been manufactured using electron beam melting powder bed fusion systems from Sweden’s Arcam AB. These are standard, off-the-shelf products that come in a range of sizes. More than 30,000 of these parts have been implanted into patients. AM technologies are also making inroads into the consumer products industry. The sporting goods company New Balance is developing custom 3D-printed soles for its track spikes and running shoes. In January, a profession- al runner wore 3D-printed shoes for the first time at the New Balance Games in New York. The cleat plate of Nike’s new Talon football shoe is manufactured by 3D printing. The ultra-light Talon’s cleat plate was designed to provide optimal traction and help athletes maintain their “drive stance” while sprinting, according to Nike. Two manufacturers of eye- glasses, Mykita and pq, offer products with 3D-printed nylon frames. The Corbs line from pq, designed by Ron Arad, features one-piece frames with hinging action created by a series of scores in the material.
Fact vs. Fiction
Despite many examples of growth and progress, a considerable amount of hype surrounds AM, and many myths and misconceptions associated with the technology have developed. Myth #1: AM is a low-labor con- tent, “pushbutton” technology. While it’s true that AM often runs overnight in lights-out operations, a lot of work occurs before and after the actual production of the parts. Data needs to be prepared at the front end, which may require CAD expertise, the repair of the models, and optimization of support structures. (Most AM systems require that structures are designed to support overhanging features and other areas of parts.) Build parameters, such as layer
thickness, temperature, build speed, and a number of other options may need to be adjusted for a particular part, group of parts, or type of material. Thermal AM processes require pre- build chamber heating and post-build chamber cooling and
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June 2013 |
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