The manufacturing industry is in the midst of a 3D printing boom. From prototyping to creating tools, jigs, and assembly fixtures, it’s being used across the supply chain to improve operations.

However, the technology is constantly evolving and keeping up can be challenging. In this article, we’ll explore some key trends and innovations that are changing the way 3D printing is being used.

High-Resolution 3D Printing

As the 3D printing industry matures, the focus is shifting from questions about the technology to ambitions about what can be accomplished with it. This is particularly true for high-resolution printing, which aims to fabricate multifunctional 3D constructs at the micro/nanoscale. The field is advancing toward this goal through advancements in print resolution, speed, printable materials, accuracy, part complexity, build volume, and more.

One such technology is resin printers, which work by selectively curing UV-sensitive liquid polymer one layer at a time. By lowering the layer height, printers can create finer transitions and detail along curved or diagonal surfaces, but these higher-resolution prints take longer to build.

Another example of high-resolution 3D printing is Selective Laser Sintering (SLS), which builds objects out of plastic powder using a laser. This process is highly accurate, with layers so thin they are practically imperceptible. Manufacturers turn to SLS printers for components like jigs and fixtures that need smooth surfaces and engineering-grade materials, such as carbon-fiber filled nylon or flexible TPU. The expanding availability of safe-to-print reactive metals is driving adoption of this technology in automotive applications, such as fluid system parts and air ducts that benefit from lightweight optimization.

Virtual Inventories

As 3D printing moves from a prototyping tool to a viable production manufacturing tool, it will need to scale and be fully incorporated into series-production processes. This will require a full ecosystem, including end-to-end processes, software, and systematic training for operators.

Advances such as large-format printers are making metal 3D printing more feasible for production applications, reducing the costs of complex parts. In addition, materials developments are enabling greater mechanical properties. For example, the emergence of granulates for use on industrial machines is projected to reduce printing time and costs by replacing filaments with a solid material that can withstand abrasion.

One of the primary ecological issues associated with 3D printing is its reliance on plastics, most of which are derived from non-renewable sources. Additionally, the lack of recycling and reuse options for test prints, supports, and failed parts is contributing to waste. Consequently, many companies are working to develop renewable materials and establish robust recycling and reuse infrastructures. Additionally, they are aiming to improve printing speed and precision. This will allow more advanced features such as gradient color and variable surface texture to be produced.

Smart Materials

In 2024, it’s likely that 3D printing will transition from being a prototyping tool to being fully integrated into end-use production processes. This will require a significant shift in workflows and the development of new machines capable of handling multiple materials for greater flexibility. Many professional printer manufacturers still favor dedicating a machine to one particular material type, but it’s critical for the industry to allow for easy swaps between different parts to streamline complex projects, quick-turn orders, and limited editions requiring parts with diverse mechanical properties.

Advancements in smart materials will also play an important role, as they will enable the creation of objects with built-in sensors and actuators. For example, piezoelectric materials — which change shape based on temperature changes and magnetic fields — can be used to power sensors and energy harvesters without modifying the printed object itself.

Meanwhile, fiber-reinforced extrusion technologies are enabling the production of parts up to a meter square, while metal processes like wire arc additive manufacturing are demonstrating that large-scale printing is possible for industrial applications. This resurgence of localized manufacturing will support leaner logistics and on-demand customization for industries across the board.

Localized Manufacturing

3D printing has many applications in a wide range of industries. For example, doctors use it to create bespoke implants and devices for patients. This democratizes production and reduces costs and time to market.

3D printers can produce a vast array of materials, including plastics and metal alloys, making them ideal for prototyping. However, it is not efficient for high-volume manufacturing. Traditional methods like CNC milling or injection molding are better suited to this type of work.

Another important development in the 3D printing industry is the ability to print with multiple materials simultaneously. This allows for parts to be built with a mixture of different materials that combine desirable properties such as strength and heat resistance. For instance, chopped carbon fibers may be added to a thermoplastic filament to improve its strength.

Other advancements are focused on improving the speed, quality and accuracy of 3D prints. This includes optimizing the printing process and reducing waste. It also involves minimizing harmful fumes that can be released during the printing process. This is done by ensuring proper ventilation or using extractors.

Sustainability

For many manufacturers, especially those in the industrial sector, 3D printing represents a major opportunity to improve their sustainability. Using fewer resources leads to lower manufacturing costs and less waste. In addition, the elimination of traditional tooling can help reduce production expenses. Traditionally, producing certain items like shoes or dental appliances requires molding them with molds that are unique to each customer. With 3D printing, manufacturers can use digital files to print each part that is required for production.

This eliminates the need for molds and allows businesses to make each product as they require it, reducing the need for costly shipping and waste. It also helps companies to meet cost-per-part and time-to-part KPIs.

As the industry continues to advance, a focus on sustainability will become a necessity for all players. This will mean incorporating biodegradable filaments into the mix, exploring energy-efficient printers and proactively minimizing our ecological impact. For instance, some 3D printers can be powered by solar panels to minimize the need for fossil fuels. Other companies are developing construction printers that can be used to build sustainable houses and other structures.