A Brief history of Additive Manufacturing

AM Fundamentals A Brief history of Additive Manufacturing

History

Industrial Additive Manufacturing overcoming the hype​

Over the past years, Additive Manufacturing has seen a rapid development. Starting from a technology that was mainly used for prototyping in the 90s, Additive Manufacturing has come a long way. We will use the Gartner Hypecycle to display the different cycles the technology has gone through over the last 10 years. 

It needs to be noted that it is hard to pinpoint the exact location of a certain technology or industry on the hypecycle. To make a more accurate statement, each application should be placed individually on the hypecycle. The technologies and industries that are described in the following thus need to be seen as aggregation of the respective applications. 

Consumer 3D printing, which has seen a massive hype in the early 2010s, is currently stuck in the “trough of disillusionment“. While in the past people thought in the future every private person might have a 3D printer at home, this is today only true for a small niche. 

Enterprise 3D printing, on the other hand, has already passed the trough and has according to Gartner continued to go through the “slope of enlightenment” between 2013 and 2018. 

Looking at Additive Manufacturing across different industries and technologies, we consider that mature technologies such as Powder Bed Fusion (PBF) are generally still somewhere in the slope of enlightenment. The medical industry can be seen as an exception that has already reached the “plateau of productivity“. We expect further industries, such as the space sector, follow in the years to come.

A more detailed discussion of the maturity of different AM technologies can be found in the courses on Metal and Polymer technologies.

What you will find in this section

The early days

Science fiction and enabling technologies

Reading up on the historical developments on the AM market helps to understand how the market has evolved into what it is today. We will give an overview of what we consider the most important developments since the 1980s. Before that we would like to take a brief look back at the time before that. 

One of the first persons to describe what we call 3D-printing today was American science fiction author Raymond Fisher Jones. Jones published the short story “Tools of the Trade” that appeared in the November 1950 issue of Astounding Stories. Even though he referred to it as “Molecular Spray”, this is often considered to be the first story dealing with 3D printing. 

In the following, years underlying technologies that would later enable the emergence of 3D-printers, have developed. Most notably these technologies include computer aided design (CAD), advancements in computers and the possibility to process large amounts of data, as well as rapid developments in laser-technologies.

1980s

The first patents around 3D-Printing

The early developments of 3D printing started with a range of patents around building up parts layer-by-layer across Japan, France and the USA in 1984. These patents emerged into the first companies commercializing Additive Manufacturing in the subsequent years. During that time technologies such as Stereolithography, Selective Laser Sintering (SLS) and and Fused Deposition Modeling (FDM) emerged. 

Application of Stereolithography patent by Charles Hull

In 1984, Chuck Hull applies for the Stereolithography patent. The technology develops into one of the most widely used technology for rapid prototying in the years to come.

Read More1984

3D SYSTEMS market entry

Chuck Hull co-founded 3D SYSTEMS in the same year that his patent is granted in the USA. In 1987, 3D SYSTEMS launched the first 3D printer, the SLA-1.

Read More1986

Application of the SLS patent by Carl Deckard

Carl Deckard files the patent for the Selective Laser Sintering (SLS) process. Shortly after Deckard founded the company DTM, that was acquired by 3D SYSTEMS.

Read More1989

Application of the FDM patent by Scott Crump

In 1989, Scott Crump applies for the Fused Deposition Modeling (FDM) patent. In the same year he founds STRATASYS, which remains one of the leading companies in the market until today.

Read More1989

Machine Supplier EOS is founded

In 1989, machine supplier EOS is founded by Dr. Hans Langer. The company later evolves into one of the leaders of industrial Additive Manufacturing.  

Read More1989

1990s

The commercialization begins

During the 1990s, more and more companies started commercializing various 3D printing technologies. At the same time, the first metal processes were patented and started to be commercialized. 

Service bureau and software supplier MATERIALISE is founded

In 1990, the company MATERIALISE is founded in Belgium with one Stereolithography machine. The company later developed into one of the leading service bureau and software supplier in the AM market.

Read More1990

Direct Metal Laser Sintering (DMLS) introduced by EOS

The German machine OEM EOS introduces the EOS M160, their first metal printer. As the name suggests, the laser was not actually melting the metal but it was rather a sintering process. 

Read More1994

Metallic laser 3D printing patent filed by FRAUNHOFER

Wilhelm Meiners, Konrad Wissenbach and Andreas Gasser file the patent for metal laser 3D printing. The technology has since then evolved into the most widely used process for metal Additive Manufacturing.

Read More1996

EBM machine supplier ARCAM is founded

In 1997, the Swedish company ARCAM producing Electron Powder Bed Fusion (E-PBF) machines is founded. The company then became a leader in E-PBF technology before being acquired by GENERAL ELECTRIC in 2016.

Read More1997

2000s

Growing popularity of 3D printing

Metal 3D printing saw a strong rise, especially among german companies. At the same time, 3D printing gains more popularity in the consumer world. 

Laser Cusing machine launched by CONCEPT LASER

In 2001, the German manufacturer of Powder Bed Fusion machines CONCEPT LASER introduces its first metal machine with the Laser Cusing process. 

Read More2003

TRUMPF discontinues AM activities

In 2006, only 3 years after entering the metal AM market, TRUMPF discontinues their AM activities. 

In 2014, TRUMPF reenters the AM market. 

Read More2006

Service bureau SHAPEWAYS is founded

In 2007, the Dutch service bureau SHAPEWAYS is founded. 

Read More2007

2010s

Widespread Adoption of Additive Manufacturing

During the 2010s, AM has started to become a main production technology in several industries. Led by the medical and aerospace industry, both OEMs and AM users have made significant investments into technologies and production facilities. 

First Material Extrusion patents expire

In 2013 patents from polymer Material Extrusion (ME), a polymer-based AM technology, expired and low cost ME printers were pushing into the consumer market.

2013

GE AVIATION acquires MORRIS TECHNOLOGIES

In 2012, GE AVIATION acquires the metal AM service bureau MORRIS TECHNOLOGIES. This cements their position as one of the leading AM users in the aerospace industry. 

Read More2012

DESKTOP METAL is founded

In 2016, DESKTOP METAL is founded to introduce their Metal Binder Jetting Technology. The company has since then acquired several companies, such as EXONE, and grown to over 1000 employees. 

Read More2016

GE buys CONCEPT LASER and ARCAM

In 2016, GENERAL ELECTRIC acquires the two machine manufacturers CONCEPT LASER and ARCAM.

Read More2016
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Sinter-based AM technologies and process chain

Sinter-based AM - a technology overview

Many different printing technologies - one sintering process

The sinter-based AM (SBAM) technologies have, as the name suggests, the sintering process in common. In this process, the printed green part is consolidated into a dense part and receives its final properties. The green part can be printed in advance using different technologies.They all have in common that metal powder is bound to the desired shape by a binder. The best-known printing technologies include Binder Jetting and Filament Material Extrusion.

In this section, you learn everything about the sinter-based AM  process chain and get an overview of the different printing technologies.

Goal and structure of this course

This course is aimed at engineers, designers and other professionals that are working closely with sinter-based AM technologies. The goal is to cover the most important aspects that will enable engineers and designers to fully grasp the capabilities and technical limitations of the printing technologies and the sintering process to succeed in technology selection and part design. Besides going through the course from the beginning until the end, this course can also act as a constant source of knowledge while working on AM projects. 

The course is structured into the following sections.

This section will start with an overview of the sinter-based AM process chain and its printing technologies, followed by a technology deep dive into the most important aspects of the BJT technology, followed by a closer look at the debinding and sintering step also including sintering simulation .

The second section will provide an overview of the different materials that are available as well as part characteristics that can be achieved with the BJT process and typical methods for quality assurance. Finally, several common defects in the BJT process are presented. 

The last section will act as a guideline for designers. Besides generally describing the process when designing for Additive Manufacturing, actionable restrictions and guidelines for the BJT process are provided. The final section will present several design examples from different industries. 

What you will find in this section

Sinter-based AM process chain

From digital model to finished part

Data preparation

Simulation to compensate the deformation during the sintering step, nesting of parts and definition of printing parameters

Printing

Through various printing processes, different feedstocks such as metal powders, filaments, pellets or dispersions are processed into green parts

Unpacking

Unpacking of fragile green parts needs to be done carefully and is typically a manual process.

Debinding

Debinding describes the process of removing the binder which results in a brown part

Sintering

To reach the structural integrity of a metal part, a sinter process is required. The powder particles fuse together to a coherent, solid structure via a mass transport that occurs at the atomic scale driven via diffusional forces.

The brown part shrinks ~13-21 % in each direction.

The process chain of sinter-based technologies differs from other AM Technologies. Especially the post-printing processes (debinding and sintering) are crucial to achieve the intended mechanical properties.

Technology principle

How does Binder Jetting work?

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Afterwards the build platform moves downward by the amount of one layer thickness and a new layer of powder is applied. Again, the liquid binder is deposited and hardened in the required regions of the next layer to form the green body. This process is repeated until the complete part is printed. After the complete printing process is finished the parts have to be removed from the “powder cake” meaning the surrounding loose but densified powder. To improve the removal of the excess powder from the green body often brushes or a blasting gun with air pressure are used.

To create a dense metal part the 3D printed green body has to be post-processed in a debinding and sintering process. Similar to the metal injection molding process BJT parts are placed in a high temperature furnace, where the binder is burnt out and the remaining metal particles are sintered together. The sintering results in densification of the 3D printed green body to a metal part with high densities of 97 % to 99,5%, dependent of the material.

Printing Technologies

Metal Binder Jetting

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Material Extrusion

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Mold Slurry Deposition

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting

Metal Selective Laser Sintering

Binder Jetting is a powder based Additive Manufacturing technology in which a liquid polymer binder is selectively deposited onto the powder bed binding the metal particles and forming a green body.

The metal powder is applied to a build platform in a typical layer thickness of 40 µm to 100 µm. Subsequently a modified 2D print head apply a binder selectively onto the powder bed. Depending on machine technology a hardening or curing process of the binder is performed in parallel for each layer and/or at the end of the whole build. During the in-situ curing process a heat source is used to solidify the binder and form a solid polymer – metal powder composite.

Working Principle of Binder Jetting