The history of 3D printing

Sometime in the mid-2010s, additive manufacturing, or 3D printing, became the hottest buzzword amongst engineers. Before then, it almost seemed like science fiction, where only the most advanced schools had printers to help in research. This host of technologies has taken over engineering since then and is now a required skill for an estimated 35% of open engineering job postings. So, when did 3D printing actually start? What did these early attempts even look like?

What is it:

Additive manufacturing is the over-arching term, which 3D printing falls under. Included in additive manufacturing are thermal spray techniques, electro-plating, welding and of course 3D printing. In modern vernacular, 3D printing and additive manufacturing are used interchangeably.

There are 3 main production methods utilized, Fused Deposition Modeling (FDM), Stereolithography (SLA), and Selective Laser Sintering (SLS). We have blogs coming out for each of these, including some great information on pros and cons. We aren’t going to cover the techniques directly here, but understand there are several methods, each with different material and mechanical considerations. Through these different processes we have access to plastics, metals, concrete, even chocolate as materials!

How did 3D printing start:

Interestingly, in the 1940’s two different science fiction authors wrote about machines which could create plastic models in a drawing like motion. Sometimes science fiction misses the mark on the future, but for these two, they really nailed it. Little did they know how computers would simplify the process and make it so ubiquitous.

The first patents and real research into 3D printing as we know it today were carried out in the 1980’s. In this time frame, the stage was set for the SLA and SLS printing methods mostly. Much of the early research was abandoned due to the machines high cost, extensive computer power requirements, expensive materials, and slow speeds. The technology just didn’t seem feasible after centuries of casting and metal working expertise. At this time, the machines were referred to as “rapid prototyping” and were solely the play thing of large research institutions.

When did 3D printing improve:

In the late 2000’s, with the start of widespread internet usage, and proliferation of more powerful computers, 3D printing started becoming a viable technology. This is when internet communities rallied around the “RepRap” printers and information on CAD usage became more available. The RepRap designs allowed one person with a printer, to make additional printers for their friends and families. About 70% of the components could be printed, the rest purchased via online retailers. A large hobbyist community grew around these machines, and taught thousands what 3D printing was.

Mean while industrial grade printers were getting faster, and more materials became available. Metal 3D printing got major traction with companies, allowing them to produce geometries otherwise thought impossible. An early adopter of additive manufacturing were low volume casting shops. Using printed plastic blanks allowed them to make sand molds without all of the usual cost of making a master.

By the 2010’s, just about everyone, especially engineers, knew someone with a 3D printer. Home use printers were finicky and ran a limited number of materials, but they could make prototype pieces quickly. Every university seemed to rush and set up additive manufacturing labs, lest they get left behind. We all knew someone who would sing the old refrain: “I could print that so easily!” Unfortunately, it never was that easy…

Meanwhile, metal 3D printing became a viable process for many companies. Aviation was an early adopter. Once Inconel pieces could be reliably printed, it allowed for major improvements for parts weight and manufacturability. The LEAP engine was one such product line which made extensive use of metal 3D printed parts to save weight and costs.

Where are we today:

The 2020’s have been an era of refinement and further proliferation. Most work places now have a printer for their engineers to pump out prototypes. Advances in fiber filled plastics mean stronger parts can be printed easily. Metal 3D printed parts are slowly making their way into more consumer level goods like automobiles and electronics. Consumer printers have also become reliable and usable by almost anyone. No longer does having a 3D printer, make you a 3D printer hobbyist. Now they can be tools to aid in other pursuits. In addition, CAD skills have proliferated allowing more people to bring their imagination into the physical world.

Where is it headed:

While we cannot say for certain what advancements are headed our way, further reliability, higher speeds and advanced materials are an expectation. Some hobbyists are experimenting on how to bring metal 3D printing into people’s garages. Usage of additive manufacturing in the medical field is an ongoing research topic, which we are likely to see progress rapidly. Artificial intelligence is also likely to impact the field, changing how we interact with the physical world vs the virtual one.

Conclusion:

3D printing is one of those topics that tends to either excite people or make their eyes roll. I think the reaction mostly comes from when the person was exposed. For instance, if your first printing experience was with a RepRap in a college dorm room, you might think they’re all toys. However, if you first saw the machines pumping out blanks in a casting shop, you would see real tangible benefits.

We’ve seen both sides and genuinely believe there is a time and place for every manufacturing technique. We use 3D printing when appropriate, but also machine parts when required. Stay tuned to our blog for additional 3D printing topics and contact us today to let us see how to manufacture your parts!

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