Functional products

What is the next generation of 3D printed products?

When the first applications of commercial 3D printing emerged, they were mostly about appearance models and prototypes. These are still, and will be, powerful and valuable applications in many businesses. During the past 10 years we have seen radical development in design tools, materials, 3D printing technologies and skills. 3D printing is now serious and reliable manufacturing method for end products, product series and spare parts in all industries. We have 3D printed products that are beautiful, optimized in many ways and serve perfectly for the intended purposes.

Is this the end of evolution? Not even close! We only start to have a good platform to imagine the future systems, after practising the technology basics and having a vague understanding of what we can make. So, here is my vision for the next generation products, made with the help of 3D printing.

“The future is already here – it’s just not evenly distributed.

– William Gibson –

Examples

  1. Interactive products will merge different technologies seamlessly, and interact with the user, system or environment in many levels. This future window is cracked open by Anouk Wipprecht. Products like Spider Dress or Proximity Dress show how products can sense and react to data or different signals from the environmnent.
  2. Personal amplifiers will give new capabilities to people. Paralympian athletes already use 3D printed prosthetes and appliances to support with a given sport, for example to run faster with spring-like artifical legs. Exosceletons are used to help lifting heavy weights. When this opportunity develops to the next level, we will build products that give us strength, better senses or capabilites never seen before. In the future we may have bionic olympics that drive the development of personal amplifiers in the same ways as Formula 1 races drive the development of better cars.
  3. New vehicles. In 1950’s the dream of a flying car emerged. Now we start to have manned drones. There are many obstacles slowing down the wider adoption, such as manufacturing cost, safety, regulation and non-existing traffic management systems for these small manned vehicles. Putting obstacles aside, let’s just ask, is it doable to make low cost flying vehicle? The concept was presented by Janne Kyttänen in his vision about 3D printed manned drone. By using suitable materials and careful optimized design, the body of the vehicle can be 3D printed in few hours with a large format 3D printer. The rest is about putting electronics, motors and other components automatically in place.
3D printed manned drone. Model 3D printed by 3DStep. Design by Janne Kyttänen.

The making of functional products

The next generation products will be based on strong systemic view. It is not about having perfect components, optimized for specific features, such as cooling or minimizing materials, but about justifying the whole reason for a product the be realised. We can make optimized components for an airplane for saving weight, or we can design new categories of sustainable flying vehicles.

The next generation products will gracefully ignore the boundaries of sciences. Rich multidisciplinary knowledge is applied to achieve the goals, such as making technology products that react with biosignals and apply artificial intelligence to perform better in a certain social context.

We will master the whole spectrum of available materials. Already today 3D printers can use an unbelievable range of materials, from living cells to tailored metal alloys. New materials emerge practically every day with amazing features. Making of the next generation functional products is not about if there is suitable materials available, but being able to define which features we want want to have in the products.

Strategic guidelines

What steps we should take towards the next generation functional products?

Collaboration is the key. Now we simply need to take collaboration into new levels. This happens by global ventures, connecting individuals, teams and developers with the help of smart development platforms. Facilitating trust between stakeholders is a mandatory activity.

Maximize creativity and imagination. Development projects are often defined by business case or ROI. The are often justified, but to maximise creativity and innovation we need more value based motivators. We, as humans, get fundamentally motivated by other things than money, especially when we face the opportunity to create radically new.

Extreme multidisciplinarity. As mentioned earlier, we need to ignore the boundaries of sciences. Products and systems of the future use the best of what humans or nature have ever invented. A powerful way to guide the development is to establish global development funds that require connecting sciences in unexpected ways. In local level great examples are, for example, hacker and maker communities, such as biocurious.org, which are based on citizen science, curiousity and co-learning.

Lets’ make it.

Pekka Ketola, February 18, 2021

CEO 3DStep Oy & Ideascout Oy. Innovator. LinkedIn

3D printing and the customer insights. Case: Car Industry & spare parts

3D printing has opened wonderful opportunities for collaboration between customer and the company. This dialogue is useful and creates value for all. It is no wonder that companies like Local Motors, Volkswagen and Shapeways take community management and co-development with 3D printing seriously.

Car industry has found maybe the largest number of 3D printing applications. It has also managed to connect users, engineers and the industry in innovative ways. However, there are still untapped possibilities. I will discuss some examples of the new value generation and open horizons for industrial collaboration for better customer engagement.

1. Connect company with user insights

3D printing aggregators, such as Thingiverse, provide rich world for exploring do-it-yourself 3D-printables. People are solving their concrete needs with all kinds of tools and parts, such as GoPro camera holders, and sharing the results for others to use. Often the DIY part has features that are far better than the original from the manufacturer.

Manufacturing companies are following these online forums in order to get insights on the next products, understand needs that are related to the uses of their products, and also to identify talented designers and innovators.

Some companies are even smarter. They actively engage and invite online talents to join their development projects and design challenges, offering soft rewards like great community of co-developers, learning journeys and recognition, or tangible rewards. For example Local Motors has used online community for the development of the 3D printed cars.

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2. Use community to develop better parts

Spare parts is a promising 3D printing application for car industry.  Mercedes Benz is starting the manufacturing of metal 3D printed on-demand spare parts for older trucks. The parts are manufactured from the digital models that either exist already or are reverse engineered from existing parts.

”Using additive manufacturing, the company was able to achieve parts with almost 100% density, greater purity than conventional die-cast aluminium parts, very high strength and thermal resistance – making the process particularly suitable for small batches of mechanically and thermally stressed components.” Source

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Mercedes Benz 3D printed spare parts. Source.

Also Daimler is developing 3D printed spare parts manufacturing, especially for plastic parts using SLS technology. The current offering covers more than150 on-demand parts.

Beyond brand specific solutions there are also companies offering spare parts for any applications. For example, Spare Parts 3D from Singapore offers a general spare part service for all and everywhere, mainly printed with plastics. The company’s mission is to digitalize the stocks. Also this service is based on the digital community. 3D printing service offices anywhere can join and become local service providers in Spare Parts 3D network. Target delivery time for spare parts is 24 hours.

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The promise and value is not only in the spare parts. Rapid manufacturing of car spare parts enables fast response to developing user needs and emerging product problems. For example, when the original spare part lacks a feature or tends to break in certain way, it can be re-designed and then printed without delays. The concept of better parts emerges. The customer gets better solution (maybe not CE approved, though) and the original manufacturer gets concrete proposals for improving the products. Of course, only if the manufacturer has a method for discussing and collaborating with the customers.

Case: Avant hydraulic block

Avant loaders are high quality machines for many kinds of jobs that require horsepower in compact and ergonomic form. The engine has hydraulic block of 2.9 kilograms with over 30 different parts. Finnish 3D printing company 3DStep re-designed the block for 3D printing, together with engineering company Enmac. Special attention was paid on the improved functionality and faster installation. The resulting part weights less than 400g:s and is made from one component. This part is a typical example of 3D printed better part. It is lighter, integrated and provides better functionality than the original.

avanttecno-machine      avant3d

3. Empower the engineers with 3D printing

Volkswagen has demonstrated that 3D printing can have crucial role in optimizing car design, manufacturing and maintenance. VW factory in Portugal makes over 100 000 cars every year. This factory is specialized in the manufacturing innovations related to new models.

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The poka-yoke makes it possible to position and assemble screws without damaging the wheels. Source.

Desktop 3D printers were brought to help the design and manufacturing of new cars. During 2016 more than 1000 tools were 3D printed on-demand. Volkwagen reports major savings in making new tools (95%) and radically decreased manufacturing costs. The biggest shift was mental: taking the step from closed R&D environment to the use of open innovation culture.

4. Think about your 3D printing strategy

The global ecosystem of spare part catalogues, service providers and crowdsourced designers is forming right now. The open ecosystem will straightforwardly serve the customer and engineer needs rather than the company business strategy. From the company perspective, the business is shifting from dealing parts and logistics to dealing with copyrights and mastering the creative developer community.

3D printing is an opportunity to renew the company business, digitalize services and build cost-efficient solutions for logistics, maintenance and production. Any company working with cars, loaders, trucks and other vehicles needs to study the business opportunities and new avenues of competition for the next 1-3 years. 3D printing will change the car industry from village garages to manufacturing plants.

Take coffee and think:

  1. How your business could be improved with 3D printed parts and tools?
  2. How your customers could be co-developers?
  3. How you can try out 3D printing in your business?

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Views on spare parts business. Source: Strategy&

– Pekka Ketola, CEO 3DStep –


 

3DStep is the scandinavian forerunner in 3D printing business. Our mission is to make 3D printing business as usual. 3DStep factory and innovation centre locate in Ylöjärvi, Finland.

3DStep provides all you need from idea generation to design, optimisation, prototypes, serial additive manufacturing (metals, plastics), training and strategy development. 3DStep is your trusted partner for spare parts and better parts.

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