3D printing and international security: risks and challenges of an emerging technology

"3D printing - or additive manufacturing - is a challenging dual-use technology: One and the same device can print toys or guns. The author explains the basics of the technology, describes its current applications, and provides an overview of its global diffusion. He shows the potential of this emerging technology and analyzes its possible risks with respect to the pro­lif­eration of small arms, major weapon systems, and even weapons of mass destruction. He investigates how 3D printing might pose serious challenges to national and international security. The author discusses first proposals of risk mitigation through safeguards, export controls, cyber security, awareness raising, and industry self-regulation." (author's abstract

A comparison of processing techniques for producing prototype injection moulding inserts.

This project involves the investigation of processing techniques for producing low-cost moulding inserts used in the particulate injection moulding (PIM) process. Prototype moulds were made from both additive and subtractive processes as well as a combination of the two. The general motivation for this was to reduce the entry cost of users when considering PIM. PIM cavity inserts were first made by conventional machining from a polymer block using the pocket NC desktop mill. PIM cavity inserts were also made by fused filament deposition modelling using the Tiertime UP plus 3D printer. The injection moulding trials manifested in surface finish and part removal defects. The feedstock was a titanium metal blend which is brittle in comparison to commodity polymers. That in combination with the mesoscale features, small cross-sections and complex geometries were considered the main problems. For both processing methods, fixes were identified and made to test the theory. These consisted of a blended approach that saw a combination of both the additive and subtractive processes being used. The parts produced from the three processing methods are investigated and their respective merits and issues are discussed

The specification of a consumer design toolkit to support personalised production via additive manufacturing

This thesis stems from the future scenario that as additive manufacturing (AM) technologies become cheaper and more readily available, consumers without formal design training will begin to customise, design and manufacture their own products. Much of this activity is likely to infringe on brands' intellectual property. The research explores the feasibility of a situation in which, rather than attempting to prohibit such activity, manufacturers engage with consumers to facilitate it, thus retaining control (albeit reduced) over their brand's image and the quality of products offered. The research begins with a literature review encompassing AM technologies and their adoption by consumers; mass customisation (MC) and the management of variation in product offering; and traditional models of industrial design (ID), including user-centred design and co-design. It finds that conventional definitions of MC and ID are unable to provide for the possibility of consumer intervention in the shape and non-modular configuration of products. Further research was then conducted in the areas of Open Design (including crowdsourcing, open sourcing and 'hardware hacking') as well as bespoke customisation, which were found to be much more accommodating of the scenario proposed. A new term, 'consumer design', is introduced and defined, together with the hypothesis that in future, the role of the industrial designer may be to design 'unfinished' products. An original classification of consumer involvement in ID is presented. Empirical research, undertaken with consumers using an iterative design software package (Genoform), demonstrated a preference for designing within pre-determined boundaries. Action research was conducted to assess consumer-oriented 3D CAD software, and compare its capabilities with that of MC toolkits. A survey of senior designers and brand managers revealed strategies for implementing and managing a brand's product design language, and a guide was created to show the relative importance of designed features. Using these findings, a prototype toolkit was created to demonstrate how a brand might facilitate consumer interaction with the shape design of a complex consumer electronics product (in this case a mobile phone). The toolkit was tested with both consumers and experienced designers to assess its viability. The research finds that it is possible to create a consumer-design toolkit which enables untrained users to change the form of a product, whilst maintaining brand equity and ensuring the product's functionality and manufacturability

Innovation in composite additive manufacturing

This master thesis contains an overview of existing additive manufacturing methods and considers possible new methods. The purpose being to develop a method for additive manufacturing that can create 3D objects with composite material and/or out of metal. Further this method should work on a low cost additive manufacturing machine. A development process is used in order to select an appropriate method. The method is then divided into parts that are individually analysed in order to produce a proof of concept model. Initially an overview of existing patents regarding additive manufacturing was conducted in order to see if the devised problem was addressed and how. A patent search regarding both additive manufacturing of composites and of metallic objects was performed. The next phase was conducting a market overview of existing low cost 3D printers and selecting one model that was appropriate for purchase. The purchased 3D printer was then assembled and tested to build up a general experience of properties and limitations of low cost printers. These properties regard both control parameters, mechanical properties (such as eigen frequencies, resolution) and print limitations (typical errors, materials etc.). Concept generation took place by brainstorming a wide range of possible ideas to address the project goal. Existing manufacturing methods and processes that inspired the concepts are described in the theory. The final concept was selected by a process of first concept screening followed by concept scoring and selection. After screening the bulk of four concepts remained. One mainly addressed the goal of manufacturing metallic parts and the others composites. Further literary study of material properties and manufacturing processes relevant to these methods was conducted for the scoring step. Also appropriate retailers of materials and parts and machines were contacted for relevant cost information. The selected concept uses photopolymers cured by UV radiation. In order to finalise the proof of concept a print head was constructed and several tests were conducted in order to observe possible fill rates and required radiation levels in order to achieve a required flow rate and curing times respectively. Finally suggestions for further development and studies is summarised.This project aimed to look at low cost 3D manufacturing technologies and develop a method to expand existing material options. Existing manufacturing methods for sets of materials were conducted in order to map out possible manufacturing steps. A review of existing models of 3D-printers was done and one was purchased and assembled. Design concepts were developed inspired by existing manufacturing methods and one method was selected using a pre-mixed compound and UV curing matrix material extruded through a nozzle and solidified with directed UV-LEDs in order to allow for manufacturing of composites. The method was verified to work and suggestions for further improvements and studies were made