Tag: 3D printing

Additive manufacturing, 3D printing and rapid prototyping: What’s the difference?

Posted , updated on by

Keyboard with 3D print key

(Courtesy of Guest Blogger Liz Fox, senior marketing associate, MAGNET: The Manufacturing Advocacy & Growth Network)

If you type “additive manufacturing” into Google, thousands of results pop up, including everything from magazines to materials manufacturers to membership organizations devoted to the subject.

Many of these sites also use the terms “3D printing,” “additive manufacturing,” and “rapid prototyping” interchangeably, which brings up an important question: are these really all the same, or are crucial differences being overlooked?

Let’s start with the basics. Additive manufacturing is a methodology made up of new processes that have been developed during the last 30 years. While these vary on a technical level, all of them involve quickly building components layer-by-layer or drop-by-drop using printers and digital files. This differs from traditional manufacturing processes (such as CNC machining) because it builds up rather than takes away; thereby, constructing something from scratch instead of chipping away at existing material to form a specific shape or object.

At the root of it all, 3D printing and additive manufacturing are one and the same. While most experts prefer “additive,” “3D printing” has become a buzzword that resonates more with the average consumer, as well as the new class of makers that’s emerged in the last 10 years. Some debate this theory, but in our experience, it extends little beyond personal preference, like calling soda “pop” or vice versa.

Rapid prototyping is a different story. While additive and 3D printing describe a process, rapid prototyping is a way to use that technology, specifically in a testing environment and/or for design purposes that have little or nothing to do with service applications. The phrase “fail fast, fail cheap” often applies to this practice, as additive tech allows manufacturers to experiment with different ideas, designs, and functions without worrying too much about the cost of materials. Some options include Color Jet Printing (CJP), Direct Metal Laser Sintering (DMLS), and Stereolithography (SLA), which have been used to create things as diverse as car components, toys, and surgical implants.

Regardless of its applications, 3D printing continues to revolutionize the manufacturing sector. As current tech is improved upon and new methods are developed, these innovations are impacting companies for the better by offering a faster, cheaper alternative to using traditional processes and materials.

Check out how MAGNET is helping manufacturers harness the power of additive manufacturing capabilities in their products and processes:

For more information, call MAGNET at 216.391.7766, visit manufacturingsuccess.org, or follow us on Twitter at @MAGNETOhio!

Photo courtesy of Shutterstock

MAGNET’s 2016 State of Manufacturing address took place at Jergens, Inc.

Posted , updated on by

MAGNET state of manufacturing symposium at Jergens

On Nov. 16, 2016, MAGNET: The Manufacturing Advocacy and Growth Network, in conjunction with PNC Bank, presented its 2016 State of Manufacturing: Important Trends Affecting Northeast Ohio Manufacturers at Jergens Inc., 15700 S. Waterloo Road, Cleveland. There was standing room only as manufacturers and service-industry representatives arrived to hear presentations by Rich Wetzel, Youngstown Business Incubator, on the state of additive manufacturing and Dr. Ned Hill, The Ohio State University’s John Glenn College of Public Affairs and Ohio Manufacturing Institute, on manufacturing, the economy and the future.

In opening remarks, Paul Clark, regional president, PNC Bank, noted that “Thirty percent of PNC’s loan commitments in Northeast Ohio have been in manufacturing for the past 20 of 40 years.” These loans help manufacturers with new product development, new markets and acquisitions.

Wetzel, in his presentation on additive manufacturing, aka 3D printing, shared the seven main processes of additive manufacturing, with material extrusion being the most common, and says, “Northeast Ohio is becoming the capital of additive manufacturing and putting the area on the map.” He also shared that low-volume tooling is the low-hanging fruit and the easiest to implement for near-term opportunities but that the market tends to be risk averse.

Last, Dr. Hill (if I had an economics professor like this in college, I might have liked economics and learned something) talked about the current uncertainty in the market due to the election but the positive increase in interest rates. He says, “Manufacturing is looked at nostalgically by the public since it’s gone overseas, and they believe we aren’t making things.” In 2014, although China was the top nation for manufacturing, the U.S. was a close second. He shared that the largest market opportunity in the world lies in the NAFTA nations. He did a retrospective and shared that manufacturers were always in the top 10 employers in Ohio but now the reality is that part-time, low-wage jobs in healthcare, retail and food service have become the mainstay. In that reality, he says, “Midsized companies will be driving this state.”

Another trend he discussed in depth was automation. Since 1979, we lost almost 5-million factory jobs but at the same time more than doubled the value due to productivity. In addition, he shared statistics that we have lost 13 percent of factory jobs to trade and 88 percent to automation and continuous improvement, and that robotics is expected to reduce labor by another 22 percent in the U.S. He asked the audience to consider how many jobs technology has saved rather than lost. The U.S., for the first time in recent years, is a threat to China due to its quality, efficiency and improved internal supply chain. He says that when manufacturing can 3D print a die, it will save 20-30 percent and can compete with China. And, as much as we would like to believe that manufacturing powers the economy, it’s actually powered by consumers who do 70 percent of the spending. They are buying the products we manufacture!

Finally, he acknowledged the present problem of aging-out workers and the lack of a skilled workforce to replace them. He says manufacturing’s greatest enemies are parents, school counselors and OSHA, which limits workers under 20 from being on the manufacturing floor. We are losing talent to other industries. Let’s make these people our allies and work toward STEM education and a resurgence of interest in a field has evolved and shed its former stereotypical image.

 

MakerGear, manufacturer of 3D printers, discusses the amazing real-world applications and how-tos of additive manufacturing

Posted , updated on by

3D printer architectural prototype

(Courtesy of Guest Blogger Annie Liao, director of educational outreach, MakerGear, LLC)

What is MakerGear?

MakerGear designs and manufactures desktop 3D printers, primarily for use by businesses, schools, and makers. We originally started in a residential Ohio garage in 2009 and have continued to grow ever since. Currently, we have 25 employees at our factory in Beachwood, Ohio. Also, we received an exciting award this week! Our MakerGear M2 3D printer was ranked #1 in the world out of 513 printers. We’re excited to shine a light on technology and manufacturing here in Northeast Ohio.

What is additive manufacturing?

Additive manufacturing processes create objects by adding layer-upon-layer of material to build an object. These processes are in contrast to traditional subtractive types of manufacturing, such as those utilizing CNC machined parts, where material is removed from an object to create the finished product.

What is the benefit of a 3D printer? What problems does it solve?

3D printing is revolutionizing the manufacturing industry for a number of reasons. One significant contribution is that it saves time and money by allowing for rapid prototyping. When producing an object, the prototyping process has historically occupied a bulk of time between concept and launch. Today, with 3D printing, we can substantially shorten that gap by giving engineers and designers the ability to create their own prototypes in house – and as many iterations as they need — without dependency on an outside source or back-and-forth shipping delays.

Beyond those advancements in the industry, 3D printing is one of the most cost effective ways to produce small batch or custom items. This is great for everyone from small businesses creating unique products, all the way to doctors printing scale models of a patient’s heart before surgery. And on top of all of that, 3D printers create less waste, if any at all, compared to traditional manufacturing processes. The technology is constantly improving and changing, and we expect to see the number of problems that 3D printing solves continue to grow.

How can you use a 3D printer? What kinds of things are being made? Who are your customers/what are they making?

Our M2 3D printer requires 3D modeling software to design or import the object to be printed, and convert (or slice) that design into a language the printer can understand called G-code. We use a program called Simplify3D, but we also have recommendations on our website for freeware that works great, as well.

Seeing the range of applications our customers are creating is the most exciting part! The students at Mayfield City Schools’ Excel TECC have been creating 3D printed prosthetic hands, which are functional and only cost about $12 in printing materials. It’s an incredible achievement. One of our customers is printing tailor-fit horseshoes for horses with difficult-to-treat hoof conditions. And, we have customers printing parts for drones that transport medication to remote villages in East Africa. There is a limitless range of applications, and we’re surprised daily by the innovative products people are creating.

What materials can you use to build?

Some 3D printers on the market require the use of proprietary filament, which limits options and innovation. But, we’ve worked really hard to ensure that MakerGear printers can print in a range of materials, including a variety of plastics and metal composites. The list of possibilities is constantly growing.

These materials are packaged on spools in filament form. The filament is fed into the heart and soul of the printer called the hotend. The hotend consists of a heater, thermistor and a nozzle and is capable of heating the printing material to a certain temperature and then extruding it in successive layers onto a build platform. In the case of our M2 3D printer, the build platform also is heated to allow the object to better adhere to the bed during printing.

What does it cost?

Our MakerGear M2 printer costs $1,825. A 1-kg spool of PLA plastic, which is the material we recommend people begin printing with, costs $35, but can see you through multiple projects.

Do you see any trends with the industry or technology?

We are definitely seeing more interest in the types of materials available for 3D printing. We’re constantly testing new materials on our machines and have been excited by the results of some of them, from elastics to metal composites. It opens up a whole new world of innovation.

To avoid what happened with Cleveland Indians’ Pitcher Trevor Bauer when he bought a 3D printer from you and used it to make a drone that cut his finger, what safety tips do you have for users and consumers?

If you were following the Cleveland Indians this year in the playoffs you may have heard that Trevor Bauer owns a MakerGear M2 and 3D prints parts for his drones. He explained in a press conference that he got cut while plugging in his drone when the propeller started spinning at max throttle. We are certainly glad that he was able to recover quickly, and we can assure you that his accident didn’t have anything to do with the 3D printing process.

Thoughts from Justin: 3D printers coming to a library near you

Posted , updated on by

Maker space at library

(Courtesy of Guest Blogger Justin Mobilian, HGR’s sales & marketing summer intern)

If you remember, I wrote a blog about the future of 3D printing (additive manufacturing). Hopefully my goal of sparking your interest in the industry was achieved. If not, well, I’m sorry. BUT, this post should change your mind.

If you live near Cleveland and aren’t a member of the Cleveland Public Library, you may want to change that. Back in 2014, the library added 3D printers for the public’s use. Note: Libraries offering 3D printers to the public are available nationwide. Just call your local library to see if they are available. If you’ve ever wanted to give one of these printers a shot, now is your chance.

Libraries across the country are unveiling ‘MakerSpace’ stations, which are essentially places for people to gather to learn about technology and get hands-on with the machines – 3D printers being a hot topic right now.

For those who have access to the Cleveland Public Library, their MakerSpace station provides access to 3D printers, laser cutters, music production equipment and many other tools. It is located in the lower level of the Louis Stokes Wing at 325 Superior Avenue (open Monday through Saturday: 9 a.m. to 5:30 p.m.).

If you’re looking to pick-up a new hobby, make a trip to a MakerSpace. I haven’t been to a library since high school, but that will change in the next couple weeks! Who knows, you might find your next favorite activity AND a new friend. If you have been to a MakerSpace station before, feel free to comment below with your experience of it and where it was.