3D Printing and Mass Customization, Hand in Glove Part III

As discussed in the first and second installments of this series, we are drifting into a consumption-driven stupor and self-medicating our way through lives that, if we live in OECD countries, use 15 tonnes of material per year. Even though some things are recycled, these recycled goods do not often become high-value items. Repurposing existing waste streams and materials that are already near are to me key low marginal cost ways to better our world and lot. Yes, there may be more impactful things that we could do, but this is one with few, percieved unintended consequences. Also, whereas planting a billion trees would seem like a good idea, there would be a lot to control there operationally, and a lot of things could not pan out in the long run. Recycling existing waste into high-value consumer goods, however, has a much shorter and directer feedback loop. These products would need to survive based on their own merits in the marketplace alongside goods made of new materials. If they are to really work and expand, they would be cost-competitive or maybe even less expensive to make but higher performing than regular goods. If we want to take recycling from something we have to do to something that we like doing, we need to make it fun, enjoyable and pleasing. If we can then transform recycled goods into high-value ones, we can begin to make a dent in all of the senseless weight in materials that we use up.

The weight of the Eurocopter Tiger, the Sikorsky Blackhawk, and Boeing Apache helicopters together is less than the total weight of material that you use up per year. That’s kind of sad but also an opportunity. There are a few distinct advantages to recycling materials as opposed to using new ones.

  • Recycled materials are often found close to consumers. This is super obvious but also in terms of the low cost of transport and storage a huge advantage.
  • Recycled materials have fewer parties participating in the value chain, which can give you more control, direct interaction with every market participant and leverage. A virgin material may be made of a few different petrochemicals which are transported, processed and distributed by dozens or more companies until they reach a consumer. A recycled material is collected, sorted and processed; very often through one firm in one region. Less consecutive margin cuts make for a potentially attractive business overall as well.
  • Recycled materials are often very inexpensive. There are exceptions to this of course but generally recycled materials are available at a discount to virgin materials, giving you pricing advantages.
  • Consumers like recycled materials because it makes them feel less bad about their consumption.

There are also some disadvantages to recycled materials:

  • Tracability in recycled materials is often difficult. We don’t always know which polymer has which additives and how it has been processed if we find it in a trash bin. The same material with a pedigree will be worth much more than one without.

  • Due to this certification of recycled goods is difficult unless processes are designed such as the rPet process that Krones has whereby used water bottles can be turned into flakes, then preforms and finally food-safe certified waterbottles. The image above shows you the layout of a Krones rPet plant.
  • There is still something icky about recycled materials as in, you wouldn’t mind a recycled book bag but would mind a recycled baby bottle. But, then again you wouldn’t mind a paper recycled napkin touching your mouth but you would probably have misgivings about a recycled plastic mouthguard.

  • Recycled materials have a particular rough/mixed esthetic that is not always appealing. Particularly this is by design to make things look recycled and partially this is to offset costs, but in some cases, it is also not always possible to recreate the look and feel of a virgin object.
  • You can’t recycle everything infinitely and most recycled objects lose strength for example when they’re recycled.
  • Sorting, separating and processing recycled items is time-consuming and expensive.
  • There are no real standards for recycled or green or environmentally friendly which puts the bar very low for a lot of recycling projects.
  • There is a lot of greenwash, that undercuts the value of real recycling projects.

So generally as a product family, all recycled materials everywhere are not ideal. Recycling will also not work for many products. But if we pick the right categories of recycled goods and make them the right way we could very well find success for ourselves and the planet.

Photos by: ClevrCat, Timothy Swinson, Karliss Dambrans, Anna Zevereva, Krones, Scoobyfoo.

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3D Printing and the Circular Economy Part 6: CNC Machining

Desktop Metal CNC

CNC machining is a manufacturing process in which pre-programmed computer software dictates the movement of factory tools and machinery. The process can be used to control a range of complex machinery, from grinders and lathes to mills and routers. With CNC machining, three-dimensional cutting tasks can be accomplished in a single set of prompts. CNC refers to computer numerical control. Today we will be comparing CNC methods to 3D Printing and additive manufacturing in terms of their places within a circular economy. 

Transportation waste is not as large of a concern when it comes to CNC machining. It is important to have one’s material ready before they are to place the material within a CNC center. The layout of one’s factory or fabrication environment is more critical towards this type of waste. Similar thoughts can be arrived at in terms of additive manufacturing. Based on the types of material used for a CNC machine, it is slightly difficult to transport larger amounts of the metals used for these machines. 

Inventory waste is mostly oriented towards what material you are using for the CNC process. Typically we are using metal materials. The type of materials typically used consist of brass, copper alloys, aluminum, steel, stainless steel, titanium, and plastics. The type of material is very important because of production needs. CNC machining is a subtractive process. Hence, the various materials will cause different shearings as well as carving residue and debris that will be produced during a cutting out of a piece. 

Image result for cnc machine debris

CNC Waste

Waiting time in terms of CNC machining depends on the feed rate. Feeds specifically refers to the feed rate the tool advances through the material while speed refers to the surface speed that the cutting edge of the tool is moving and is needed to calculate the spindle RPM. Feed is generally measured in Inches Per Minute (IPM) in the US and speed is measured in Surface Feet per Minute. Feed speed as well as material density causes the amount of wait time to differ per manufactured part. Part geometry also has a role to play here as well as hardness. A CNC typically is faster than a 3D printer device, but this is again dependent on material and geometry. 

Over-processing is not as much of a concern for both of these methods of manufacturing. CNC machining and 3D printing are both great at building quick prototypes of designs. Over-processing can become problematic in CNC when one wants to make very polished cuts of a material to have sharper edges and rounded surfaces. There may be an element of over-processing there that leads to time wasted. 

Post processing is a big issue when it comes to 3D printers. Post processing issues are not as apparent with CNC parts. They typically are ready for deployment after they have been produced with excellent surface finishes. 

Image result for cnc waste

CNC Carvings

Recyclability is apparent with various CNC waste materials post production. It is important to be constantly aware of the different products used. In order to recycle, it necessitates the separation of materials. This requires bins oriented towards specific materials labelled clearly near a CNC machine. Without this, most of the scrap will be left unattended and mix together to a point of difficult separation. 

Overall the differences between CNC machines and 3D print are considerable. The sheer amount of waste material produced by a typical CNC is way more than a 3D printer. There are efficiency trade offs that are associated with 3D printers in terms of speed and material transportation. In the future advances to additive manufacturing will shrink the gap in terms of creating products in a more sustainable and additive manner versus a subtractive fashion.

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3D Printing News Briefs: November 23, 2018

We’re starting with a little business news in today’s 3D Printing News Briefs – Intech confirmed its first order for Additive Industries’ MetalFAB1 3D printer, and Roboze CEO Alessio Lorusso has won a prestigious Ernst & Young award. Moving on, researchers are working on 3D printable thermoelectric materials that can convert heat from the surrounding environment and convert it into electricity, while an architecture studio has developed a unique concept for a 3D printed, transportable toilet that converts something very different into electricity. Finally, if you’re looking for a unique gift this holiday season, check out Bloomingdale’s, which is working with Twindom and KODAK to offer 3D printed holiday portraits.

Intech Confirms MetalFAB1 Order with Additive Industries

On the last day of formnext 2018, Bangalore-based Intech, a leader in metal 3D printing in India, confirmed its first order of the MetalFAB1 system from Dutch 3D printer manufacturer Additive Industries. This order marks Additive Industries’ expansion into Asia, and will also help Intech accelerate its business. Application and process development and customer support will be handled from the new regional Additive Industries center in Singapore.

Accelerating adoption of additive manufacturing is the primary objective at Intech. Moving from prototyping to series production with focus on cost per part with repeatable quality is the way forward. This is a stepping stone for Intech in achieving its goal to meet the demands of customer requirements of printing large parts with excellent quality,” explained Sridhar Balaram, the CEO of Intech. “Intech has been working with various customers in different industry verticals by identifying parts for mass production as a proof of concept. With Additive Industries’ MetalFAB1 we can now scale for volume. The system is unique in the industry and we are excited to add this to our fleet of equipment.”

Roboze CEO Alessio Lorusso Wins Award from Ernst & Young

Alessio Lorusso

Alessio Lorusso, the CEO and founder of Italian 3D printing company Roboze, was recently awarded the prestigious 2018 Startup Award by Ernst & Young (EY) at its Entrepreneur Of the Year 2018 awards. Established for the first time during the 2015 awards, the Startup Award is awarded for contributing to a major growth of the Italian, and worldwide, economy, and is dedicated to an individual’s ability to create value with a spirit of innovation and a strategic vision. The award aims to make young, bright minds, who create a company from an innovative idea, more visible.

“In 2015, when we presented our first solution to the global market, I could not even imagine to achieve our goals in such a short time. We faced the logics of the machines design for additive manufacturing with clear, real and innovative competitive advantages. The market chooses us because our technology is definitely the best one, as specifically designed and produced to meet the real needs of the manufacturing companies,” said Lorusso. “This award is the result of the entire Roboze team’s hard work and constant commitment; so I want to dedicate this to each member of it. It was hard but we always believed it and this award does confirm that we are following the right way to conquer and revolutionize the whole global market.”

Thermoelectric Materials Converting Heat into Electricity

Flexible thermoelectric device embedded in a glove for generating electricity by body heat. [mage: Dr. Song Yun Cho, Korea Research Institute of Chemical Technology]

According to a review of new research in the Science and Technology of Advanced Materials journal, a team of scientists are working to design thermoelectric materials that can harvest heat from the environment, then convert it into electricity in order to power appliances and devices. Products made with these materials, such as wearable devices, could be more cost-effective, as they won’t need to recharge, change, or dispose of batteries. The team, which published a paper called “Thermoelectric materials and applications for energy harvesting power generation,” is investigating three different types of conducting materials, including inorganic and organic.

The abstract reads, “Thermoelectrics, in particular solid-state conversion of heat to electricity, is expected to be a key energy harvesting technology to power ubiquitous sensors and wearable devices in the future. A comprehensive review is given on the principles and advances in the development of thermoelectric materials suitable for energy harvesting power generation, ranging from organic and hybrid organic–inorganic to inorganic materials. Examples of design and applications are also presented.”

Most organic thermoelectric devices involve polymers, and semiconducting ones are more lightweight and inexpensive, can hold heat better than conventional inorganic semiconductors, and are flexible enough to be 3D printed. Inorganic thermoelectric devices can convert heat into electricity, but aren’t that flexible. The researchers say that while thermoelectric devices could actually replace traditional batteries in many applications someday, a lot more work is required first. Time will only tell with this one.

Spark’s 3D Printed Toilet 

Speaking of electricity, architecture studio Spark has developed an innovative concept for a transportable toilet, made with 3D printed elements, that can actually convert human waste into electricity. Fittingly, the studio launched its Big Arse Toilet on Monday to coincide with World Toilet Day. The module was designed for use in remote villages in India, where the UN is working hard to tackle the sanitation and hygiene issues stemming from open defecation. The toilet elements would be 3D printed from bamboo fibers mixed with biopolymer resin, and the completed module would be anchored to a 3D printed reinterpretation of a traditional biogas dome buried underground, which uses waste to generate and store gas.

Spark told Dezeen, “The Big Arse toilet reinterprets the use and organisation of traditional bio-gas domes to create electricity and gas for those communities that have no access to power networks and utility infrastructure that we take for granted.

“Bio-gas is a product of the breakdown of organic matter, in the case of the Big Arse Toilet the biogas is a product of human waste, food waste and agricultural waste. The biogas can be used directly for activities such as cooking or can be used to drive a micro CHP turbine that converts the gas into electricity.”

Bloomingdale’s Offering Personalized Holiday 3D Printed Portraits

3D body scanning leader Twindom, a brand licensee of Kodak, is offering a unique gift promotion this holiday season to shoppers at the Bloomingdale’s stores in San Francisco and New York City: personalized, 3D printed holiday portraits, made with the KODAK Full Body 3D Scanner until the end of December, just in time for Christmas. Shoppers who want to have a 3D printed portrait made can either make an appointment or just walk in to the store.

Once there, simply enter your information, walk into the KODAK Full Body 3D Scanner, and pose for the scan, which only takes 1⁄4 of a second to complete. Then, review the 3D capture, choose your size – 3 to 14 inches – and place your order, which will be 3D printed in full color and ship in about 1-2 weeks. Pricing starts at around $69 for the 3D printed portraits, and local support at each store location is provided by Twindom’s local partners: PocketMe, PeoplePrints 3D, and Memories in 3D.

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