With the rapid development of science and technology, 3D printing technology, as a cutting-edge manufacturing technology, has triggered a profound change in the manufacturing industry worldwide.
Since the 1980s, 3D printing technology has realized the leaping development from laboratory concept to commercial application. From the initial simple modeling, to now being able to print complex, high-precision and even functional parts, its technological progress is obvious to all.
The core principle of the technology is to build 3D objects by stacking materials layer by layer. It eliminates the need for molds and forms parts directly from computer design data.
This innovative model subverts the traditional “reduced material” or “equal material” manufacturing methods. It offers unprecedented convenience for rapid prototyping, customized production, and the creation of complex structural components.
In the field of machinery manufacturing, 3D printing plays a crucial role. It enables the direct production of complex parts and reduces reliance on traditional equipment and processes. This technology also accelerates product development and lowers manufacturing costs.
In addition, 3D printing technology supports lightweight design. It improves material utilization and helps optimize the performance of mechanical equipment. This is significant for reducing energy consumption.
On the one hand, some scholars have elaborated and analyzed the basic principle, workflow and main classification of 3D printing technology, which lays a solid theoretical foundation for this research.
On the other hand, some scholars focus on the actual needs of mechanical manufacturing. They explore 3D printing applications in product design, process planning, and production optimization. Their research reveals the great potential and advantages of 3D printing in this field. It also offers valuable insights and references for this study.
However, there are some shortcomings in the existing research. For example, current discussions on the challenges faced by 3D printing in mechanical manufacturing lack depth and completeness. Research on future development trends and emerging applications is also relatively limited.
This paper builds on existing research to further explore the application of 3D printing technology in machinery manufacturing. It also addresses related challenges to support the industry’s transformation, upgrading, and sustainable development.
3D printing technology foundation
1.Overview of 3D printing technology
Additive manufacturing technology, also called 3D printing, is a revolutionary method. It builds three-dimensional objects by layering materials one layer at a time. This method differs from traditional manufacturing methods like subtractive manufacturing, which involves cutting or milling. It also differs from formative manufacturing, such as casting and forging. Additive manufacturing works directly from digital models. It does not require molds or complex machining. This allows fast production of solid products.
The core advantages of this technology are high flexibility, design freedom and the ability to respond quickly to market changes.
The core process of 3D printing technology mainly covers the following steps:
First, computer-aided design (CAD) software is used to design or obtain a three-dimensional digital model of the target object;
Second, the model is divided into many very thin 2D layers. Each layer shows the exact cross-section of the object at a certain height.
Third, using the data from the segmented layers, material is added layer by layer. This is done by nozzle jetting, laser irradiation, or other methods. The process continues until the whole object is built accurately.
2.Introduction to Major 3D Printing Technologies
(1) Fused Deposition Modeling (FDM)
Fused Deposition Modeling (FDM) is one of the more commonly used modeling methods in 3D printing technology. It mainly adopts thermoplastic materials, such as ABS, PLA, etc., as the construction base.
The materials are used as the basis for the modeling.
During printing, the materials are heated to a molten state. Then, they are precisely extruded as filaments through a nozzle. The filaments are deposited layer by layer onto the substrate along a preset path.
FDM technology offers clear advantages such as low cost and ease of use. It is widely applied in education, rapid prototyping, and personalized product customization.
(2) Stereo Light-Cured Molding (SLA/DLP)
In light-cured 3D printing technology, stereolithography (SLA) and digital light processing (DLP) occupy an important position.
Both use liquid resin as the printing medium, and in the printing process, the ultraviolet light source – SLA uses a laser source, while DLP uses a projection light source to irradiate the resin surface layer, so that the resin undergoes a curing reaction layer by layer.
SLA technology offers high print accuracy and excellent surface finish. It is ideal for producing precise parts and high-quality models.
DLP technology speeds up printing by projecting an entire layer’s image at once. This greatly improves efficiency.
(3) Selective Laser Sintering (SLS)
Selective Laser Sintering (SLS) technology relies on a laser beam to sinter powdered materials (e.g., nylon powder, metal powder, etc.) to complete the construction of an object. In a print job, the laser beam scans a bed of powder along a preset trajectory, causing localized areas of the powder to sinter and bond to each other.
As the printed layers are added one by one, a complete object can eventually be constructed.
SLS technology is suitable for manufacturing parts with complex internal structures and strong mechanical properties.
(4) Other Advanced Technologies
In addition to the mainstream 3D printing technologies mentioned above, other advanced technologies include binder jetting (BJ) and direct energy deposition (DED).
Binder Jet (BJ) technology sprays binder to bond powder materials effectively. It is especially suited for large objects and complex parts.
DED technology, on the other hand, emphasizes the use of high-energy beams (such as lasers, electron beams, etc.) to melt and deposit metal powders or wires directly onto the substrate, which is suitable for the repair and remanufacturing of metal parts.
3.Types and Properties of 3D Printing Materials
The development of 3D printing technology is inseparable from the innovation and progress of printing materials. At present, there are many types of 3D printing materials available on the market, including plastics, metals, ceramics, composites and so on.
(1) Plastic Materials
In 3D printing technology, plastics are frequently used because of their affordability, easy processing and light weight.
Common plastic materials include acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), and nylon.
ABS is the material of choice for structural and housing components due to its excellent mechanical strength and chemical resistance;
PLA, as an eco-friendly material, shows excellent bio-adaptability and natural decomposition ability, and is especially suitable for medical applications and food packaging.
(2) Metal Powders
In the field of 3D printing, metal powder plays an important role as a key material for manufacturing high-strength and high-precision components.
Common types of metal powders include stainless steel, titanium-based alloys and aluminum-based alloys.
With the help of metal powder 3D printing technology, metal parts with complex internal structure and excellent mechanical properties can be produced, and these parts are widely used in aerospace, automotive industry, medical devices and other fields.
(3) Ceramics and Composites
Ceramic materials are characterized by high-temperature stability, abrasion and corrosion resistance, and are suitable for manufacturing high-temperature-resistant parts and tools.
Composite materials show excellent mechanical properties and chemical stability by integrating the advantages of multiple materials.
As 3D printing technology develops, more ceramics and composite materials are being used. This brings new innovations and possibilities to manufacturing.
3D printing technology in mechanical manufacturing applications
3D printing technology has a very wide range of applications in the field of mechanical manufacturing, from product design and rapid prototyping, to complex structural parts and customized production, to the rapid manufacturing of tools and molds, as well as maintenance and remanufacturing, showing unique advantages and potential.
As technology advances and costs decrease, 3D printing will play a bigger role in machinery manufacturing. It will support industry transformation, upgrading, and sustainable development.
1.Product Design and Rapid Prototyping
Product design and rapid prototyping is one of the more direct and extensive applications of 3D printing technology.
In terms of the traditional product development process, designers need to produce 2D drawings first, and then produce prototypes through molds or CNC machining. This process is not only time-consuming and labor-intensive, but also costly.
In contrast, 3D printing technology has the ability to materialize designers’ ideas directly into three-dimensional entities, significantly shortening the prototyping and production cycle and effectively reducing the cost of the development process.
With 3D printing, designers can quickly generate multiple solid prototypes based on their designs, and then perform functional checks, assembly checks and aesthetic evaluations to identify problems and optimize designs early in the design process.
In addition, 3D printing technology can also realize the direct manufacturing of complex structural parts, such as internal parts with complex channels, thin-walled structures, etc., which are often difficult and costly to process under traditional manufacturing methods.
2.Complex structures and customized production
In the actual production process, there is a need for some of the complex structure of the parts for processing and manufacturing.
These parts may have complex curved surfaces, internal channels, and fine textures. Such features are hard to achieve with traditional methods. 3D printing uses a unique process that builds parts layer by layer. This allows precise manufacturing of complex structures. It also eliminates the need for molds and tooling equipment. As a result, manufacturing efficiency and accuracy are greatly improved.
3D printing technology can also achieve customized production. In mechanical manufacturing, some parts may need to be customized according to the specific needs of customers, such as automotive parts, aviation and spacecraft components.
The application of 3D printing technology can quickly respond to the personalized needs of customers and accurately manufacture parts that meet specific requirements.
This innovative initiative not only significantly improves production efficiency, but also brings better user experience and satisfaction for customers.
3.Rapid Manufacturing of Tools and Molds
Tools and molds are indispensable and important elements. Traditional tools and molds need to be manufactured through multiple processing procedures, including casting, forging, machining, etc., which is time-consuming and costly, while 3D printing technology can quickly manufacture tools and molds that meet the requirements based on the design data directly, thus significantly improving the manufacturing efficiency.
3D printing technology can realize the lightweight design of tools and molds. By optimizing structures and reducing the use of unnecessary materials, the technology reduces the weight of tools and molds, increasing productivity and longevity.
In addition, tools and molds with complex shapes and structures can be produced. For example, molds with complex curved surfaces and tools with fine internal structures, which are difficult to produce efficiently under traditional manufacturing methods, can be made possible by 3D printing technology.
4.Repair and Remanufacturing
Repair and remanufacturing of equipment and parts is also an important task. Traditional repair methods require replacement of new parts or implementation of complex repair processes, high cost and long cycle time, while 3D printing technology can be based on the shape and size of the damaged parts, rapid production of replacement parts or repair parts, thereby effectively improving the repair efficiency and reduce production costs.
3D printing technology can also realize the upgrading and modification of parts. During the repair process, if the design or performance of certain parts are found to be deficient, 3D printing technology can be used to upgrade and modify them to improve the overall performance and reliability of the equipment.
This flexible repair and remanufacturing method not only extends the service life of the equipment, but also reduces the operating costs of the enterprise.
Challenges and Countermeasures of 3D Printing Technology in Mechanical Manufacturing
1.Challenges faced by 3D printing technology in mechanical manufacturing
At the technical level, 3D printing materials still need to be optimized in terms of performance and cost to match the strength, heat resistance and corrosion resistance of traditional manufacturing materials.
Improving printing speed and accuracy is also crucial for the wide application of 3D printing. This is especially important in machinery manufacturing, which demands high efficiency and precision.
In addition, the maturity and stability of the technology is also a challenge, requiring continuous technological development and improvement to ensure its reliability over long periods of time and in mass production.
At the market level, the market acceptance of 3D printing technology in the field of machinery manufacturing is still to be improved. At the same time, price competition is also a major challenge.
The high cost of high-performance 3D printing materials makes it difficult to match the overall manufacturing cost with traditional manufacturing methods.
Additionally, supply chain and logistics integration pose challenges at the market level. A more complete supply chain system is needed to support the broad use of 3D printing technology.
At the legal and policy level, the development of 3D printing technology has brought new intellectual property protection issues. How to ensure that the rights and interests of designers are not infringed upon and to prevent illegal copying and distribution of designs has become an urgent issue.
At the same time, the government needs to strengthen supervision of 3D printing technology. It should create better policies to guide its healthy and orderly development.
In the field of education and training, the popularization and promotion of 3D printing technology needs to be supported by talents with corresponding professional skills and knowledge background.
However, the market currently lacks enough skilled professionals. There is an urgent need to strengthen education and training. Higher education and vocational schools should offer relevant courses. Training should focus on 3D printing technology and related experience. On-the-job training and continuing education are also important. These efforts will improve staff understanding and application skills in 3D printing technology.
2.Countermeasures for 3D printing technology in machinery manufacturing
From a technical perspective, 3D printing needs improvements beyond speed and precision. It also requires new materials and better printing processes. Additionally, breakthroughs in intelligence and automation are essential. With rapid advances in AI and the Internet of Things, combining these with 3D printing can lead to more accurate and efficient production.
For example, integrating intelligent computer algorithms allows real-time monitoring and optimization of the printing process. This significantly improves printing accuracy and efficiency.
Internet of Things (IoT) technology enables remote monitoring and pre-failure warnings to enhance the reliability and stability of the equipment.
Within the legal framework, the key to ensure the steady progress of 3D printing technology is to strengthen the protection of intellectual property rights and data security.
The government should improve laws and regulations. It should clearly define intellectual property rights and benefit distribution. This will build solid legal support for innovation.
At the same time, enterprises should strengthen their awareness of intellectual property protection and adopt necessary technical means and management measures to prevent illegal copying and dissemination of design data.
In addition, they should actively build a copyright trading platform to promote the sharing and commercial utilization of design resources and help solve intellectual property issues.
At the education level, cultivating talents with relevant experience in 3D printing technology is key. This will promote the technology’s development effectively.
To solve the current shortage of professionals, higher education and vocational education institutions should strengthen education and training on 3D printing technology, set up relevant specialized courses and practical sessions, and cultivate students’ practical ability and innovative thinking.
At the same time, enterprises should also take the initiative to participate in the cultivation of talent construction, and collaborate with schools to jointly promote internship training projects, training programs and other activities to provide students with a wealth of opportunities for practical exercise and clear career development orientation.
At the market level, a supportive environment and policies are needed. These will promote the wide use of 3D printing technology in machinery manufacturing.
The government can formulate and implement a series of incentives, such as tax incentives and financial support, to motivate enterprises to increase R&D investment, accelerate technological innovation and promote industrial upgrading.
At the same time, the industry should strengthen self-regulation and government supervision. This will help maintain market order and curb unfair competition and malicious infringement.
In addition, exhibitions and forums can be held to enhance communication and cooperation within the industry. These activities help promote the popularization and application of 3D printing technology.
Analysis of 3D Printing Technology Applications in Other Fields
1.Fashion accessories: personalized art and craft innovation under 3D printing
In the fashion accessories industry of light industry, 3D printing technology is gradually becoming an important force to promote personalized customization and design innovation.
Using advanced 3D modeling software, designers are able to create models of accessories of different shapes and complex structures with unprecedented freedom.
These models not only have a strong sense of design, but also accurately reflect the designer’s creative ideas.
At the same time, 3D printers can quickly turn design models into real objects. This significantly shortens the design-to-product time cycle.
The application of 3D printing technology in the manufacture of fashion accessories not only makes the accessories full of personalization and artistic sense, but also promotes the innovation of the process.
While traditional manufacturing methods require complex molds and tooling, 3D printing technology can directly build complex structures based on design data in a layer-by-layer manner, effectively reducing manufacturing difficulties and costs.
In addition, 3D printing technology also has the ability to print a variety of materials such as metal and plastic, which opens up a wide range of possibilities for the production of fashion accessories.
For example, some jewelry brands are already using 3D printing to design complex metal jewelry. Through precise 3D modeling and printing, these accessories not only have a beautiful appearance, but also show a high level of craftsmanship in the details.
This personalized customization and innovation meet consumers’ diverse fashion accessory demands. It also brings new growth and momentum to the entire industry.
2.Furniture Manufacturing: Green Concept and Design Innovation of 3D Printing
In the furniture manufacturing industry, 3D printing technology also shows great potential and value.
3D printing technology allows designers to overcome traditional manufacturing limits. They can create furniture with unique shapes and well-designed structures.
These furniture not only has a prominent sense of design and practicality, but also to meet the personalized needs of consumers for home life.
The application of 3D printing technology in the furniture manufacturing industry has not only revolutionized the design field, but also successfully integrated the core concept of environmental protection.
Traditional furniture manufacturing consumes large amounts of wood and materials. In contrast, 3D printing can create desired shapes and structures as needed, reducing material waste effectively.
In addition, 3D printing technology is capable of printing on a wide range of materials, including recycled and bio-based materials, providing a more environmentally friendly option for furniture manufacturing.
Currently, some furniture manufacturers are already utilizing 3D printing technology to create samples and prototypes.
Through accurate 3D modeling and printing, not only can their products be completed in a short period of time, but also accurately reflect the creative concepts of the designers, which improves design efficiency and reduces manufacturing costs.
In addition, 3D printing technology enables on-demand manufacturing. It allows personalized customization based on consumer needs, better meeting the diverse demands of the market.