Additive Manufacturing brings new opportunities to the plastics supply chain. Systems once used for rapid prototyping have matured enough to supply a number of end-use parts. Still AM piece parts need better material properties and finishes to expand into new markets. Polymer science houses, compounders and processors are key to growth.

1. Additive Manufacturing (AM), Creating New Tradespace for Plastics
Jack Dispenza, Design Results, LLC
Introduction
Manufacturing has certainly changed in the last hundred years. Originally craftsmen built products by hand
concentrating on quality but needed to produce with speed. Automation answered the requirements for speed and
helped to reduce costs on multiple units. Molding improved manufacturing further offering highly detailed, lightweight
and consolidated parts that eliminated many secondary operations including finishing. Reshaping manufacturing is
continuous and advancements happen daily. Where do we see exceptional advances and innovation today? Additive
Manufacturing (AM).
History
3D printing (3Dp) was additive manufacturing’s predecessor. Invented in the mid eighties, 3D printing instantly became
very popular in various market segment R&D communities. It took twenty years to become a billion dollar industry; it
doubled in the previous five years and will double again by 2015 according to Wohlers Associates, experts on the 3Dp /
AM markets. Deloitte analysis shows the 2013 AM market to be 3.1 billion up at least 35% over 2012. Exponential
market growth is expected to continue into 2020 when the AM industry may exceed $20 billion. Lux Research predicts
AM markets will easily quadruple by 2025. Interestingly, the Gartner report shows enterprise printing machines (sub-
$100,000.) grew 49% last year. Manufacturers of personal 3D printers also had double digit growth which is expected to
continue with the popularity of printers in education, hacker spaces and a variety of special interest and user groups. All
stakeholders in the AM value chain including machine builders, software houses, material producers, distributors and
service providers are trying to educate customers on the best process and material fit for a given application. While
there are limitations in machinery, print methods and materials, daily technological advancements provide more and
more opportunities. Early 3D printing was costly and limited to commercial or enterprise prototyping but today the
technology is within easy reach of all sizes of businesses, ‘prosumers’ or professional artists and makers, design offices,
schools and even the average household or consumer. Today’s 3Dp is transitioning to additive manufacturing making
product realization more nimble and opening new market channel
Definition
ASTM International provides a recognized description of additive manufacturing as: “A process of joining materials to
make objects from 3D model data, usually layer upon layer, as opposed to subtractive methodologies.” Additive
manufacturing builds parts utilizing a three-dimensional (3D) computer-aided design (CAD) file or scanned image (point
cloud file) converted into surfaces (triangles, polygons) and saved as a standard tessellation language (.STL). The .stl file
is then sliced into layers which serve as instructions for the AM device. The most popular AM processes include
SLA/stereolithography (vat polymerization of photopolymers), FDM/fused deposition modeling (thermoplastic
monofilaments extruded through a nozzle), SLS/selective layer sintering (fusing thermoplastic powder by laser) and
material or poly-jetting (polymer droplets placed by print heads). The aforementioned SLA, FDM and SLS processes
account for the majority of AM today. Other processes include binder jetting (an inkjet print head moves across a
powder bed placing binder material) and laminated object manufacturing or sheet lamination (cut sheets, bonded layer
by layer to form a part). Also some manufacturers are using LMD/laser metal deposition (focused thermal energy to fuse
metal material) and directed energy deposition (metal powder feed) to produce mold tools and factory aids.
Thermoplastics Focus

2. Thermoplastic piece part designers and molders have been in the forefront of patternmaking, model fabrication,
computer numerical control (CNC) machining of sample parts, building manufacturing jigs and fixtures, producing
functional prototypes and mold core and cavity creation using subtractive methods. Additive methods have impacted all
of these areas and now we are learning to progress past prototypes and provide low and high volume manufacturing
with more choices for functional or end-use parts. Additive manufacturing brings to product realization a convergence in
design, materials and machines.
AM Examples
A number of segments, especially medical, have made AM the method of producing their products. Hearing aids that fit
the individual patient’s ear(s) for example are not made from machined steel molds, they are printed. Using a scan of
the ear or a physical pattern, a digital file is created and sent to a stereolithography (SLA) machine to expose
photopolymer with lasers, layer by layer, to create the unique device housing. Over 10,000,000 devices are in circulation
today due to the high-accuracy, micron level 3D builds. Dental aligners are another example of printing thousands of
parts a day, each part with unique geometry. The metal wire aligners can now be replaced with printed, clear plastic
aligner trays. The largest firm in the aligner business produces over 40,000 piece parts a day running a few dozen SLA
machines continuously.
Competition with molding
Is AM replacing traditional molding? No, not today. Additive manufacturing needs higher build speeds, better aesthetics
(layer lines show) and improvements in mechanical properties such as Z strength to compete with high-speed injection
molding. AM machine builders, government national laboratories, academia, consortiums, large corporations, even
hacker spaces are aggressively trying to improve AM speeds and quality. Does AM present a level of risk to traditional
plastic part manufacturers? Yes, there is some degree of risk as AM processes and materials improve. Existing
manufacturing depends on very large and complex supply chains that ship product over great distances, and build
assemblies and replacement part quantities in numerous regional centers on each continent. The inventory liability for
appliance companies, automobile builders, power tool companies and consumer products to name a few is incredible. I
have spoke with a number of Fortune 500 companies that are anxiously waiting for the day when tens of millions of
dollars of inventory in a number of major cities can be replaced with modest 3D printers. In the near future, when a
customer calls a service center with a part request, many believe parts will be printed overnight for pick-up or shipment
the following day. Digital fabrication of a replacement part for your car, lawn trimmer or appliance is expected to be
orders of magnitude less expensive than stocking warehouses with a wide variety of codes or parts.
Changing business models
Few would argue AM is a disruptive technology. At a minimum, we should expect faster product development, easier
customization and new areas of revenue. At the same time this technology will increase the number of competitors as it
allows for less tooling capital expenditures, high early confidence in designs, collaborative engineering and lower costs
providing faster market introduction calendars. Our manufacturing strategies may be challenged as AM machines come
down in price and capabilities increase. Some parts may migrate from molded to printed forcing us to rethink our
manufacturing facilities and offices while developing new strategies and plans for future business. The optimistic
industrial designer in me sees many more AM benefits than challenges. I have enjoyed making overnight models from
digital scans, convenient 3D printed molds used for short-run production parts, fast patterns for the foundry, forms for
vacuum bagging of composite parts, fixtures for assemblies and the list goes on. It is very easy to print negatives or
molds instead of positives or physical parts. Using these printed molds, multiple parts can be vacuum-formed or molded
in specific thermoplastic resins in order to meet stringent end-use requirements. We certainly need to be more creative
with these emerging AM technologies and be sensitive to where business models need to change.

3. Key Players
The big players in AM are 3D Systems (nyse: DDD), supplier of SLA machines and SLS machines, Stratasys (nyse: SSYS),
leading supplier of FDM machines (commercial and personal) and polymer jetting systems. EOS is another important
supplier of SLS machines and competitor to 3DS. 3DS is 13th
on Forbes 100 Most Innovative Growth Companies and
finished last year with an incredible $513M in revenue. Stratasys finished 2013 with an impressive $486M. The big
players are battling for position with acquisitions in addition to new machines and materials. 3D Systems has purchased
a number of software firms, robot companies, scanner producers, other 3Dp machine builders and major service
providers. 3D Systems also runs their own service provider network called Quick Parts. Stratasys merged with Objet in
late 2012 to offer inkjet-based polymer part creation in addition to FDM. In August of 2013, Stratasys and MakerBot
completed their merger adding desktop systems to the Stratasys commercial and production machine line-up. M&A
activity is fierce and you would need to watch the technology news feeds daily to stay on top of the action. Adding to
the big AM players are countless groups introducing new machines and technology through funding vehicles such as
KickStarter, Fundable and Crowdfunding.
Market segment activities
Additive manufacturing target markets span most industries including automotive (17%), medical (14%), consumer
products (18%), aerospace (12%) and industrial parts (19%) according to Deloitte. There is a significant rate of change
with production or end use parts. The end use parts grew from 19% a few years back to over 29% today. Production
parts are increasing in giftware, home furnishings, jewelry and shoe segments in addition to the major industry
applications. With modest improvements in polymer powders, thermoplastic filaments and photopolymers we will see
many new applications in end use parts. Tooling for all the industries is also progressing as a number of limitations in
conventional manufacturing are not common to additive manufacturing. In AM there is little waste, much lower capex
and less complicated facilities and operations. The consumer and ‘prosumer’ markets are taking advantage of the ease
of entry to manufacturing.
Innovation
I am very fortunate to work with a number of AM developers and users on fascinating applications. I am always amazed
at the creativity I see during business travels and at the various trade shows. In Europe, Formula One race car builders
are printing half-scale models of the cars for wind tunnel testing. Once the half scale parts show balanced aerodynamics,
full size spoilers, air dams and body components are produced. In China’s Guangdong province, known to produce a
large percentage of the world’s recreational shoes, 3D’ers started printing not only approval models but patterns used
for cast tooling as well. Visiting MIT, I viewed research on 4D printed models that have moveable features and using
geometric code transform into other shapes. There were even functional models that performed self assembly! Using
FDM, a small exoskeleton was created to help a young girl with underdeveloped muscles play and hug. Microlattice
materials, or open-cellular architectures, are being printed at high-speeds to provide rigid, lightweight structures that
offer impact protection. The open cell structure of these parts allow for embedded sensors, fluid movement and air
flow. There are too many cool projects to list here.
Game changers
What may be next? There are some advanced technologies that are sure to upend the AM industry. Arburg recently
provided information on the soon to be released Arburg Plastic Freeformer (AKF). This machine is loaded with standard

4. thermoplastic pellets and utilizes a fixed nozzle. The plastic part is printed on three axis and with a component carrier
five. Single parts can be economically built in the thermoplastic the user requires. Autodesk, one of the top 3D modeling
software suppliers, announced a lower-end or consumer printer called ‘Spark’. Autodesk created an open 3D printing
platform from part visualization to physical printing control. Design of the printer, based on SLA / stereolithography, will
be made available to developers and machine builders to enhance capabilities. Autodesk states one of the limitations is
material science or chemistry and will encourage the AM community to develop materials of their own for the printer.
We will see if this system will become an accepted operating system. Relative to machines, Hurco filed a patent for a
hybrid CNC/3Dp machine that combines their CNC or subtractive capabilities to printing or additive capabilities.
Matsuura is another company combining CNC with AM of metal parts. The hybrid machines will provide customers with
large robust platforms, precision control and one machine for all types of model, tools and end-use parts. Organovo is
making steady progress on ‘bioprinting’, the deposition of living cells or bio ink on hydrogels. Today they supply tissues
for testing and are working on parts or patches for implant and repair. In the future, they expect to print lobes or pieces
of organs. The robots that provide the machine functions, either for large parts or small bioprints are rapidly advancing
as well. Robots span from simple open source hardware models (the RepRap build it yourself project) to delta bots,
SCARA arms and octopods to name a few.
Summary
In a perfect world, machine builders and polymer science houses would be working together to solve the myriad of
process and material issues effecting additive manufacturing methods. Putting the hype aside as well as the media love
fest with 3Dp, all AM builds need improvements in material physical and mechanical properties. Service providers are
always working with the customers to establish a ‘fit’ or process and material combination that may come closer to end-
use requirements. There is no perfect system and there are known limitations to materials developed for any of today’s
AM systems. Since AM usually builds by layers, we need to concentrate on the bonds between each layer and often the
resulting porosity. FDM materials for example have poor Z strength, weaker along the build axis. SLA photopolymers are
somewhat brittle resins and even after post curing most parts cannot survive a severe drop. SLS powders create a fairly
durable part but the rough surfaces are difficult to finish. Polyjet models are beautiful to look at but are not durable
enough for simulated use testing. The newer machines may build faster and more accurate but the thermoplastics,
thermoset resins and photosensitive materials need to improve before additive manufacturing will fit all market
segments.
Additive manufacturing is combining art with the ease of manufacture. None of us know if 3D printers will be as
commonplace as 2D ink printers but the units sold keeps doubling. People are making very, personal products
themselves at home using printed plastics. We have new groups of consumers, they are creators and makers. An artist
can manufacture an item as easily as the technical firm. There are high expectations with educators who are saying,
‘students are learning to make, some are making to learn’. Shops called fab labs, hacker spaces and maker groups are
springing up all over the world and using all types of AM systems.
Industries such as aerospace, automotive, consumer products, defense, industrial parts, medical, dental and sports
equipment are all stakeholders and embracing the AM capabilities. We need to take another look at our strategies and
business plans as thermoplastics will benefit from the emerging technologies and the rate of acceleration. Raw material
houses, polymer scientists, compounders, extruders, grinders, additive suppliers, distributors and service bureaus
hopefully will drive AM from a materials perspective. We are living in the future and opportunities abound.
SPE focus
Additive Manufacturing is an important theme in Society of Plastics Engineers’ (SPE) events and was presented in depth
at the recent SPE ANTEC, the annual technical conference on plastics. Held in Las Vegas this past April 27th
through May

5. 1st
, the SPE New Technology Forum’s invited speakers provided attendees with the latest in multi-functional parts, 3D
build improvements, changes in engineer’s desktop technologies, advanced thermoplastics for AM technologies and 3D
printing of prototype injection molds. SPE events are very popular and the society is viewed as one of the largest,
manufacturing special interest and educational groups in the world. Since 1942, the society has provided the latest in
processes and materials and this year’s ANTEC with AM sessions was no exception.
Jack Dispenza
Jack is a Fellow in the Society of Plastics Engineers (SPE), member of their New Technology Forum and serves on the
Injection Molding Division Board of Directors. Jack is Consultant and Founding Engineer of Design Results, LLC in Long
Valley, NJ. Design Results is a full service product realization consultancy focused on plastics, composites and additive
manufacturing. jackdispenza@gmail.com, Design Results, LLC, 908 876-5774