=> Introduction to Additive Manufacturing

Additive manufacturing, commonly known as 3D printing, is a transformative approach to industrial

production that enables the creation of complex structures by adding material layer by layer. Unlike
traditional manufacturing methods, which often involve subtracting material through cutting, drilling, or
machining, additive manufacturing builds objects directly from digital models, typically using materials
such as plastics, metals, or composites. This technology allows for high levels of customization, reduced
material waste, and the production of intricate designs that would be difficult or impossible to achieve
using conventional techniques.

Emerging in the late 20th century, additive manufacturing has evolved from a prototyping tool to a full-
fledged production technology, with applications spanning industries such as aerospace, healthcare,
automotive, and consumer goods. One of its key advantages is the ability to rapidly produce parts on
demand, which significantly shortens the product development cycle and reduces inventory costs.
Moreover, its capability to manufacture lightweight and optimized structures makes it particularly
valuable in fields where performance and material efficiency are critical.

=> The History of 3D Printing Technology

The history of 3D printing dates back to the early 1980s when Chuck Hull, the co-founder of 3D Systems,
invented stereolithography (SLA). This was followed by the development of other additive technologies
like selective laser sintering, fused deposition modelling (also known as Fused Filament Fabrication), and
direct metal laser melting.

Over the years, these technologies have undergone significant evolution and improvement. For
instance, SLA machines have become more precise and can now print at resolutions as low as 25
microns. Similarly, SLS machines have become faster and more energy-efficient.

In the early days of additive manufacturing, the technology was mostly used for prototyping and making
small batches of parts. However, with the advancement of additive technologies, it is now possible to
produce large-scale production runs using these technologies.

=> How Additive Manufacturing Technology Has Evolved Over the Years
The additive manufacturing industry has undergone tremendous evolution since the technology was
first invented in the 1980s. Here are some of the key milestones in the History of additive manufacturing
technology:

=> Additive Manufacturing in the 1980s

The foundation for additive manufacturing was laid in 1980 when Dr Hideo Kodama, a researcher at the
Nagoya Municipal Industrial Research Institute, filed the first AM patent.

Kodama’s idea was to use a container of photopolymer material and expose it to light to create
prototypes. However, his idea never came to fruition due to a lack of funding.

A few years later, in 1986, Chuck Hull, the co-founder of 3D Systems, invented stereolithography,
considered the first rapid prototyping system.

With SLA, Hull discovered a way to solidify liquid resin using a UV laser, which created the first 3D-
printed object. In the same year, Hull filed a patent for his invention and founded 3D Systems to
commercialise stereolithography.

A year after Hull’s invention, Carl Deckard of the University of Texas at Austin developed selective laser
sintering, another additive manufacturing technology. SLS uses a laser to fuse small particles of plastics,
metals, or ceramics to create 3D objects.

In 1989, Scott Crump, the founder of Stratasys, invented fused deposition modelling, another popular
3D printing technology. FDM works by extruding a filament of melted plastic material, which solidifies to
create the 3D object.

=> Additive Manufacturing in the 1990s

The 1990s was a decade of rapid growth for additive manufacturing technology. In 1991, a company
called Cubital invented Solid Ground Curing. SGC is a technology that uses ultraviolet light to solidify
liquid photopolymer resins.

In the same year, laminated object manufacturing was invented by a company called Helisys. LOM is an
AM technology that uses sheets of paper, plastic, or metal glued together and cut into shapes using a
laser or knife.

In 1999, researchers at the Wake Forest Institute for Regenerative Medicine created the first 3D-printed
tissue. This breakthrough in the medical field opened up the possibility of using 3D printing to create
transplantable organs.

=> Additive Manufacturing in the 2000s and Beyond

The 21st century has been a period of tremendous growth for additive manufacturing technology. More
companies have entered the market, and technology has become more mainstream.
Prof. Adrian Bowyer of the University of Bath invented the first desktop 3D printer, called the RepRap, in
2005. The RepRap was open-source, meaning anyone could build one for themselves, which made 3D
printing more accessible to the general public.

Objet, a 3D printer manufacturer, released the first multi-material 3D printer in 2007. This breakthrough
allowed users to print objects with multiple materials, hence, parts with multiple material properties.

The turn of the decade saw the release of MakerBot, the first consumer-grade 3D printer. MakerBot was
founded in 2009 by Bre Pettis, Adam Mayer, and Zach Smith. The company aimed to make 3D printing
accessible to the average person. DIY-ers and hobbyists could purchase a 3D printer for their home or
office.

Another company that was founded in 2011 is Prusa Research. This company developed the Prusa i3, a
3D printer based on the earlier work on the RepRap, which has become one of the most popular 3D
printers due to its low price and easy-to-use design.

Following the success of the Prusa i3, MakerBot released the Replicator 2, a 3D printer that was
designed for more advanced users and has become the most popular desktop 3D printer on the market.

In 2012, Stratasys and Objet merged to form Stratasys Ltd., now the world’s largest 3D printer
manufacturer. The merger of these two companies created a behemoth in the 3D printing industry.

In 2013, Stratasys Ltd. acquired MakerBot in a deal worth $403 million. This acquisition helped Stratasys
to gain a foothold in the consumer 3D printing market. At the time of the acquisition, cheap desktop 3D
printers that lacked the mechanical properties and accuracy required for serious applications were all
the rage.

In 2013, Markforged, a 3D printer manufacturer, revolutionised the 3D printing industry with the release
of the Mark One. The Mark One was the first 3D printer that could print metal objects. This opened up a
whole new range of applications for 3D printing, as metal objects can now be printed with the same
ease as plastic ones.

The Future of Additive Manufacturing Technology

The additive manufacturing industry is expected to grow at a compound annual growth rate (CAGR) of
15% from 2015 to 2025. This growth is driven by the increasing use of 3D printing technology in many
industries and the falling prices of 3D printers.

One of the most important applications of additive manufacturing technology is in the medical field.

3D-printed organs and tissues are being developed that could one day be used for transplants, which
would help address the shortage of organs and tissues currently being experienced.
More 3D-printed medical devices are being developed all the time. For example, 3D-printed hip implants
are now being used to replace worn-out or damaged hip joints. This is a much less invasive surgery than
traditional hip replacement surgery, and the patient can usually go home the same day.

The aerospace industry is another area where additive manufacturing technology has a major impact.
The use of 3D-printed parts in aircraft is increasing as the technology can produce lighter and stronger
parts than those made using conventional manufacturing processes.

The automotive industry is also making use of AM technology. Although we’re not quite at the point of a
fully 3D-printed car, parts are being used to create prototypes and low-volume production runs. This
helps to reduce the cost and lead time associated with traditional manufacturing processes.

In the foreseeable future, additive technology is expected to become more widely used in various
industries. The technology will continue to evolve, and new applications will be developed, helping to
drive the growth of the additive manufacturing industry in the years to come.

=> The 7 Categories of Additive Manufacturing

Although media likes to use the term “3D Printing” as a synonym for all Additive Manufacturing
processes, there are actually lots of individual processes which vary in their method of layer
manufacturing. Individual processes will differ depending on the material and machine technology used.
Hence, in 2010, the American Society for Testing and Materials (ASTM) group “ASTM F42 – Additive
Manufacturing”, formulated a set of standards that classify the range of Additive Manufacturing
processes into 7 categories (Standard Terminology for Additive Manufacturing Technologies, 2012).

=> VAT Photopolymerisation

Vat polymerisation uses a vat of liquid photopolymer resin, out of which the model is constructed layer
by layer. Find out more here.

=> Material Jetting

Material jetting creates objects in a similar method to a two dimensional ink jet printer. Material is
jetted onto a build platform using either a continuous or Drop on Demand (DOD) approach. Find out
more here.

=> Binder Jetting

The binder jetting process uses two materials; a powder based material and a binder. The binder is
usually in liquid form and the build material in powder form. A print head moves horizontally along the x
and y axes of the machine and deposits alternating layers of the build material and the binding
material. Find out more here.

=> Material Extrusion

Fuse deposition modelling (FDM) is a common material extrusion process and is trademarked by the
company Stratasys. Material is drawn through a nozzle, where it is heated and is then deposited layer
by layer. The nozzle can move horizontally and a platform moves up and down vertically after each new
layer is deposited. Find out more here.

=> Powder Bed Fusion

The Powder Bed Fusion process includes the following commonly used printing techniques: Direct metal
laser sintering (DMLS), Electron beam melting (EBM), Selective heat sintering (SHS), Selective laser
melting (SLM) and Selective laser sintering (SLS). Find out more here.

=> Sheet Lamination

Sheet lamination processes include ultrasonic additive manufacturing (UAM) and laminated object
manufacturing (LOM). The Ultrasonic Additive Manufacturing process uses sheets or ribbons of metal,
which are bound together using ultrasonic welding. Find out more here.

=> Directed Energy Deposition

Directed Energy Deposition (DED) covers a range of terminology: ‘Laser engineered net shaping, directed
light fabrication, direct metal deposition, 3D laser cladding’ It is a more complex printing process
commonly used to repair or add additional material to existing components.

=> Conclusion

Additive manufacturing or 3D printing represents an innovative change in the concept, design and
manufacturing of objects. The ability to create complex forms, adapt products, reduce material waste,
and accelerate the development cycle makes it a powerful innovation tool for the industry. Meanwhile,
challenges including material limitations, surface-mass production quality and scalability continue to
expand the potential and continuous advances in technology, materials and processes. Looking into the
future, additive manufacturing promises a more central role in redesigning the production situation,
making it more flexible, more efficient and sustainable.