Additive manufacturing was introduced in 1987 with stereolithography, the process of bonding fine layers of polymer with a beam of UV light.
Additive manufacturing or 3D printing has come a long way in the last 32 years, from the invention and of the three main technologies, (SLA, SLS and FDM) in the early 90’s to the break through into the medical industry in the early 2000’s with the first 3D printed cell scaffold and prosthetic limb. The development continued from the late 2000’s up to present day with 3D printing becoming commercially viable and the introduction of machines that could print with multiple materials.
Today we are able to print with a huge range of materials from metals like titanium, stainless steel, aluminium and nickel alloy through to carbon fibre and ceramics many examples of which are in use in everyday life.
This process relies heavily on computer aided design (CAD) as the 3D printing process regardless of the material is automated, companies such as Qualis Engineering have seen a sharp rise in the demand for CAD design services and reverse engineering from highly accurate laser scans to reproduce an item in a digital format, allowing it to be entered into the new world of digital manufacturing.
But where will this technology go next, after speaking with a representative from the MTC (the national centre for additive manufacturing) it becomes very clear that the pace at which this technology has evolved is becoming its biggest road block in success. The world of 3D printed components has evolved so quickly that the engineering industry is not yet agreed on how to verify it or control the process and characterise components. Whilst it is widely used for decorative and mostly unstressed parts there are many concerns around using printed components in applications that ensure public safety. This is due largely to the manner in which layers of material are fused making it very difficult to verify that a component is defect free and that the material properties will remain a constant thorough out the component.
Modern digital manufacturing technology also allows for a much greater use of organic free form shapes such as turbine blades and blisks, making traditional dimensional inspection insufficient as there is a much greater chance of surface variation over linear axis. Again companies such as Qualis Engineering have seen a sharp increase in the requirement for laser scanning in the metrology role as we are able to take 100,000’s of points over a surface and compare them directly to the CAD model.
The next big step forwards for additive manufacturing could well be metallic printed parts in aviation, there are currently many decorative parts used but the industry is yet to sign off on system or rotating components being used. Something that could drastically change over the next five to ten years as the engineering regulatory bodies such as ISO and ASME come to adopt and understand additive manufacturing and provide greater confidence and control.
If you have any questions regarding our reverse engineering and 3D laser scanning services in Oxfordshire, Buckinghamshire, Milton Keynes and the Midlands, please get in touch.
info@qualisengineering.co.uk
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