3D Systems' Technology Overview and New Applications in Manufacturing, Engineering, Science, and Education

Abstract

Since the inception of 3D printing, an evolutionary process has taken place in which specific user and customer needs have crossed paths with the capabilities of a growing number of machines to create value-added businesses. Even today, over 30 years later, the growth of 3D printing and its utilization for the good of society is often limited by the various users' understanding of the technology for their specific needs. This article presents an overview of current 3D printing technologies and shows numerous examples from a multitude of fields from manufacturing to education.

Figure 1.

A small push toy car created by a single print on a Projet 3500 of 3D Systems: (a) out of the printer, (b) melting the support material away, and (c) final functional car produced in a single build with no assembly. The car utilizes a flywheel to store energy, allowing it to travel up to 25 feet (T. Snyder).

Figure 2.

Gearing system of push toy car. Design rules can result in parts of gear mesh being slightly welded together and must break free during initial use.

Figure 3.

An educational catapult that uses a gear train and torsional spring for energy storage. Includes an extending crank handle and lever arm lock and release system. Multiple ball sizes, spring energy, and a multiposition lever arm allow use for Design of Statistical Experiments (DOE), statistics, and/or physics/engineering education.

Figure 4.

A flywheel motorcycle, which includes slip-fit wheel bearing surfaces and a gearing system with flywheel energy storage. The device is charged from a hex head fitting with the use of an electrical drill.

Figure 5.

A pull toy spring car. The back axle is connected with a chain to two springs, which extend and drive the rear wheels for locomotion.

Figure 6.

A rotational carousel with a flywheel at the bottom driven by a shaft located at the top. A planetary system steps up the energy input to the flywheel. A bevel gear system is attached to a support column and drives the reciprocating motion of the individual figures. The bevel system is mounted to an epicyclical gear set to reduce the rotational speed of the figures.

Figure 7.

A mantel clock. A key is used to wind up a torsion spring. Energy is transferred to the escapement, which powers the pendulum. The spring unwinds by changing the frequency the pendulum oscillates at, which is determined by its length. Through 1:60 and 60:1 gear ratios, the minute shaft drives the hour and second hands, respectively.

Figure 8.

3D-printed models of (a) a myoglobin and (b) a caffeine molecule.

Figure 9.

3D-printed models of (a) a Japanese α-quartz twin and (b) an “opened up” unit cell representation of the cubic densest packing of equal spheres.

Figure 10.

Silicone oil liquid droplets of 1 cS passively ejected from a parametric array of tubes and nozzles in a drop tower experiment.

Figure 11.

(Left  ) Approximately 300 0.32   µL, 1 cS silicone oil liquid droplets passively ejected from a 10  × 10 array of tubes. (Right  ) Droplet ejection tests simulating the effects of nozzle defects shown: (a) 5  mm nozzle with no defect (162  µL); (b) 5  mm nozzle with a 2 × 2  mm enlarging defect (236  µL); and (c) 5  mm nozzle with a 2  × 2  mm constricting defect (96   µL).^,

Figure 12.

Microscale droplet nozzle capable of capillary droplet ejection under Earth's gravity: (a) failed ejection and (b) multiple droplet ejection.

Figure 13.

(a) Square features with dimensions of 0.5  mm square for negative extrusions and (b) positive towers created on a Projet 3500.

Figure 14.

Water droplet sitting in 1 g on a 3D-printed superhydrophobic surface created with square towers approximately 0.5  mm × 0.5  mm × 2  mm tall.

Figure 15.

(a) Water puddle sitting flat because of gravity forces. (b) Surface tension drives the puddle together as gravity is eliminated. (c) The puddle ultimately detaches from the surface.

Figure 16.

Puddle jumping from 3D-printed superhydrophobic dishes of varying curvature.

Figure 17.

SolidWorks sectional view of dendritic disk, and photographs of a 3D-printed device. Annular plenum and tree-shaped bifurcating channels can be observed.

Figure 18.

Parts of a functional prototype of a Project Ara phone, including the endoskeleton frame, the screen, electrical components, and custom 3D-printed module enclosures.

Figure 19.

Top view of a printer showing cart/racetrack approach.