Digital technologies have transformed the nature and delivery  of our media and communication technologies, how will recent advances in Additive Layer Manufacture and 3D software change the way we make thing?



This session maps out advances in 3D Printing technologies and considers the opportunities for innovation in this new manufacturing paradigm

Masterton, Drummond

Falmouth University Research Repository (FURR)

Making the FutureFalmouth UniversityPresented by,Drummond MastertonHead of Sustainable Product DesignWhat is 3D Printing?An additive layer manufacture process that creates 3D objects quickly and efficiently one layer at a time.What is it for?Product Designers: As a communication tool, as new business opportunities, to save cost and time to reach market and to identify costly mistakes before mass manufacture. Manufactured ProductsNew Balance and Nike have both released mass market shoes which use 3D printed components.Manufactured ProductsRaceware offer a level of customisation and provide low volume solutions for bicycle components.Manufactured ProductsFabric collaborated with Airbus to create this onepiece 3D printed carbon fibre saddle.What is it for?Designer Makers explore these technologies as a new method of creating unique objects, often one off or very low volumeDesigner/Maker Businesses Nervous Systems use web interfaces to enable customers to customise their products. Who is the designer in this relationship?Design ConceptsDigital Forming worked with Cooksons using their latest gold sintering processes developed with EOS to directly print this chainmail surface. Does the loss of craftsmanship matter?Design ConceptsThe XYZ shoe by Earl Stewart used 3D scanning processes to ensure custom fit data and 3D printing in flexible materials to create a bespoke footwear solutionWhat is it for?Design Engineering: High Value sectors, currently focused at light weighting non-critical parts. Geometry is refined with algorithms, what role does the designer/engineer now offer?AerospaceAirbus worked on optimised topology for titanium brackets. The AVLAM project was part funded by Innovate UK.Faster, Lighter, more reliable production, less waste (5% total)AM National StrategyKTN:’ The Case for Additive Manufacturing’ Positioning paper(2015).• Technology Awareness• Skills Gaps• Education• Supply ChainWhat's wrong with a name? 3D Printing: Generic term used to position these technologies in an understandable way for the public.Will Home printing ever take off? Consumer Perception: ‘I want to take a shower, not print a shower head!’Should we be worried if it does? More people printing more stuff will ultimately generate more waste, while carbon savings are realised in the reduction of freight Printed parts present new problems for recycling .New Materials may reduce impacts Better Future Factories (BFF) Perpetual Plastic Project (PPP) transforms plastic waste from disposable cups to create 3D printing filament Closed Loop systemsCo – oproduct won a green oscar award for its work on developing a closed loop system for 3D printed plastic waste. It is estimated that there are 10K RP machines in the UK. The PP used here has 20 MJ less energy and 50% less water per 1Kg than the current, most popular 3D printing solution(PLA).Factories of the Future Knyttan has designed a model similar to Nervous Systems that engages users through interfaces and enables new levels of customisation.Future Factories – Horizon 20/20Robots and AI will play a significant role in the factories of the future.Future Factories – ALMAbility to print in multiple materials and print electronics will become the standard for industry.AI workforceAirbus is testing Smart robots in its Factory of the Future. On the fly programming through observation of trained operators.High end Additive ManufactureRenishaw is at the forefront of AM technology in MetalsHybrid Manufacturing CentresDMG MORI’S Lasertec machines utlise scanning, additive and subtractive processesNew material developmentsNew material developments will enable the new market opportunities and innovation.The built environmentUpscaling and flexible robotic and gantry solutions will transform the building sectorDistributed FactoriesSustainability: Energy, raw materials, shipping (localised manufacturing). Digital Design rights? Rural economies, Local vernacular.3D printing, Fashion Fad or Future?For 3D printing advice and project supportFalmouth Universitydrummond@falmouth.ac.uk

Making the Future

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Falmouth University Research Repository (FURR)