The 3D Printing Revolution: Past, Present, and Future

In the realm of modern manufacturing, 3D printing, also known as additive manufacturing (AM), has emerged as a revolutionary technology, transforming the way we conceptualise and produce three-dimensional objects. This article aims to provide an in-depth exploration of the history, terminology, and technological advancements that have shaped the 3D printing landscape.

From its humble beginnings in the 1980s as a tool for rapid prototyping to its current status as a viable industrial-production technology, the journey of 3D printing is nothing short of remarkable.

Historical Overview

• 1940s and 1950s: The roots of 3D printing can be traced back to the speculative ideas of visionaries like Murray Leinster and Raymond F. Jones in the 1940s and 1950s. Leinster, in his 1945 short story “Things Pass By,” described a constructor that utilised magnetronic plastics to create three-dimensional objects layer by layer. Jones, in his 1950 story “Tools of the Trade,” referred to a “molecular spray” for creating objects.
• 1970s: The 1970s witnessed crucial developments with Johannes F. Gottwald patenting the Liquid Metal Recorder in 1971, showcasing the early concept of 3D printing. David E. H. Jones elaborated on the idea in 1974, laying out the groundwork for future advancements.
• 1980s: The 1980s marked the birth of additive manufacturing equipment and materials. Hideo Kodama’s 1980 invention of two additive methods for fabricating three-dimensional plastic models and Bill Masters’ 1984 patent for computer-automated manufacturing processes were pivotal moments. Alain Le Méhauté, Olivier de Witte, and Jean Claude André filed a patent for stereolithography in 1984, contributing to the diversification of 3D printing technologies.
• 1990s: The 1990s saw the development of various additive manufacturing processes for metal, including selective laser sintering and selective laser melting. MIT’s Emanuel Sachs introduced the powder bed process in 1993, and in 1995, the Fraunhofer Society developed the selective laser melting process, expanding the capabilities of 3D printing.
• 2000s: The early 2000s witnessed 3D printing primarily in the manufacturing and research industries due to its high cost. However, initiatives like RepRap and Fab@Home in the mid-2000s paved the way for open-source 3D printing, making it more accessible. In 2009, the Fused Deposition Modeling (FDM) printing process patents expired, leading to a surge in startup companies focused on developing commercial FDM 3D printers.
• 2010s: The 2010s marked the maturity of various additive processes, with metal end-use parts gaining prominence. Industries like aviation began integrating 3D printing for cost reduction, weight reduction, and optimised designs. The decade also witnessed the development of sustainable applications of 3D printing in the developing world.
• 2020s: By 2020, 3D printers had become more affordable, with entry-level machines priced below $200. The technology had reached a level where it was accessible to a broader audience. In November 2021, Moorfields Eye Hospital in London achieved a groundbreaking milestone by providing the world’s first fully 3D-printed prosthetic eye to a patient named Steve Verze.

Terminology and Evolution

• Additive Manufacturing vs. 3D Printing: The terminology surrounding 3D printing has evolved over the years. In the 1980s, the term “rapid prototyping” was more commonly used, reflecting its initial applications for functional or aesthetic prototypes. The umbrella term “additive manufacturing” gained popularity in the 2000s, emphasising the addition of material layer by layer. However, both “3D printing” and “additive manufacturing” are often used interchangeably, with some experts attempting to distinguish additive manufacturing as a broader concept that includes various technologies beyond polymer-based printing.
• Other Terms: Throughout its evolution, 3D printing has been associated with terms like “desktop manufacturing,” “rapid manufacturing,” and “on-demand manufacturing.” These terms reflect the shift towards more agile and responsive production processes enabled by 3D printing technologies. “Subtractive manufacturing” has also been used as a retronym for traditional machining processes, highlighting the contrast with additive manufacturing.

Key Technological Advances

• Fused Deposition Modeling (FDM): Fused Deposition Modeling (FDM), developed in 1988 by S. Scott Crump, stands out as one of the most common 3D printing processes as of 2020. This technique utilises a continuous filament of thermoplastic material, allowing for cost-effective and versatile printing. FDM has found widespread use due to its precision, repeatability, and material range.
• Stereolithography (SLA): In 1984, Chuck Hull patented stereolithography, introducing the SLA process. This method involves curing photopolymers layer by layer using ultraviolet light lasers, creating precise and intricate objects. Hull’s contribution includes the STL file format, which has become integral to many 3D printing processes.
• Selective Laser Sintering (SLS): Selective Laser Sintering, a technique for sintering powdered material using a laser, gained prominence in the 1990s. This process allows for the creation of durable and complex objects by selectively fusing powdered materials.
• Selective Laser Melting (SLM): The 1995 development of selective laser melting further expanded the possibilities of metal 3D printing. This technique involves melting metal powders layer by layer to produce robust and intricate metal components.
• Open-Source Initiatives: The 2000s witnessed a surge in open-source initiatives like RepRap and Fab@Home, democratising 3D printing technology. These projects encouraged collaboration and innovation, leading to the development of more affordable and accessible 3D printers.
• Sustainable Applications: In the 2010s, 3D printing began to be seen as a tool for sustainable development, especially in the developing world. The technology’s potential to provide cost-effective solutions and locally manufactured goods has sparked interest in addressing various challenges.
• Integration in Aviation: The aviation industry embraced 3D printing in the 2010s to enhance fuel efficiency, reduce costs, and produce complex components. Examples include Airbus integrating 3D printed fuel nozzles in GE’s LEAP engines, showcasing the technology’s ability to optimise design and reduce assembly times.

Current Landscape and Future Prospects

• Accessibility: As of 2020, 3D printing has become remarkably accessible, with printers available for less than $200. This affordability has opened doors for enthusiasts, hobbyists, and small businesses to explore and leverage 3D printing technology.
• Medical Advancements: In November 2021, Moorfields Eye Hospital achieved a significant breakthrough with the world’s first fully 3D-printed prosthetic eye. This exemplifies the ongoing exploration of 3D printing in the medical field, where custom and intricate solutions can be tailored to individual patients.
• Evolving Materials: The materials used in 3D printing have also evolved, ranging from thermoplastics to metals. Innovations in material science continue to expand the possibilities, allowing for the creation of functional and durable end-use parts.
• Sustainable Manufacturing: As environmental concerns become more prominent, 3D printing offers potential solutions for sustainable manufacturing. The ability to produce complex structures with minimal waste aligns with the growing emphasis on eco-friendly practices in the manufacturing industry.
• Integration with Other Technologies: The future of 3D printing may involve increased integration with other cutting-edge technologies. Advancements in artificial intelligence, robotics, and IoT could synergize with 3D printing, leading to more automated and efficient manufacturing processes.