additive manufacturing Archives

Every Day is Earth Day with Additive Manufacturing

As we celebrate Earth Day 2025, it’s important to remember that the spirit of Earth Day isn’t confined to just one day each year. Every day can — and should — be Earth Day. The choices we make, the actions we take, and the technologies we support all contribute to the long-term health of our planet. In fact, the small, consistent steps we take every day are just as important as those big moments of awareness and action.

This year, the theme of Earth Day is “Our Power, Our Planet”, but the truth is, we don’t have to wait a year to make a difference. Whether it’s in our personal lives, within our communities, or in the industries that drive our economies, sustainability is a daily responsibility, and one we all have the power to take on. One industry in particular that drives sustainability forward in our consumerist world is the additive manufacturing industry.

Why Every Day Matters: Sustainability as a Constant Commitment

Traditional manufacturing often involves cutting, drilling, and shaping raw materials, resulting in significant waste. In fact, according to Business Waste, approximately 9.2 billion tons of industrial waste are generated worldwide every year. (Yes, billion!) However, unlike typical manufacturing, 3D printing is an additive process, meaning that it builds objects layer by layer, using only the material necessary for the product. This method helps manufacturers eliminate overproduction and greatly reduce the environmental impact of their production. This means that every single print job made through additive manufacturing is an intentional step toward reducing material waste, making it a sustainable choice every day.

The process of 3D printing also directly contributes to energy conservation. Unlike traditional manufacturing, which relies on massive factories and energy-intensive machinery, 3D printing operates with significantly less energy consumption. The printer uses only the energy needed to create the object, making it more efficient and reducing the strain on energy resources. For context, traditional manufacturing uses an estimated 18.2 billion gallons of water per day. This reduction in energy consumption happens daily, meaning that every day, additive manufacturing helps lower our collective environmental footprint.

Localized Production: Reducing Carbon Emissions Every Day

In traditional manufacturing, products often travel long distances from factories to consumers, contributing to a significant amount of carbon emissions. This is especially true for global supply chains, where goods are shipped across countries and continents. Additive manufacturing, however, allows for localized production, meaning products can be made closer to their final destination, often on-demand.

By producing items near their point of use, 3D printing reduces the need for long-distance shipping, cutting down on transportation-related emissions. This reduction in carbon footprint is a daily contribution to sustainability. When products are made locally, they can be produced without the large, wasteful transportation footprint associated with traditional manufacturing, which makes every print job a small but impactful action toward a greener future.

Recycling and Repurposing: A Closed-Loop System for Sustainability

One of the most exciting features of additive manufacturing is its ability to recycle and repurpose materials. In traditional manufacturing, errors and excess materials often go to waste. However, with 3D printing, mistakes or leftover materials can be recycled and reused for future prints, keeping resources in circulation and reducing waste. This ongoing, closed-loop system ensures that materials are used efficiently and reduces the demand for new resources.

At ABCorp 3D, for example, we use sustainable materials like PA11, a nylon derived from vegetable castor oil, which has a 70% recycled content. We also use PA12, with an 80% recycling rate. By recycling unused materials back into the production process, we’re reducing waste every time we print a part. This is a perfect example of how 3D printing is not just a green solution on Earth Day, but a daily practice that reduces material consumption and contributes to a circular economy.

Everyday Innovation in Healthcare: Sustainable Solutions for Life

Sustainability isn’t limited to just consumer products. Additive manufacturing is also transforming the healthcare industry by enabling the production of custom medical devices like prosthetics and implants. These products can be made on-demand and tailored to individual patients, reducing the need for mass production and minimizing waste.

At ABCorp 3D, we create FDA-approved prosthetics and medical devices using 3D printing. By leveraging this technology, we not only provide personalized solutions but also contribute to a more sustainable healthcare system. The ability to produce these items on-demand, without the need for excessive inventory or large manufacturing facilities, means that healthcare is benefiting from the environmental advantages of additive manufacturing every day. Through 3D printing, the healthcare industry is becoming more sustainable, ensuring that patients get the care they need while minimizing environmental impact.

The Bigger Picture: How Additive Manufacturing Supports a Greener Future

Every time a product is made using 3D printing, we’re taking another step toward a more sustainable future. From reducing waste and energy use to enabling localized production and creating closed-loop recycling systems, additive manufacturing is making a measurable difference. It’s not just a technology for Earth Day; it’s a technology that makes sustainability possible every single day.

By embracing additive manufacturing, industries can streamline their processes, reduce their carbon footprints, and contribute to a more sustainable future. Whether it’s making consumer goods, medical devices, or industrial parts, 3D printing offers an ongoing solution to the challenges of resource depletion and environmental impact. And because it’s an evolving and adaptive technology, its potential to drive sustainability will only continue to grow.

As we celebrate Earth Day 2025, let’s remember that sustainability isn’t a one-time event; it’s a daily commitment, and additive manufacturing is helping industries and businesses like ABCorp make that commitment easier by enabling greener, more efficient production. We hope you will join us in supporting and embracing technologies like 3D printing that allow us to make every day Earth Day.

Exploring the Mechanical Properties of PA12 W: A High-Performance Material for Additive Manufacturing

As industries and their needs continue to evolve, the need for durable, high-quality materials in additive manufacturing is becoming increasingly critical. One material that stands out in this space is HP 3D High Reusability (HR) PA12 W—or simply PA12 W. This resilient thermoplastic is specifically designed for the HP Jet Fusion 5400W Series 3D Printing Solution and offers designers a unique mix of strength, flexibility, and recyclability. By understanding its mechanical properties, engineers and designers can make more informed decisions when selecting materials for their projects—everything from medical devices to consumer goods.

Tensile Strength and Modulus: Strength Under Stress

When selecting a material for a 3D printing project, tensile strength and tensile modulus are two of the most important factors to consider. In layman’s terms, tensile strength refers to a material’s ability to resist breaking under tension, while tensile modulus measures its resistance to elastic deformation. PA12 W has both of these properties, making it an ideal choice for parts that need to endure significant forces without failing, such as prosthetics or medical equipment.

Given these properties, PA12 W performs exceedingly well under stress, making it perfect for parts that will have to endure more demanding conditions. Its tensile modulus ensures that the parts not only hold their shape and functionality over time, but provide manufacturers with reliable, durable parts that perform consistently across different uses and applications.

Elongation: Flexibility Without Compromising Strength

Another key property for many 3D printed parts is elongation, or a material’s ability to stretch or deform before breaking. While strength is crucial, PA12 W strikes the perfect balance between flexibility and durability, ensuring parts can absorb stress without losing their structural integrity. This is particularly valuable for applications where parts may need to bend, twist, or stretch, like wearable technology or medical devices.

PA12 W offers the flexibility needed to design parts that are tough yet adaptable. Whether used in protective housings, enclosures, or prosthetics, it handles the strains of everyday use without breaking down, delivering long-lasting performance.

Resilience Under Dynamic Conditions

While PA12 W excels in stable conditions, it really shines when it’s subjected to more fluctuating conditions. The material’s ability to maintain its form and resist breaking when exposed to variable forces makes it a perfect fit for applications involving impact or dynamic stress.

In addition, PA12 W’s inherent strength and flexibility means it can also handle sudden, high-impact conditions that are often found in automotive, industrial, and consumer products. This ability to endure fluctuating stresses is essential for parts exposed to shock or vibration, whether automotive components or wearables constantly on the move.

Print Profile and Performance Testing

Now that we’ve covered how PA12 W can withstand the elements post-creation, understanding how a material behaves during the 3D printing process is just as important. In the case of PA12 W, the material has undergone extensive print profile testing to ensure consistent performance in the X, Y, and Z orientations. These tests, carried out using a standard print job with various tensile specimens, evaluate performance under different stresses and conditions. You can read more about these tests here.

By utilizing balanced print modes and standard tests, PA12 W ensures reliable performance no matter how a part is printed, whether that’s vertically or horizontally. This means manufacturers can produce high quality parts with minimal variation, even in large volumes, making it a great choice for parts with tight tolerances and high-performance demands.

A Better Base For Color Customization

3D printing with PA 12 W opens up a world of possibilities for color customization, making it an excellent choice for industries and creatives alike. Its naturally white base provides a perfect canvas for vibrant and precise color application, allowing for stunning visual results. Unlike darker materials that can mute colors, the bright white hue of PA 12 W ensures that dyed or painted finishes appear true-to-tone and more vivid. This characteristic is especially beneficial for industries like consumer goods and automotive design, where aesthetic appeal and color accuracy are critical.

Why PA12 W Is Ideal for High-Performance Parts

There’s no denying that the mechanical properties of PA12 W make it a standout material for a variety of industries, especially those requiring strength, durability, and precision. Its combination of tensile strength, elongation, and modulus makes it perfect for applications where parts need to perform under stress — think automotive components, medical devices, and consumer goods like wearables or household appliances.

Beyond its mechanical properties, PA12 W offers an impressive environmental advantage: up to 80% powder reusability. This means unused powder can be recycled and reused in future print jobs, drastically cutting down material waste and overall production costs. The ability to reuse 80% of the powder not only makes PA12 W cost-effective, it also supports sustainability goals—an attractive benefit for companies like ABCorp aiming to reduce their environmental impact.

Applications Across Industries

Thanks to its exceptional mechanical properties, PA12 W is ideal for producing functional parts across a range of industries, from healthcare to automotive to consumer goods and fashion. In healthcare, it’s used to create durable prosthetics and surgical tools. In automotive, it offers high-strength solutions for parts that need to withstand extreme conditions. For consumer goods and fashion, its versatility allows manufacturers to produce customizable, high quality parts with intricate detail.

Conclusion

PA12 W is a versatile, high-performance material designed to meet the demands of modern additive manufacturing with the benefit of added color customization post print. Its tensile strength, elongation, and modulus make it the go-to choice for producing functional, high-quality parts that thrive in demanding environments. With the added benefits of 80% powder reusability and biocompatibility, PA12 W offers a reliable, cost-effective, and sustainable solution for industries ranging from healthcare to automotive. By choosing PA12 W and ABCorp 3D for your 3D printing needs, you can be confident that your parts are built to last, offering you long-term performance in a wide range of applications.

How 3D Printing is Revolutionizing the Holiday Season

Ever considered a 3D printed holiday gift? The holiday season is all about giving, but in an era where consumerism, more often than not, leads to excess and waste, it can be difficult to find gifts that are both meaningful and sustainable.

Enter 3D printing, a technology that’s not only transforming industries but also completely revolutionizing the way we shop. From highly personalized gifts to sustainable materials and faster production times, 3D printing is changing the holiday experience for both consumers and creators alike—all while reducing waste and excess. (Isn’t that what the holidays are really about?)

Complete Customization and Personalization for Gifts

The hallmark of a great holiday gift is its thoughtfulness and personal touch. In the past several years, 3D printing has made it easier than ever to give your loved ones something truly unique. Imagine gifting a custom Christmas tree ornament with a family member’s name or a significant date engraved on it. Or a miniature 3D model of a cherished pet, a favorite hobby, or even a memorable vacation destination. With 3D technology, almost anything can be customized — from personalized ornaments to jewelry or one-of-a-kind home decor pieces.

In addition, 3D printing allows for personalization on a much larger scale. Consumers can dream big by considering custom home decor items like a 3D-printed vase with a unique geometric design, or a decorative piece that incorporates a loved one’s handwriting. With such a vast array of creative options, this technology empowers artists and individuals to craft gifts that truly stand out, ensuring the holiday season feels extra special.

Sustainability at the Forefront of Holiday Giving

With the holiday season often marked by rampant consumerism, the desire for eco-friendly gifts has never been greater. Traditional manufacturing processes often lead to waste, but 3D printing offers a sustainable alternative by reducing waste, optimizing materials, and creating products layer by layer with minimal excess. It’s this aspect that makes it particularly important during the holidays, when mass-produced items flood the market and contribute to excess packaging, transportation emissions, and unnecessary waste. To put things into perspective, the EPA has found that the average household produces up to 25% more waste between Thanksgiving and New Years, totaling approximately 25 million tons of extra waste.

By using additive manufacturing, 3D printing builds objects layer by layer, a process that is much more material-efficient than traditional manufacturing. Contrast to conventional methods that often involve cutting away material from a block, 3D printing minimizes excess and can utilize recycled or renewable materials, such as bioplastics or metal alloys. For example, ABCorp 3D offers a range of eco-friendly options made from plant-based sources or recycled materials. These materials not only reduce the carbon footprint but also promote the use of renewable resources — aligning with the growing demand for sustainable gifts.

Additionally, 3D printing can produce products on-demand, which eliminates the need for overproduction and unsold inventory that typically ends up collecting dust in expensive warehouses and eventually as waste. Consumers can choose precisely what they want and when they want it, without the heavy environmental burden of mass production. This especially comes in handy for the holidays, when the rush to manufacture and ship products can lead to significant environmental strain. So a 3D printed holiday gift could not only be cool and unique, but a direct reduction in waste produced.

Streamlined Manufacturing with Rapid Prototyping

One of the key benefits of 3D printing is its ability to streamline the manufacturing process through rapid prototyping. This capability allows designers, entrepreneurs, and businesses to complete swift trial runs on product designs before committing to mass production. For holiday-specific items, this means faster turnaround times and the ability to adapt to consumer trends or specific requests.

During the holiday season, time is of the essence, and the demand for unique gifts often skyrockets. Traditional manufacturing processes can take weeks or even months to produce large quantities of a product. With 3D printing, the production time is drastically reduced, allowing designers and businesses to rapidly prototype and manufacture custom gifts in a fraction of the time. (Perfect for those last-minute shoppers!)

This also enables creators to offer limited edition or exclusive products, with little to no risk of excess inventory. Whether you’re an artisan selling holiday-themed products or a large retailer looking to offer a unique line of customizable gifts, 3D printing ensures that your products are made quickly and efficiently, without sacrificing quality.

The Future of Holiday Shopping

As 3D printing continues to evolve, the potential to revolutionize the holiday shopping experience becomes even greater. The ability to personalize gifts, reduce waste, and speed up production could reshape the way we think about the holidays. Whether you’re looking for a meaningful, one-of-a-kind present or want to ensure your purchases have a smaller environmental footprint, 3D printing is making it easier than ever to have a holiday season that’s not only special but also sustainable.

This holiday season, consider embracing the power of 3D printing. With endless customization possibilities, eco-friendly materials, and the ability to streamline production, it’s clear that this technology is more than just a passing trend — it’s shaping the future of gift-giving for generations to come.

So, why not make your holiday shopping experience a little more creative, a little more sustainable, and a lot more memorable? The future of gifting is here, and this year could be your first 3D printed holiday gift!

How 3D Printing is Changing Manufacturing…for the Better!

Once viewed as a niche technology, additive manufacturing (or 3D printing) has quickly become a powerful tool, transforming the manufacturing industry on a global level. As industries face increasing pressure to innovate and adapt, 3D printing has emerged as a prime solution. From reshoring production to the U.S. to enhancing the efficiency of short-run productions and reducing costs, this technology is changing how goods are designed, developed, and delivered.

Reshoring Manufacturing to the U.S.

In recent years, there has been a growing trend toward reshoring, or bringing manufacturing jobs and operations back to the United States from overseas. 3D printing is playing a pivotal role in this movement by making domestic production more accessible and feasible. Traditionally, manufacturers shifted operations to countries with lower labor costs to remain competitive. However, advances in 3D printing are reducing the reliance on manual labor, ultimately leveling the playing field between domestic and offshore manufacturing.

With 3D printing, companies can now produce components and finished products locally, drastically reducing lead times. Parts that once took weeks to ship from overseas factories can now be produced on demand in a matter of hours or days. This not only decreases transportation costs but also cuts down on carbon emissions from shipping, making it a more sustainable option for companies focused on reducing their environmental footprint.

Additionally, the flexibility of 3D printing allows manufacturers to be more responsive to changes in customer demand. Companies no longer need to place large, bulk orders to make international manufacturing cost-effective. Instead, they can produce smaller batches locally, catering to fluctuating market trends without the risk of overproduction. This shift allows the U.S. to regain its position as a global manufacturing leader while creating new opportunities for high-tech jobs and innovation domestically.

Efficient Short-Run Productions

One of the most significant benefits of 3D printing technology is its ability to efficiently facilitate short-run production. Traditional manufacturing, such as injection molding or CNC machining, often requires extensive setup times and high upfront costs for tooling, which can be inefficient for producing small quantities of a product. In contrast, 3D printing eliminates the need for costly molds and tooling, making it an ideal solution for businesses looking to produce limited-run items.

In industries where customization is key—such as healthcare, aerospace, and automotive—3D printing excels at producing tailored, one-off components. Medical devices, for instance, often require patient-specific modifications, and 3D printing allows for rapid prototyping and production of custom parts without incurring the exorbitant costs associated with traditional methods. This adaptability is also invaluable in prototyping and product development stages, where quick iterations can mean the difference between success and failure in a competitive market.

Moreover, this streamlined process helps companies minimize waste. Traditional manufacturing methods often involve cutting away excess material, resulting in large amounts of waste. 3D printing, however, is an additive process, building parts layer by layer using only the material needed. This not only reduces waste but also significantly lowers material costs, especially for high-value materials like titanium or specialty plastics used in industries like aerospace.

Cost-Effective Manufacturing

The traditional view of 3D printing has been that it is too costly for mass production. However, recent advancements are proving that it can be a cost-effective solution for many industries. As the technology has improved, the cost of 3D printers, materials, and associated equipment has decreased, making it more accessible for businesses of all sizes.

One of the major ways 3D printing helps reduce costs is by cutting down on material waste, as mentioned earlier. But beyond material savings, it also significantly reduces labor costs. Traditional manufacturing often involves multiple stages and manual labor to create and assemble parts, especially for complex geometries. 3D printing can produce intricate designs in a single build, reducing the number of production steps and, consequently, the labor needed.

The ability to produce parts on demand also leads to savings in inventory costs. Instead of maintaining large inventories of parts or finished products, companies can use 3D printing to create items as needed, reducing the overhead associated with warehousing. This on-demand production model is particularly valuable in industries with rapidly changing technology or designs, as it allows manufacturers to avoid the risk of being stuck with obsolete inventory.

Additionally, 3D printing is making it easier for small businesses and startups to enter the manufacturing space. In the past, large upfront investments in manufacturing equipment and tooling often acted as barriers to entry. With 3D printing, companies can start small, scale up as needed, and avoid the financial burden of traditional manufacturing infrastructure. This democratization of manufacturing is opening doors for innovation and entrepreneurship across various industries.

Conclusion

The impact of 3D printing on manufacturing is profound, bringing significant improvements to the way products are designed, developed, and produced. By enabling reshoring, enhancing the efficiency of short-run productions, and offering a cost-effective solution for a wide range of industries, 3D printing is positioning itself as the future of manufacturing. As the technology continues to evolve, it will undoubtedly play an even more critical role in helping businesses navigate the complexities of modern manufacturing, driving innovation, sustainability, and economic growth.

Need 3D printed parts or prototypes? Contact us today for a free quote.

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.

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.

All About BASF Ultrasint TPU01

I recently had the opportunity to hear how Additive Manufacturing or 3D Printing made a dramatic difference in someone’s life. Through a combination of digital scanning, CAD work, and 3D Printing, this client was able to get the “perfect fit” with his lower limb prosthetic — something he’s wanted for 20 years

It reminded me of the sensitive side of manufacturing and how 3D Printing or Additive Manufacturing can be an asset to traditional manufacturing. As I mentioned in an earlier post, Additive Manufacturing continues to grow and touch on markets segments that are new and labor intensive that can benefit from the digital component of 3D Printing. As printing processes and materials develop, we will see more life changing benefits outside the traditional manufacturing space.

When we look at HP’s Multi Jet Fusion (MJF) process, we see a variety of materials for different applications. And the material that gave this client that “perfect fit” was BASF Ultrasint TPU01.

What is BASF Ultrasint TPU01?

Thermoplastic Polyurethane (TPU) is a very elastic and flexible material. It is durable, strong, and smooth to the touch, and it has high wear resistance, withstanding environments of oils, grease, and solvents. Additionally, TPU has superior resistance to high and low temperatures, making this material a great substitute for hard rubber parts.

Current markets that can benefit from the BASF TPU material are as follows:

Sports
Automotive
Footwear

Electronic cases
Industrial tools/fixtures
Orthotic & Prosthetic (O&P) and other medical applications

Each of these markets require unique material requirements and finishes. The Ultrasint TPU01 along with post processing applications can give the customer a part that is quicker to market with similar characteristics to a traditionally manufactured part.

Post Processing of TPU01

Several post-processing applications are available for the BASF TPU Ultrasint material. ABCorp 3D currently provides dyeing and vapor smoothing. When MJF printed, TPU01 will be grey in color; dyeing the part gives the printed part a black uniform color that has penetrated the part surface.

When Vapor Smoothing is added as a surface treatment, a part that has been printed with the MJF process will change from grey to black and parts that have been dyed will have a part finish with an average surface roughness (Ra) of around 1.18. This effectively seals the part, adding to the surface properties of moisture and airtightness along with improving bacteria protection.

Another popular post process is ceramic coatings: Cerakote and Durakote. Both have solutions for 3D Printed parts.

Latticing with Ultrasint TPU01

The lattice structure is found in nature and mimicked within the structural foam industry. Incorporating lattice design into the HP MJF printing process gives parts an additional level of performance properties. Parts can be printed with different lattice structures incorporated into specific areas of the part, and the result is added flexibility in those areas with what could be called a “customized durometer” applying to different areas of the part.

Latticing of MJF Printed TPU parts has opened up areas in the sports, O&P, and automotive industries.

A recent article in AM Magazine discussed how latticing along with TPU material can be used to better fit a sports helmet to the wearer’s head. The article goes on to note, “Meanwhile, padding made via 3D printing in this way can also be customized to the wearer by designing from a scan of the head. We experienced this with digital-material helmet padding that was made from our personal scan data.”

In the O&P field we are seeing parts that have custom lattice structures that specifically tailor to different parts of the prosthetic, giving a better fit and happier client. Just ask the guy that finally found the best prosthetic fit after 20 years!

“He was very excited about it. Happy to see we finally got him fit going totally plasterless — he has been working to that goal for the last 20 years”.

Who we are, what we do, and how to connect for more information.

ABCorp has been a secure contract manufacture since 1795, creating the first anti-counterfeit currency for the United States. As markets change, we now create and manufacture a good portion of the world’s plastic Credit Cards, Passports and Gift cards. When COVID hit, our punch presses transitioned to face masks and we ventured into Additive Manufacturing to help address the tightening supply chain concerns.

In a sort time ABCorp 3D Inc. has grown to house multiple HP MJF 580 and 5210 series printers in our secure Boston facility. Our current material offerings are Nylon PA-11, PA-12, Polypropylene and flexible TPU. The HP 580 creates colors parts in Nylon PA-12CB material.

If you’re in a position to review your parts for a digital inventory or would like us to print a few parts, please reach out to us. A CAD file with an .stl or 3MF file along with design specifications is enough to start the conversation.

And of course, samples are available upon request.

Vic Little
Business Development
ABCorp-3D