3D printing—or additive printing—is a process by which the ‘printer’, deposits layer upon layer of a certain material, each layer is a thin slice of what, in the end, will be an actual three dimensional object. These machines, in various forms, have been around for some years and have usually been reserved for rapid prototyping, to create reference models for testing and handling purposes. However, for an engine set to debut next year, GE believes they can print fuel injectors for jet engines. The concept is the same as above but instead of laying the material, it uses a laser that melts a layer of cobalt-chrome powder. Same slicing concept, different manner of adding each slice.
“These innovations are at the forefront of a radical change in manufacturing technology that is especially appealing in advanced applications like aerospace and cars. The 3-D printing techniques won't just make it more efficient to produce existing parts. They will also make it possible to produce things that weren't even conceivable before—like parts with complex, scooped-out shapes that minimize weight without sacrificing strength. Unlike machining processes, which can leave up to 90 percent of the material on the floor, 3-D printing leaves virtually no waste—a huge consideration with expensive metals such as titanium. The technology could also reduce the need to store parts in inventory, because it's just as easy to print another part—or an improved version of it—10 years after the first one was made. An automobile manufacturer receiving reports of a failure in a seat belt mechanism could have a reconfigured version on its way to dealers within days.”
Currently, 3D printing is limited by speed and by a narrow selection of ‘printing’ material, preventing such techniques from replacing more traditional manufacturing processes. However, for short runs or very specific parts where the benefits of the shapes achieved outweigh the speed cost, printing is making inroads. As material options become more varied, as speed increases and as more testing and better understanding of stress behavior of those parts progress, we will be seeing broader use of additive printing.