Feature published in the February 2019 issue of 3D ADEPT MAG, then online in May 2021. Examples and offerings reflect that period, not a current product catalogue.
Prototyping, tooling and end-use parts offer several routes to industrial polymer 3D printing. This feature examines automotive applications, customised devices and consumer products, alongside suitable manufacturing processes.
Jérémie Soulestin, then a researcher at IMT Lille Douai, emphasised polymers’ role in prototyping. That use does not exclude end-use parts. Stereolithography (SLA) uses photopolymer resins, distinct from the thermoplastics used in processes such as extrusion and powder bed fusion.
Lightweighting does not inherently favour metal over polymer. The choice depends on design, loading, temperature, durability and qualification requirements. Carbon is not a thermoplastic: carbon fibres can reinforce a polymer matrix.
Selected PEEK or PEI grades, including grades sold under the ULTEM brand, can replace metal in a qualified application. Weight savings must be calculated for equivalent function in the particular part. The original 5–9% estimate had no identifiable source or scope and is not retained as a reference value.
What are the opportunities of 3D printing with polymers?
The following applications illustrate different industrial uses of polymers.
The automotive industry
Automotive prototypes help verify part shape, fit and function. The original feature did not identify a source supporting its claim about the sector’s ranking in printer purchases in 2017.
In the motor sports sector for example, additive manufacturing is often used with polymer materials to produce functional parts for racing car tests.
CRP Technology produces additive-manufactured components, while CRP Meccanica provides capabilities including precision machining. Energica is the manufacturer of the motorcycles discussed here. Windform denotes a range of materials: properties and validation requirements vary by grade.
Ego Corsa development combined printed aerodynamic components with mechanical work involving braking, suspension and the battery. CRP’s report of 28 May 2018 places the demonstration quoted below at the French Grand Prix in Le Mans.
Randy de Puniet, former MotoGP rider and 250cc race winner shares his feelings about the demo lap: “The connection with the throttle and the power delivery are very smooth”, he said. “The bike reaches high speed in a very short amount of time, and that’s a good thing. Another good point of the bike is that the rear is very stable when opening the throttle. It’s a very easy bike to get to grips with, so it would be fun to be racing the Energica Ego Corsa against twenty or more riders on identical machinery. I am really pleased with this experience and grateful for the opportunity; I hope my feedback will help Energica continue in the right direction.”
For the Bolid-E concept, this 2019 feature reports SLS manufacture of lighting-related components and CNC machining of the structural seat support. This does not mean the whole motorcycle was 3D printed.
Tooling suited to the shop floor
3D printing can shorten selected tooling lead times and make customisation easier. Cost, strength, accuracy and service life still need comparison with other options for the intended use.
Filament extrusion and SLA are among the processes used. Ultimaker presented a Ford custom-tooling example in December 2018.
Medical applications and customised devices
Applications include anatomical models for pre-surgical planning, selected guides and tools, and prosthetic components. These uses must be distinguished from manufacturing functional human organs.
SLA is not required for every prosthesis or hearing device. Process, material, post-processing and controls must suit the particular device and intended use.
In a 6 November 2018 announcement, 3D Systems reported that ACS Custom had quadrupled capacity after introducing two Figure 4 Standalone printers. The workflow printed sacrificial shells, which were filled with silicone and then removed; the final device was not simply printed directly. These are results reported for that case.
Customization of mass consumption products
Polymers can support customised product runs. Economic viability still depends on volumes, machine time, finishing operations and required quality.
The Gillette and Formlabs Razor Maker programme, introduced in October 2018, used SLA to produce customised razor handles.
The offering described in 2019 included 48 designs, seven colours—black, white, red, blue, green, grey and chrome—and added text, with handles for MACH3 or Fusion5 ProGlide cartridges. These details describe the historical offering, not its current availability.
Processes used for polymer 3D printing
The table outlines four process families and selected examples. It is not an exhaustive list or a guarantee that every polymer is compatible.
| Family | Examples |
|---|---|
| Material extrusion | FFF / FDM |
| Vat photopolymerisation | SLA |
| Powder bed fusion | SLS ; Multi Jet Fusion |
| Material jetting | Photopolymer jetting |
This feature was originally published in the February 2019 issue of 3D ADEPT MAG.
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