototyping methods, such as Computer Numerical Control (CNC) machining or injection moulding, can take weeks to produce a single prototype. With 3D printing, a working model can be produced in a matter of hours or days. This rapid turnaround accelerates the iteration process, allowing businesses to refine their designs quickly.
- Cost Reduction:
3D printing eliminates the need for expensive tooling and moulds, reducing upfront costs. For small production runs and custom parts, 3D printing can be significantly more economical than traditional manufacturing methods. This cost advantage is particularly beneficial for developing specialized components.
- Design Flexibility:
Complex geometries and intricate designs that would be challenging or impossible to produce using traditional methods can be easily created with 3D printing. This enables engineers to explore innovative design solutions and produce lightweight, high-performance parts.
- Reduced Material Waste:
Unlike subtractive manufacturing processes (such as CNC machining, which carves material away), 3D printing is an additive process. This means that material is only used where it is needed, leading to significant reductions in waste and overall material costs.
- Customisation and Personalisation:
3D printing allows for on-demand customisation, making it ideal for applications where tailored solutions are required. This is especially useful in industries like healthcare, automotive, and mining, where specialised components may need to be designed for unique applications.
The cons of 3D printing in prototyping and product development:
- Limited Material Selection:
While the range of 3D-printable materials is expanding, it still falls short compared to traditional manufacturing. Many high-performance metals, composites, and specialized plastics are either unavailable or costly in 3D printing, which can limit its application for heavy-duty industrial use.
- Strength and Durability Concerns:
Parts created with 3D printing often lack the strength and durability of those made through traditional methods like forging or casting. This is because the layer-by-layer additive process can introduce weak points in the final product. For applications requiring high mechanical strength, traditional methods may still be the better option.
- Higher Unit Costs for Mass Production:
While 3D printing is cost-effective for prototyping and small production runs, it becomes less economical at scale. Traditional manufacturing methods, such as injection moulding, have higher initial setup costs but much lower per-unit costs when producing large volumes.
- Post-Processing Requirements:
Many 3D-printed parts require significant post-processing, including support removal, sanding, or additional finishing to meet quality standards. This can add time and labour costs, reducing some of the efficiency gained through rapid prototyping.
- Equipment and Software Limitations:
Advanced 3D printers require specialised software, skilled operators, and regular maintenance. Additionally, high-end industrial-grade 3D printers can be expensive, making it necessary for businesses to carefully assess whether the investment aligns with their needs.
Is 3D printing right for your business?
For companies in industries like mining, construction, and manufacturing, 3D printing offers a powerful tool for rapid prototyping, custom part development, and innovation. However, it is not a one-size-fits-all solution. The decision to adopt 3D printing should be based on factors such as material requirements, production volume, and the complexity of the parts being created.
At Texcel, we are utilising 3D printing quite extensively for prototyping and product development. We have also started to utilise it for production manufacturing where volume requirements are quite small. The experience we have had to date is all positive and we are actively expanding our knowledge of this exciting technology.
