Paul Falcone, Author at ABCorp 3D

Choosing the Right 3D Printed Materials

Choosing the right 3D printed materials for a 3D printing project is arguably the most critical step. Depending on what is chosen, it can truly make or break a project when it comes to achieving that perfect balance of durability, cost-effectiveness, and performance.

When choosing a material, it’s important to consider the following:

Mechanical strength and flexibility: Does this project require the ability to withstand heavy weight or high impact? Does it have to bend or stretch, and can it do so without breaking?
Chemical and water resistant: Will your project be exposed to chemicals, fuels, or oils? Will it be in humid or damp conditions, and be subjected to high levels of moisture?
Environmental factors and sustainability: Is the material made from renewed sources? What is the environmental impact and what kind of footprint does it leave behind?

All of these properties come into play when designing a project. However, selecting the perfect 3D printed materials for a project can be daunting given the diverse range of materials available. Whether you’re designing prostheses, functional prototypes, or custom automotive parts, understanding the key properties of the materials and their applications can help designers make the best informed decision for their project.

At ABCorp 3D, we make it easier for our clients by only working with state-of-the-art 3D printers like HP Multi Jet Fusion printers, along with the best 3D printed materials, such as HP 3D HR PA12 (otherwise known as Nylon PA12), HP 3D HR PA11, HP 3D Polypropylene, Ultrasint TPU01, and Metal (17-4PH Steel). Let’s learn more about each of these materials.

HP 3D HR PA12 (Nylon PA12)

HP 3D HR PA12, or Nylon PA12, is a thermoplastic polymer that is ideal for complex assemblies, such as housing, enclosures, and watertight applications due to its high tensile strength and impact resistance. This material is chemical resistant to oils, greases, and has low moisture absorption, making it able to withstand humid and damp conditions.

A major selling point for Nylon PA12 is that it has a high powder reusability, with 80% of unused powder being recyclable, making it a cost-effective and environmentally-conscious material.

Due to its diverse range of properties, Nylon PA12 is used across industries such as the medical, automotive, and both industrial and consumer goods. For more information on Nylon PA12, you can read our guide on its design specifications and properties here.

HP 3D HR PA11

HP 3D HR PA11 is a bio-based thermoplastic polymer that was designed for the production of functional and final parts across various industries, such as healthcare and industrial goods, providing designers with the perfect balance between performance and reusability.

PA11 provides great chemical and impact resistance, making it ideal for prosthesis, insoles, sports goods, and other high impact and ductility-friendly purposes. Similarly to Nylon PA12, PA11 has a 70% surplus powder reusability and is created with renewable raw material from vegetable castor oil, making it an ideal environmentally-conscious option.

For a more in-depth overview of PA11 and its capabilities, you can read our guide here.

HP 3D Polypropylene

HP 3D Polypropylene is a thermoplastic polymer that is known for its high productivity while minimizing waste. With the ability to reuse up to 100% of its unused powder, it is able to dramatically reduce its environmental footprint. Its chemical resistance, low-moisture absorption, and long-term durability combine to make it ideal for a diverse range of industries, from medical and automotive, to industrial goods like piping and fluid systems.

What sets HP 3D Polypropylene apart from other materials is that it has excellent welding capabilities when matched with other PP parts that are produced with injection molding, making it a truly versatile and durable material.

For a more comprehensive overview of HP 3D Polypropylene, you can read our design and information guide.

BASF UltrasintⓇ TPU01

BASF UltrasintⓇ TPU01 is a thermoplastic polyurethane (TPU) elastomer, which means it has high elasticity with superb elongation at break, providing projects with both flexibility and resilience. It is abrasion resistant and flexible, making it ideal for parts that are subjected to frequent friction, fatigue, and shock absorption. These parts can range anywhere from sports protection equipment, footwear and orthopedic models, to car interior components and other industrial components that rely on elasticity and durability.

Metal (17-4PH Steel)

Metal (17-4PH Steel) is a precipitation hardening stainless steel, which essentially means that it gets stronger when certain elements are added then heated. It belongs to a group of steels known as martensitic, meaning that it has a specific crystal structure that provides it with high tensile strength and hardness, excellent durability, and wear-resistance properties.

Metal (17-4PH Steel) is known for its strong resistance to corrosion and heat, making it an ideal choice for the aerospace, automotive, and industrial industries.

Conclusion

When selecting a material for your next 3D printed project, it’s crucial that the desired performance and purpose of the project be weighed against the material’s properties and capabilities to ensure its performance. By considering the environment the project will be in, its intended uses, the stressors it will face, and the strengths and weaknesses of the materials, designers can make the best informed decision that is functional, durable, and cost-effective.

At ABCorp 3D, we regularly print on all of these materials, making us the quintessential choice for quality parts and prototypes requiring these materials.

Lean Manufacturing with Additive Manufacturing

Ever thought about how additive manufacturing can help meet the goals of lean manufacturing? In the past, we have talked extensively about how 3D printing, or additive manufacturing, has completely revolutionized traditional production methods and processes. Their cutting-edge technology enhances industries like the medical field and the automotive industry, for starters, and helps our environment by reducing waste with on-demand production and increasing energy efficiency.

There’s no denying the endless possibilities that can come with this ever-evolving field.

With these benefits, 3D printing perfectly embodies the true essence of the lean manufacturing philosophy. With lean manufacturing, additive manufacturers are able to streamline production runs, reduce waste (both physical and intangible), enhance flexibility and responsiveness to customer demands, and save both the customer and the manufacturer itself money.

How Does it Work?

Lean manufacturing is a production process that was initially developed in Japan and is a component of the Toyota Production System. This process focuses on maximizing productivity while also minimizing waste. For those who have adopted the lean manufacturing process, waste is categorized as anything that customers are not willing to pay for or see value in.

Instead of spare parts and excess materials, the type of waste lean manufacturing aims to minimize is less tangible; it includes processes, activities, or services that don’t add any value to the product but require unnecessary time, money, or skills. It can also include underused talent, excessive inventories, and wasteful procedures.

Lean manufacturing is a process that has been widely adopted in a multitude of fields, such as project management, software development, construction, or, for example, 3D printing. The objective is that, by eliminating waste in both the physical and metaphysical sense, manufacturers can better streamline their services while reducing costs and helping their customers save money.

Lean Manufacturing = DOWNTIME

In lean manufacturing, there are eight kinds of waste. It’s easy to remember them by using the acronym, DOWNTIME.

Defects that require time, effort, and cost for corrections are caused by poor quality control, poor machine repair, or a lack of proper documentation and standards.
Overproduction due to inaccurate forecasting and demand information, unstable production schedules, etc.
Waiting, whether it is unplanned downtime, idle equipment, or delayed set-up times.
Non-utilized talent can come in the form of a lack of team training and poor management, but also poor communication and a failure to involve employees in workplace design and development (after all, they know the systems and procedures best!).
Transportation, such as unnecessary shipping or transportation due to multiple storage facilities or poorly designed production systems.
Inventory in excess, or “safety stocks,” and subsequent use of spaces like warehouses.
Motion not only includes raw materials but also people and equipment, which can be caused by poor workstation layouts, shared equipment, a lack of production standards, etc.
Excessive processing due to poor communication, not understanding the customer’s needs, or even a slow approval process.

The Five Principles

In addition to the eight kinds of waste, there are five principles of lean manufacturing. Let’s dive into those and how 3D printing intrinsically adopts them.

Defining Value

The primary goal of this principle is to deliver maximum value to the customer through their products. By understanding exactly what the customer deems valuable, manufacturers can know their customers better, know what is important to them, and what they are willing to spend money on.

At its core, lean manufacturing emphasizes value for the customer, and the level of customization that comes with 3D printing is a key component of that. 3D printing allows manufacturers to create highly customized products without the need for mass production. They can tailor their products to meet specific customer needs, which lessens the chance of defects and anomalies, cuts down on waste—both physical and intangible—and makes way for more efficient production.

Value Stream Mapping

A value stream is a map of the product’s entire lifecycle and the process to take it from raw materials to a finalized state. By mapping out the stream, manufacturers can examine each stage of the process and eliminate waste by cutting out unnecessary steps. This kind of continuous monitoring on a step-by-step level allows for regular assessment of the value stream, providing the opportunities to make continuous improvements.

Since additive manufacturing is produced layer by layer, the production process is already fairly streamlined, aligning itself with this core principle of lean manufacturing. This simplified production process allows for a higher level of optimization and reduces the messy complexities that often come with traditional manufacturing. Less mess, less stress!

Creating Flow

To create a smooth and steady flow during the manufacturing process without interruptions, delays, or bottlenecks, it’s vital that obstacles are eliminated to ensure that the produced products can move more steadily and continually. This can be done by balancing workloads, optimizing production steps, and ensuring that there is reliable, accessible, and efficient equipment. In turn, this will reduce lead times, increase efficiency and quality, and maintain a steady flow of production.

Like we said above, 3D printing is already a streamlined and simplified process, meaning the production flow is already, well, flowing. Since products can be produced in a single operation, there isn’t a need for any intermediate steps or long lead times, which also helps to minimize bottlenecking and maximize efficiency.

Establishing Pull

Establishing pull is essentially producing on demand. In more traditional manufacturing, push systems are in place where inventory is often determined ahead of time and the products are manufactured to meet that prediction. However, like most predictions and forecasts, they are not a precise science. These often inaccurate predictions can result in too much inventory, not enough inventory, and disrupted schedules. Frankly, it can cause quite a headache.

On the contrary, with pull systems, materials are not made until there is an actual demand for them, which fully relies on flexibility and communication. This may seem like an easy process to adopt, but it requires manufacturers to be expert communicators with their suppliers, teams, and customers to ensure all parties are on the same page and share the same level of flexibility.

As we’ve discussed, 3D printing fully supports the pull production system. Instead of relying on inconsistent and inaccurate forecasts and maintaining large inventories, manufacturers can produce only what is needed, cutting down on inventory costs, mitigating the risk of overproduction, and providing manufacturers with more flexibility when trying to adapt to the ever-changing market.

Continuous Improvement

A cornerstone of effective lean manufacturing is continuous improvement. By closely examining the nitty-gritty of the manufacturing process on a continuous basis, it becomes easier to target the root causes of quality issues, allowing for more waste elimination. To be successful, it’s crucial that this notion of continuous improvement be integrated on a cultural level of any organization or business. From team members and project supervisors all the way to the executive level, continuous improvement is an “all hands on deck” kind of initiative.

In additive manufacturing, the nature of rapid testing and refinement of products and designs already fosters a culture of continuous improvement. With a quicker production time and streamlined process, manufacturers can much more easily identify issues and performance flaws and make the necessary changes to achieve maximum efficiency and higher quality standards.

Conclusion

Additive manufacturing already embodies the essence and philosophy of lean manufacturing. By focusing on value, utilizing value stream mapping and a smooth flow of operations, adopting a pull-based approach, and striving for continuous improvement, 3D printing manufacturers are able to continue revolutionizing the industry, making impressive and innovative improvements to their efficiency, quality, environmental footprint, and customer satisfaction.

Metal 3D Printing for Efficient Production

We’ve talked extensively about the many benefits of additive manufacturing over traditional manufacturing. We’ve also talked about how understanding the differences in 3D printing equipment, colors, and finishes is crucial when starting any 3D printed project, as the vast options can fully transform a finished product’s appearance, durability, and functionality. Well, the same can be said for the printing material — including metal 3D printing.

Metal 3D printing, also known as metal additive manufacturing, is quickly gaining traction and becoming the top material of choice for many industries. In fact, the global metal 3D printing market was valued at $2,986.25 million USD in 2024 and is set to reach $19,689.69 million USD by 2031.

With a scope that large, we have to ask: why metal?

Super Strength

Right off the bat, a main selling point of using metal as a printing material is that it is incredibly durable. Whether it’s stainless steel, titanium, or aluminum, its durable mechanical properties are unmatched by the plastic and polymer materials that are normally used in 3D printing. Not lacking in structural integrity, these metals have a much higher yield strength, are fatigue- and temperature-resistant, and, depending on the type of metal, can have a better weight-to-strength ratio, making them ideal candidates for aerospace and automotive projects.

These factors make metal an excellent material for prototypes and functional parts, and because they are more durable, finished products need less frequent replacement, saving both time and resources.

Ability to Craft Complex Geometries

With additive manufacturing comes a world of one-of-a-kind customizations and personalizations. By using metal, that world opens up even more. Metal 3D printing paves the way for creating complex geometries that normally wouldn’t be supported by traditional manufacturing methods.

When printing with more fragile materials, such as plastics and polymers, it’s much harder to create intricate designs, like, for example, hollow structures. Since metal 3D printing is an additive process, products are built layer by layer. So, by having the creative freedom to design intricate and complex geometries, production can be done in a single step, eliminating the need for assembly. By removing that need, engineers can reduce the number of parts needed and simplify the production process, cutting down on costs and effort.

This kind of creative freedom allows engineers to optimize their parts for performance, weight reduction, functionality, and other needs. By stripping away the restraints set by traditional manufacturing, creators can forgo their more conventional techniques and push the boundaries like never before.

Shorter Lead Times

Traditional manufacturing often involves multiple steps, including casting, machining, assembly, and so on, with each step adding more time to the production cycle. Like we mentioned earlier, metal 3D printing streamlines the production process by consolidating these steps into a single, automated, layer-by-layer process.

These factors not only greatly reduce the number of manufacturing stages but also significantly cut down on production time, lower labor costs, minimize waste and material excess, and make way for more on-demand production. The ability to produce parts on-demand also eliminates the need to have a warehouse (or warehouses) chock full of inventory, ultimately lowering the risk of overproduction.

Reduced Waste and Environmentally Friendly

In traditional manufacturing, the cutting, drilling, and shaping of materials creates a substantial amount of waste and excess materials. As if the waste alone wasn’t enough, it’s also not often recycled or reused. To make matters worse, large-scale productions require significant energy and natural resources. For example, traditional manufacturing roughly consumes about 18.2 billion gallons of water daily—yes, daily. On the other hand, metal additive manufacturing only uses the energy and materials needed to complete the project, significantly cutting down on waste and energy.

It is also important to mention that producing and disposing of plastic materials, especially in the manufacturing industry, results in incredibly harmful emissions, such as greenhouse gasses and other toxic substances. Metal 3D printing, especially when using recycled materials, often tends to produce less waste, meaning fewer harmful emissions over the product’s entire lifecycle.

Conclusion

With metal 3D printing, the benefits are undeniable. Its strength, design flexibility, and versatility truly set it apart from other materials. It has strong mechanical properties, reduces material waste, can create complex geometries and on-demand manufacturing, and provides shorter lead times. To put it simply: metal 3D printing is far more efficient than other materials. By leveraging these features, metal 3D printing is set to play an increasingly vital role in the additive manufacturing industry.

The Differences in 3D Printing Equipment and Why it Matters

The impact of 3D printing has spanned across industries, promising a future filled with innovative and groundbreaking advancements thanks to the differences in 3D printing equipment and what solutions they offer.

In the medical field, it has revolutionized prosthetics, organ transplants, and drug development, providing personalized medical solutions. For rare and vintage car aficionados, 3D printing streamlines restoration and preserves automotive heritage. Philanthropic organizations like Habitat for Humanity utilize 3D printing technology to create homes swiftly in an effort to solve the housing crisis.

There’s no denying the invaluable benefits 3D printing has brought to the world. With that being said, not all 3D technology is created equal.

Behind the 3D printing curtain lie a variety of distinctions that can greatly impact the quality, efficiency, and versatility of the project. Understanding these nuances is vitally important for both businesses and amateurs alike, as they can, quite literally, make a world of difference when it comes to a project’s success — or demise.

Understanding the Basics

Before diving into these subtleties, let’s first recap the fundamentals of 3D printing technology. Also known as additive manufacturing, the 3D printing process builds objects layer by layer. This process is different from more traditional subtractive manufacturing methods, where material is removed from a solid block to create the desired shape.

At ABCorp 3D, we utilize the latest generation of HP Multi-Jet Fusion and Desktop Metal Binder Jet technology, combined with our wide range of materials from PA12 and PA11 to Polypro and Full-Color PA12 and more, to bring our projects to life.

Multi-Jet Fusion (MJF)

Multi-Jet Fusion, or MJF, is an industrial 3D printing technology that was developed by HP. It provides exceptional precision, speed, and versatility and is great for creating functional parts that are suitable for end-use, like manufacturing. The technology’s high production speed also allows for the printing of multiple parts simultaneously at high speeds, making it an excellent tool for prototyping.

MJF uses a layer of material powder (like, for example, Nylon PA12) as the part’s base. A thin layer of powdered material is laid on the part bed, followed by two agents, one for detailing and one for fusing, that are then melted by infrared light. From there, you have a solid and detailed object!

Binder Jetting

Binder jetting is another kind of additive manufacturing process where thin layers of a powdered material are carefully and selectively applied to a powder bed. They are then bonded with a single liquid bonding agent. The powder fuses together, solidifying, and is then repeated layer after layer. A benefit to binder jetting is that it is a zero-waste process! Any unused powder can be reused for future builds, making this technology environmentally friendly.

The Importance of Equipment Variation

While both MJF and Binder Jetting are phenomenal additive manufacturing processes, they are not synonymous with one another. They differ in terms of materials, capabilities, and applications, which need to be taken into consideration before starting a project.

Binder Jetting uses a single binding agent, very similar to an adhesive or glue, that is jetted onto the material to consolidate the layers of powder. On the other hand, MJF uses two agents. The first is a fusing agent, which is responsible for setting out where the material will fuse, while the second, a detailing agent, marks the edges of the 3D printed part with laser level precision. Together, they make up the fusing process.

When it comes to print quality, MJF offers a superior surface finish, making it perfect for high-precision applications. Binder Jetting, while capable of producing more detailed parts, may have slightly rougher surface finishes, which can affect the product depending on the desired use or purpose.

For prototyping, MJF is an ideal tool for its high-speed printing and production capabilities, whereas Binder Jetting is a bit slower. However, since Binder Jetting is zero-waste, it’s more cost-effective for large-scale projects.

These are just a few small examples of the importance of selecting the right kind of technology. To learn more about these two processes and others, visit the HP website.

Choosing the Right Equipment

Selecting the right 3D printing equipment for your specific needs requires careful consideration of factors such as budget, desired print quality, material requirements, and production volume.

To make the best-informed decision, there are some things that should be determined first. The first step is clearly defining your project goals, which encompass the level of detail the project should have, the material’s desired properties and capabilities, and the anticipated production volume. Like we’ve shown in the above section, each kind of technology and material comes with its own properties and nuances that can determine the success of a project.

From there, the research can begin. Once the preliminary requirements are decided, your team can begin to compare various 3D printing technologies, equipment, and materials to best bring your vision to life. Next is to consider the long-term costs of the project. It’s smart to factor in not only the initial purchase price but also what the ongoing costs will be for materials, maintenance, and upgrades. Lastly, to really hone in on your best choice, it may be worth your while to consult with industry experts or 3D printing service providers like ABCorp 3D to gain more insight and recommendations based on experience.

Conclusion

The differences in 3D printing equipment and materials can have a significant impact on the outcome of your projects. Whether the priority of the project is print quality, versatility, cost-effectiveness, or production efficiency, choosing the right equipment is crucial for successfully bringing your ideas to life.

By understanding the nuances of MJF and Binder Jetting technology and carefully evaluating your goals and requirements, you can successfully navigate the 3D printing world with confidence and unlock the full potential of additive manufacturing.

Need a consultation on the best process and material for your project? We are just a click away. Contact us and we will be happy to provide any answers you may require.

3D Printing in Automotive: Advancing the Industry

3D printing technologies, like 3D printed auto parts, have been used by the automotive industry for years, especially within research and development (R&D). But as 3D printing in automotive continues to advance, this technology offers more and more beneficial use cases within this sector.

Present-day automotive manufacturing operations have expanded beyond R&D and are also using 3D printing to create commercial end-use products. From faster production times to lighter, more durable parts, 3D printing capabilities provide a number of benefits to automotive manufacturers.

3D Printing in Automotive Manufacturing

There is a significant 3D printing presence in automotive manufacturing today, for everything from prototyping to custom interior parts to personalized commercial end-use products. Metal 3D printing in particular has really taken off in automotive. But where 3D printing technologies are really progressing with the automotive industry is in the electric vehicle (EV) sector.

“In the EV sector, weight is much more important and plays a role in the vehicle’s battery life,” explains Neil Glazebrook, Vice President of 3D Solutions at ABCorp. “Industrial 3D printing can easily lightweight vehicle parts, reducing the overall weight of a vehicle.”

This decrease in weight helps EVs perform better, making 3D printed parts the obvious choice for these types of vehicles. But it’s more than just 3D printed parts, an automotive manufacturer can design parts for additive manufacturing. This allows manufacturers to make adjustments in the design process to create a better part when compared to traditional design and manufacturing methods.

“Design for additive has really taken off in the last couple of years. Using additive design principles, manufacturers are lightening the vehicle, which makes it more efficient. And they’re also looking at different stresses in the part. With additive and new design technologies, manufacturers can design for those stresses and create a 3D printed part that performs better and lasts longer than a traditionally manufactured part,” describes Glazebrook.

Additive Manufacturing vs. Traditional Manufacturing in Automotive

Introducing additive technologies into automotive production has led to some changes in the industry’s manufacturing methods. Industrial 3D printing has a faster turnaround time than traditional manufacturing. In the early days of additive technology, this increased speed was the basis for rapid prototyping and resulted in wide-scale adoption of additive manufacturing in R&D.

When manufacturers saw the benefits of additive manufacturing, they started to use this technology to produce end-use parts. In recent years, 3D printed end-use parts have become even more prevalent in automotive manufacturing. Rather than relying on a traditional production line for everything, manufacturers are now introducing more additive manufacturing into their production processes.

“One of the best things about 3D printing is automotive manufacturers can create parts a lot quicker. The faster turnaround time has led to many more 3D printed automotive components in vehicles, which improves the overall performance and efficiency of the vehicles,” says Glazebrook.

When it comes to production, 3D printing can speed up time to market for products, and it can also bring the supply chain closer to manufacturers, particularly original equipment manufacturers (OEMs). The flexibility that 3D printing gives manufacturers allows them to better navigate problems that arise, not only in their own operations, but also on a larger scale. Having easy access to a 3D printer can really minimize unexpected situations, such as supply chain constraints.

“From an OEM and supply chain standpoint, 3D printing has really been a game changer for automotive manufacturing,” explains Glazebrook. “Parts that use to take weeks to make or receive, those can now be printed overnight.”

Implementing additive manufacturing within production processes enables manufacturers to create 3D printed auto parts that are more durable while using less material compared to traditionally manufactured parts. These parts tend to perform better and often take less time to create.

“Not every design can be created with traditional manufacturing,” Glazebrook says, “that’s one reason designing for additive is gaining more traction in the automotive industry. However, additive and subtractive manufacturing can work well together to create an end-use part. Overall, though, when it comes to additive vs. traditional, additive manufacturing significantly improves production speed and time to market, in addition to creating parts up to 50% lighter.”

Automotive Industry Investing in Industrial 3D Printing

As industrial 3D printing becomes more prevalent across multiple industries, automotive manufacturers are seeing the benefits of this technology and starting to invest more into it. These manufacturers are adding multiple 3D printers into their operations and investing more capital and engineering budgets into additive manufacturing. Investing in additive enables automotive manufacturers to create better parts, have more control over their supply chain, and get products to market faster.

“With additive, manufacturers are becoming more efficient in their production operations while also creating better-quality parts,” says Glazebrook. “3D printing creates parts that are lighter, stronger, and more durable, and this technology is going to continue to grow in the automotive industry and beyond.”

If you’re a manufacturer interested in exploring 3D printed auto parts and more solutions, check out ABCorp’s 3D printing division. To explore even more industrial 3D printing, check out RAPID + TCT: North America’s largest additive manufacturing and industrial 3D printing event, taking place at the Los Angeles Convention Center from June 25-27, 2024.

Earth Day: How 3D Printing Supports Green Initiatives

It’s no secret that we, as a society, are experiencing rapid climate change and resource depletion. This Earth Day, and as global citizens, it’s our responsibility to do our part and leave our planet better than we found it.

Except it’s not just individuals who can save the planet. Large plant manufacturers and industrial facilities are some of the biggest offenders when it comes to pollution. However, there is a budding industry on the manufacturing horizon: 3D printing.

Compared to traditional manufacturing, 3D printing allows manufacturers to reduce their material waste, use energy efficiently, localize production, and reduce pollutants, but it also gives them the opportunity to recycle and use more sustainable materials. When broken down to the bare bones, 3D printing is far more economically and environmentally friendly than traditional manufacturing.

Reduced Material Waste and Energy Efficiency

In traditional manufacturing, sustainability and energy efficiency are not usually top concerns. The cutting, drilling, and shaping of raw materials produce quite a lot of waste and excess materials that often aren’t recycled or reused — not to mention the amount of energy and natural resources that are needed for large-scale productions. For context, traditional manufacturing typically uses an estimated 18.2 billion gallons of water per day (yes: per day), whereas 3D printing typically requires no water and only uses enough energy to operate the printer and heat the printing material, which is minor in comparison.

On the contrary, due to its additive nature, 3D printing only uses the amount of materials necessary to complete the job and is produced layer by layer. Often done on a smaller, on-demand scale, there isn’t much room for overproduction, excess waste, or higher energy consumption. In fact, in 2017, the U.S. Department of Energy stated that, when compared to traditional manufacturing, the future of 3D printing would lead to an approximate 90% reduction in waste and material costs while reducing energy use by 25%.

Localized Production

Since 3D printing makes way for more customizable products without the need for mass production, manufacturers can have much more precise and localized production, meaning that it can often be done in-house or locally. By having a more localized location, manufacturers can not only reduce the carbon emissions that are typically associated with shipping, leaving behind a smaller carbon footprint, but they also don’t require massive facilities, which can often benefit local economies more.

It’s also worth mentioning that, due to its on-demand and streamlined production, manufacturers don’t have to worry about bottlenecking that is common with larger productions, and it provides engineers with the flexibility to swiftly create prototypes and fine-tune their designs. In addition, 3D printing allows for a smaller production facility where space constraints to manage inventory aren’t an issue, further reducing costs.

Recycling Capability

Mistakes happen; we know this, and (most of us) have come to accept it. However, when mistakes happen during a 3D-printed production process, there’s no real reason to panic. The faulty product’s materials, whether plastic or metal, are simply processed and transformed back into usable filaments or resins for future production runs or even non-3D printed manufacturing, eliminating waste or the need for an excess of materials.

ABCorp 3D’s Green Initiatives

At ABCorp 3D, we offer environmentally and sustainable 3D printed products. The PA11 from Arkema is a sustainable nylon material made from vegetable castor oil with a 70% recycled rate, while PA12 has an average recycling rate of 80%. Recycling the unused material into the next build lowers our carbon footprint and reduces the cost of the parts. Not only does this ultimately lower production costs, but it also allows for less demand for raw materials while minimizing carbon footprint.

It’s also worth mentioning that ABCorp is a registered FDA facility, meaning we’ve gone through an extensive validation process that has proven the safety and effectiveness of our 3D printed medical devices, specifically our prostheses. Being registered and a manufacturing facility with the FDA not only proves the credibility of our products, but assures our customers, healthcare providers, and regulatory agencies that we successfully meet stringent quality and safety standards.

Conclusion

As we continue to fight the good fight when it comes to manufacturing sustainably, 3D printing embraces greener initiatives unlike any other. With a proven track record to reduce material waste and conserve energy, localize production, and allow for recycling on a large scale, industries can not only streamline their production processes but also play their role in working towards a greener, more sustainable future for generations to come.

Why Security is Critical in 3D Printing

In this new age of technological advancement, 3D printing has emerged as quite the game-changer across multiple industries, promising unparalleled innovation and customization. But in the midst of this revolutionary potential lies a critical concern within 3D printing security: cybersecurity.

Although the relationship between 3D printing and cybersecurity is not often showcased in the headlines, that doesn’t mean it isn’t of paramount importance. The 3D printing industry on its own has a set of unique challenges that demand the spotlight, one of which revolves around the protection of personally identifiable information (PII). Protecting sensitive and proprietary information, patient PII, and design files is vital wherever 3D printing is a part of the production process, like for instance the medical 3D printing prosthetics industry.

Robust cybersecurity protections are required due to the volume of sensitive data involved when designing custom-made 3D medical prostheses, ranging from medical scans to personalized prosthetic designs. Protecting patient trust and privacy depends on protecting the confidentiality and integrity of this information, which is also required under laws like HIPAA.

No matter how slight, any lapse in security could lead to not only the unauthorized access of proprietary information, patient PII, and exposure of brand and trade secrets, but major financial loss as well as tarnished brands and reputations.

What is PII and Why Do People Want it?

Personally identifiable information (PII) is any data that can, well, personally identify us. PII can take on many forms, ranging from our full names, physical and email addresses, and phone numbers, to our social security numbers, biometric data, and medical records—and everything in between.

PII is, clearly, highly sensitive. Exposure of any kind can lead to identity theft, financial fraud, and privacy breaches. When discussing cybersecurity, protecting PII is of the utmost importance, especially in industries like healthcare and finance where the collection and storage of such information are extensive. Robust security measures, encryption protocols, and strict access controls are just a few PII safeguarding methods that can prevent unauthorized access or disclosure.

When PII is mishandled or compromised, it can lead to severe financial consequences for both individuals and corporations alike. It helps to think of PII as being as valuable as the money in your bank account and wallet. Why? Simply because it really is. According to the 2023 IBM and Ponemon Institute report, the cost of an average data breach is $4.45 million. While regulatory fines and maintaining a company’s reputation make up the majority of these expenses, they can nevertheless mount up when personal information is at risk.

So, why do hackers want our PII? Well, it’s sensitive and expensive.

PII can be exploited for financial gain through identity theft and fraud, giving hackers the ability to impersonate individuals, make unauthorized transactions, or apply for loans and credit cards in their name. PII is as lucrative as gold in underground marketplaces, like the Dark Web, where it can be sold to other cybercriminals or as ransom for other illicit activities, like extortion or blackmail.

Regardless of the motive for why a hacker may seek out PII, acquiring it provides them with a wide range of opportunities for financial gain, identity manipulation, and other malicious activities, making it a nice shiny target for cyberattacks.

Issues of Cybersecurity in 3D Printing

Proprietary Information

One of the main reasons cybersecurity is so paramount in 3D printing revolves around the protection of proprietary information. Proprietary information is data that belongs to a company or individual and is not meant to be released to the public.

It’s no secret that the corporate world is competitive. (Hence the phrase, “dog eat dog world.”) So when companies heavily invest into research and development, they expect to always stay one step ahead of their competition in return. Take Apple and Samsung. The two create similar devices and are always compared to one another during new releases. However, Apple has the funds to invest significant resources into opportunities that will allow them to stay ahead of the technologically innovative curve, leaving Samsung (to be viewed by some as) “less advanced.”

Whether it’s proprietary designs, trade secrets, or intellectual property, this kind of proprietary information is as “top secret” as it gets in the corporate world. Any breach in security could lead to the unauthorized selling of replicated products, IP theft, and intentional defects, resulting in critical financial loss and reputational damage.

PII in Medical Prosthetics & Patient Confidentiality

As we know, 3D printed medical prosthetics are precisely tailored to meet the unique needs of individual patients, which means engineers are relying heavily on the use of patient PII. From detailed scans of patient anatomy to customized digital designs, the sensitive data involved just emphasizes the importance of having robust cybersecurity measures in place.

The consequences of patient PII getting into the wrong hands go far beyond just financial loss, including the expulsion of patient trust, violations of privacy, and potential harm to individuals. Patient confidentiality is not merely a legal obligation but a cornerstone of ethical medical practice, regardless of the advances in technology. Any breach in security not only compromises the integrity of healthcare providers but also undermines the very foundation of patient-doctor relationships.

To prevent unauthorized access to or exposure of sensitive medical data, strong encryption measures, access controls, and frequent audits are important. Adherence to compliance regulations, like HIPAA, is vital since it guarantees the responsible and respectful handling of patient data while alleviating the potential of falling victim to cybersecurity breaches.

Protecting Brand and Trade Secrets

In addition to the issues mentioned above, the security of 3D printing processes is crucial for safeguarding brand reputation and trade secrets. Like we said, companies invest a lot of money in order to stay ahead of their competition, and they want to keep it that way. Without adequate cybersecurity measures, these efforts are left helpless to theft and exploitation, which can jeopardize the company’s market position and competitive leg up.

In fact, a major issue with 3D printing cybersecurity is intellectual property theft, a process where hackers try to reverse engineer items by scanning and replicating them. Files used for 3D printing are digital, so a hacker might duplicate and distribute them, making it impossible to secure the files once they are no longer in the public domain.

Big manufacturers frequently invest millions or even billions of dollars in research and development for a single product; therefore, intellectual property and trade secret theft can seriously harm the business and reputation.

Conclusion

To summarize, cybersecurity in 3D printing is not merely a technical concern but a fundamental aspect of risk management and ethical practice. As 3D printing continues to expand across various industries, prioritizing 3D printing security and cybersecurity measures will remain essential in mitigating risks, protecting sensitive information, and upholding trust and integrity. Whether it’s safeguarding proprietary information, preserving patient confidentiality, or defending the brand and trade secrets, proactive physical and cybersecurity strategies such as those employed by ABCorp 3D are indispensable in ensuring the security of PII in 3D printing.

3D Printing and Robotics: The Future is Now

In recent years, we have witnessed a paradigm shift in the way we think about, create, and produce robotic parts — all thanks to the radical advancements in 3D printing technology. This shift has not only pushed the boundaries of what was once deemed possible, but has started a revolution across industries, promising a world of opportunities to better our lives in ways that were once thought to be unattainable.

The Current State of 3D Printing in Robotics

Before we embark on a journey into the future, let’s take a beat to reflect on the current state of 3D printing within the robotics realm.

There’s no denying that 3D printing has made significant strides in the robotics field (and beyond) these past few years, cultivating a newfound sense of creativity that has led to the creation of intricate, innovative, and fully customized components. It’s also worth mentioning that one of the more notable benefits of 3D printing in robotics has been the ability to improve the production of these complex geometries that would otherwise be challenging, if not impossible, to achieve through more traditional manufacturing methods.

Material World

Looking ahead, the future of 3D printing in robotics is, without a doubt, going to be defined by a significant leap in material innovation and customization. As 3D printing technologies continue to rapidly advance, we can expect a much broader range of materials to become available for robotic fabrication, one of which being soft robotics.

Soft robots, made up of flexible and compliant materials, are quickly finding their way towards more diverse fields, from medical devices to search and rescue missions. 3D printing allows for the fabrication of intricate, soft robotic components that are able to seamlessly blend in with their rigid structure counterparts, allowing robots to navigate more diverse and complicated environments with a special degree of delicacy.

This future shift will allow designers to not only tailor the mechanical properties of their components to fit these more specific applications, but to also “kick the door wide open” to unprecedented levels of performance and efficiency, allowing for innovations like multi-material printing, bio-inspired structures, and AI-driven design optimization.

As one might expect, customization — a trademark of 3D printing — will continue to play an essential role in shaping the new world of robotics. Robots are often positioned in more diverse environments and faced with unique challenges, so customization becomes a lifeline when addressing more highly specific needs. With 3D printing, robotic components can be designed and produced with laser-level precision, taking into account the various intricacies of the projects they are assigned.

This high level of customization has the potential to elevate robotic systems from the basic, more standardized tools to innovative, highly specialized solutions, and is set to unlock new frontiers in the engineering and design worlds.

Medical Field

One of the most captivating promises of 3D printing robotics lies within the realm of medical technology. Imagine a future where 3D printed robotics pave the way towards the creation of customized medical implants, meticulously tailored to suit patients’ unique anatomies and needs. It’s this level of personalization that could mark a significant jump forward in the field of healthcare. After all, 3D printed customized pharmaceuticals are already a part of our reality.

Now traditionally speaking, prosthetics and robotic hands have long faced challenges when attempting to mimic the complexities of the human anatomy, especially when it comes to prosthetic hands, which are often forced to rely on simplified designs.

Now enter 3D printing, a technology that has shattered these limitations, introducing a paradigm shift in the process.

Robot Prosthetics

Engineers now have the capability to harness the precision of 3D printing to recreate hands with individual bones, ligaments, and tendons, bringing a whole new level of detail and functionality that once seemed virtually impossible. With 3D printing, engineers can replicate bone structures and ligaments with ease, creating robotic hands that move with the same fluidity and grace of their biological counterparts.

These 3D printed hands not only look remarkably lifelike but also provide their users with a natural range of motion and sensory feedback, and enhanced sensory feedback — an aspect that is lacking in most prosthetics — as well as the prospect of a future where those with limb differences experience a level of functionality and immersion they previously did not have.

Wearable Robotics

Wearable robotics, otherwise known as an exoskeleton, are a wearable mechanism or suit that is used as a tool during physical rehabilitation. Wearable robotics help patients in relearning skills as they are able to reduce energy consumption and streamline repetitive tasks. Additionally, in many military applications, exoskeletons have proven to be an instrumental tool in helping soldiers carry heavier loads over long distances.

Wearable robotics are made possible by the lightweight and customizable nature of 3D printing, carrying uses that transcend far beyond healthcare, assisting individuals with mobility challenges or enhancing performance in various physical activities. These wearable advances might not only improve the quality of life for their users, but also open up to a world of new possibilities in fields such as sports and rehabilitation.

Conclusion

In conclusion, the future of 3D printing within the robotics world is set to be quite the game-changer (for lack of a better term) sculpting a future that was once confined to the realm of science fiction. The intricate and delicate craftsmanship of 3D printed hands with bones and ligaments, coupled with the soft robotics revolution, showcases the transformative potential of this kind of technology. And as we continue to navigate the uncharted territories of 3D printed robotics, the only certainty we do have is that the future holds a world of innovation.

The Future of 3D Printing

The impacts of 3D printing are nothing short of extraordinary, with innovations spanning across industries and pushing the boundaries of what was once deemed impossible. However, the future of 3D printing has become even brighter. From the intricacies of medical advancements and the preservation of vintage vehicles with rare part replacements to expanding the horizons of construction, 3D printing is set to revolutionize the way we create, build, and design.

Customized Pharmaceuticals

With 3D printed prosthetics continuing to gain traction in the medical field, the possibilities that 3D printing bring to the industry continue to grow more and more remarkably. In fact, 3D printing has already made several large strides in the medical field.

In 2014, a 22-year-old woman in the Netherlands suffering from a chronic bone disorder had part of her skull removed and replaced with a 3D-printed one. In 2015, the antiepileptic drug Spritam became the first 3D-printed medication to be approved by the FDA. In 2020, a woman born with a misshapen ear was able to have a 3D-printed implant made from her very own cells.

In fact, the impressive strides 3D printing has made in the medical field go as far back as 1999, when the Wake Forest Institute for Regenerative Medicine was able to 3D print a bladder, cover it in the patient’s cells, and then implant it. As of 2018, the bladder was still fully functioning.

The remarkable possibilities don’t stop there.

One of the most promising aspects of 3D bioprinting is its potential to revolutionize personalized medicine. Medical professionals predict that there will soon come the day where they are able to create same-day custom medical devices while patients patiently sit in the waiting room, provide customized medications tailored to each patient’s needs, and create far more advanced 3D printed medical implants.

Imagine receiving a perfectly matched organ for transplantation, customized at the cellular level. While experts agree that our technology is not quite there yet, some say that we’re not too far off, potentially seeing the transplanting of complex human organs, such as hearts or lungs, and even cells, within the next 20 to 30 years.

In addition, 3D bioprinting is set to transform drug development by providing more accurate and realistic tissue models for testing. Traditional 2D cell cultures may not be able to capture all of the complexities of human tissues, but bioprinting allows for the creation of far more intricate structures, enhancing the reliability of drug screening and development processes.

This type of innovation could significantly reduce the risk of organ rejection, improve the overall success rates of such procedures, open unforeseen avenues for regenerative medicine, and provide accessible, cost-effective, life-saving, and life-changing medical equipment and medication to those who need it.

Rare Parts Replacement

Among the myriad exciting opportunities that come with 3D printing, rare parts replacement emerges as quite the industry game-changer, where the fusion of 3D printing and rare parts replacement not only preserves automotive heritage but also catalyzes a new era of accessibility and innovation within the world of vintage vehicle restoration.

In a typical situation, getting your hands on rare or discontinued parts for vintage or niche cars has been an intimidating challenge, often requiring extensive searches, costly custom manufacturing, or simply getting lucky by having the right network.

Metal-based 3D printing, coupled with flexible filaments, has the power to completely revolutionize how to approach the scarcity of these rare parts. 3D printing technology uses the exact reproduction of intricate and hard-to-find components with pinpoint accuracy, meaning that automotive enthusiasts and restoration specialists alike will be able to recreate vintage or niche components, ensuring the preservation of classic vehicles and offering a more efficient and sustainable solution to the sourcing of these parts.

Not only will 3D printing improve the automotive world with regard to recreating vintage or niche vehicles, but if parts (rare or not) are able to be produced swiftly, the same can be said for larger car parts. It’s not too far-fetched to say that we could be mass-producing fully customized 3D printed cars before we know it.

Building Dreams

Beyond the niche automotive community and medical field, 3D printing has already made strides in the construction industry. In 2021, Habitat for Humanity provided their first 3D-printed home to a family in Virginia. The 1,200-square-foot home took only 12 hours to build, saving upwards of a month of construction time for a traditionally built home.

The potential impact 3D printing can have on the housing crisis is quite profound. Traditional construction methods often struggle to keep up with the ever-increasing demand for affordable homes, leading to prices skyrocketing exponentially and a lack of housing availability. In fact, approximately 582,000 people are currently experiencing homelessness in the United States.

3D printing introduces a game-changing alternative, capable of rapidly constructing cost-effective and structurally sound houses, and for the construction of these houses in unconventional locations or challenging terrains, ultimately opening up new possibilities for urban planning and, in turn, reducing the number of communities in areas deemed unsuitable for traditional construction.

The impact on the housing crisis could be revolutionary, offering a glimpse of a world where everyone has a place to call home, built with precision, speed, and a touch of technological artistry.

Conclusion

In conclusion, the future of 3D printing holds immense promise, ushering in a new era of innovation and transformative possibilities across diverse industries. As we stand at the intersection of technology and progress, 3D printing is not just a tool but a catalyst for change, transforming the way we approach medicine, the preservation of automotive history, and construction. The journey into this bright future is marked by endless possibilities, where customization, efficiency, and creativity converge to shape a world where the unimaginable becomes reality.

ABCorp 3D: A Spirit of Giving

In today’s corporate sector, the concept of philanthropy has undergone a significant transformation, shifting decisively from routine charitable giving to a more purposeful and participatory approach. Companies small and large now recognize the importance of being strategic and proactive in their philanthropic endeavors, as the focus is no longer solely on financial contributions but on fostering genuine, sustainable change through direct involvement and a thoughtful, engaged commitment to making a meaningful difference in the world — a true spirit of giving.

A Response to Crisis

One way in which ABCorp 3D exemplifies the true essence of philanthropy is by weaving compassion into our corporate culture. In fact, it was this level of compassion that led us to establish ABCorp 3D in the first place.

While our parent company, ABCorp, has been in business since 1795, ABCorp 3D’s journey began as the COVID-19 pandemic swept across the globe, causing a shortage of personal protective equipment (PPE) for frontline workers. As we experienced a global level of loss and uncertainty, we recognized the pressing need and swiftly pivoted our operations to manufacture face shields for local hospitals using 3D printing technology.

In the face of adversity, our commitment to innovation and social responsibility became the driving force behind this monumental shift, as we sought to contribute meaningfully to the global effort to protect frontline workers and address the challenges posed by the COVID-19 pandemic.

From there, we ventured into additive manufacturing and ABCorp 3D was born.

Our expertise in 3D printing technology allowed us to produce high-quality face shields at an accelerated pace, contributing to the global effort to protect healthcare workers. Our commitment went beyond profit margins; it was a demonstration of innovation meeting compassion.

As markets began to evolve, so did we.

HOLIDAY TRADITIONS

Beyond our work in providing life-changing prosthetics, ABCorp 3D extends our reach into the community through annual holiday coat drives and gift trees, demonstrating a commitment to making a positive impact beyond the realm of technology.

A Warm Embrace: Annual Coat Drive

While winter is often a precursor to the holiday season, it also serves as a stark reminder of the challenges faced by children experiencing homelessness and financial insecurity. ABCorp recognizes this, and for the last 12 years, we have organized a holiday coat drive, partnering with Cradles to Crayons. Cradles to Crayons is the largest national nonprofit that focuses solely on ending children’s clothing insecurities by providing millions of essentials every year.

ABCorp 3D’s employees come together to donate gently used coats or purchase new ones, ensuring that children in need can experience the warmth and dignity that a proper winter coat provides. The collected coats are then distributed to the families that need them most.

The coat drive is more than just a charitable act; it symbolizes ABCorp 3D’s commitment to inclusivity and care for the entire community beyond the world of prosthetics. By addressing a basic need like warmth, ABCorp 3D acknowledges that philanthropy should be holistic, purposeful, and include a shared responsibility across every member of the company.

Gift Trees: Turning Wishes Into Reality

The essence of the holiday season lies in the joy of giving and receiving. ABCorp 3D amplifies this joy through our annual gift tree initiative. Adorning the office with a beautifully decorated tree, employees can select an ornament on the tree that holds the wishes and needs of children in the community, from essential items to simple luxuries, inviting employees to become holiday heroes.

The result is an outpouring of generosity that goes far beyond the walls of the company. The carefully chosen gifts are distributed directly to each ornament’s corresponding families, creating a more personalized and intimate connection between ABCorp 3D and the community we serve.

As we can tell, philanthropy is often most effective when it extends beyond financial contributions.

Conclusion

In a world where profit margins often take precedence, ABCorp 3D’s story stands as a testament to the impact intertwining business strategy with social responsibility can have on the world. As we continue to navigate the post-pandemic era, our story serves as a beacon, reminding us that true success is measured not just in financial gains but in the positive impact we leave on the world.