According to legend, Leonardo replied to the question of how he created a lion with hammer and chisel from a block of stone: “I just hit away everything that didn’t look like a lion.” That’s a lot of rock and a core problem of all subtractive processes: large amounts of material are being wasted. Moreover, one cannot chip off from the interior, for example to produce a hollow sphere. One can produce two hemispheres and merge them later. But there always remains a seam – and either masses of waste by way of subtraction, or the effort of creating elaborate molds, which in turn is only worthwhile for large quantities.

Bottom-up

To produce one piece additively, with no minimum quantities (i.e. highly individualized), and saving transport costs and emissions through local production, has been made possible a few years ago with the 3D printing process. Layer upon layer a laser or an electron beam forms an object on demand from the bottom up, usually made ​​of a plastic. However, ceramic printing and other materials are possible, even fashion to wear. A well-known pasta producer is developing a method to print individualized noodles – industry 4.0 to eat.

Three dimensions with a future

The 3D printing process is especially suitable for single prototype items and spare parts. The latter also for people: a highly refined prosthesis made ​​of titanium has already been printed, which has saved a patient’s leg with complicated splinter fracture. Also, organic structures can be printed to replace parts of defective heart valves. The possibilities are not even all explored.

Variety and quality

3D printing as a whole has left the prototype phase behind and matures step by step to become the technical backbone for e-manufacturing. Not only in terms of variety of designs, but also in terms of durability and the material’s quality, already today some 3D-printed objects are superior to their conventionally produced thing comrades.

[October 2015]