Stratasys, the world’s biggest maker of 3D printing systems, claims to have made a breakthrough that could allow the technology — which can already be used to make things from guns to body parts to food — to make customised aeroplane interiors and personalised car dashboards in future.
Stratasys is working with Ford and Boeing to develop the technology to make 3D parts quickly and reliably, and in a much larger size than previously possible — like an entire aircraft interior panel. Stratasys on Wednesday unveiled a demonstration model which can print parts vertically — instead of horizontally as is currently the case — theoretically removing restrictions on how long parts can be.
“We are talking about completely changing the boundaries on size and a massive improvement in speed,” said Richard Garrity, Stratasys’ Americas president.
“When building vertically you could have a part that is tens or hundreds of feet long in theory, whereas in the past the biggest parts were about a metre in any direction. This could have applications for aerospace, shipping, maybe wind turbines or even movie theatre props,” said Terry Wohlers, 3D printing consultant.
3D printing large parts could also lead to greater customisation: “Imagine a future customised dashboard where . . . you get into your car and it’s your car in a very personal way”, said Mr Garrity.
The technology, which Stratasys has dubbed “infinite build”, coupled with a second demonstrator machine unveiled on Wednesday aimed at automating production of lightweight composite parts, could help 3D printing move more decisively into the industrial mainstream, manufacturing experts said. But the timetable for commercial introduction of the technologies remains unclear, as does the cost.
“We are always looking for ways to reduce the cost and weight of aircraft structures, or reduce the time it takes to prototype and test new tools and products so we can provide them to customers in a more affordable and rapid manner,” Boeing said in a statement. “The Stratasys Infinite-Build 3D Demonstrator enables products to be made at a much larger and potentially unlimited length, offering us a breakthrough tool.”
“This is a significant step forward but it doesn’t enable carte blanche disruption [of these two industries],” said Todd Grimm, an expert on 3D printing in manufacturing. “I don’t think it’s realistic in the near term to customise each car, but I think a supplier could have a different version of each aircraft for each client, if not actually customising each individual aircraft.”