3D print innovation: Auto manufacturing, dentistry and fashion applications

3D print technology is already making its mark across the industry spectrum. Here are some examples of how and where business practice is changing due to the advancement that the technology can bring. 

From innovative and relatively inexpensive tooth correction and car parts to customised safety products and haute couture, there are many uses for 3D print innovation.

Old dentistry out, 3D print in

One example of a novel 3D print technology idea using polyurethane that has caused high disruption to a well-established industry is the

Invisalign orthodontic treatment device.

The firm’s 2015 annual report posted sales close to $850m – although this includes scanner used to create CADs for 3D printing the end product.

Align Technology pioneered the invisible orthodontic device in 1999 and by 2001 a million customised clear aligners had been manufactured.

According to the Deloitte report, 3D Systems was producing 50-60K units per day in 2012.

Auto innovation

Equus Automotives’ Ford Mustang-like Equus BASS 770 car combined stereolithography, fused deposition modelling and selective laser sintering 3D print processes in its production.

Using its proprietary urethane technology QuantumCast, additive manufacturing firm Solid Concepts – now part of Stratasys – provided 3D printing processes during the vehicle’s development phase.

The instrument panel, headlight and tail light bezels, HVAC ducting, glass trim panel fender, console covers, seat belt covers and under hood components were all created by Solid Concepts using 3D printing or urethane casting methods.

Footwear innovations 

Around five years ago, Germany’s Fraunhofer Umsicht institute, unveiled what it said was the world’s first SLS prototype outer sole using a thermoplastic polyurethane powder. One of the things which made the technology so innovative was the claim that the TPU cake powder was 100% re-usable.

In 2015, TPU midsole technology formed the key to Adidas’ Futurecraft 3D running shoe – a customisable 3D-printed concept trainer it developed with Materialise.

"We have used a one-of-its-kind combination of process and material in an entirely new way."

Eric Liedtke, executive board member at Adidas

A brief run on a treadmill with footscan technology, said Adidas, will facilitate in-house 3D-printed sole production, using a SLS process.

Eric Liedtke, executive board member at Adidas, said: “Futurecraft 3D is a prototype and a statement of intent.

“We have used a one-of-its-kind combination of process and material in an entirely new way. Our 3D-printed midsole not only allows us to make a great running shoe, but also to use performance data to drive truly bespoke experiences,” he added.

In March 2016, Adidas rival Under Armour, based in Maryland, US, announced the launch of a limited number of 3D printed training shoes. It plans to use TPU from Germany chemical company Lehmann&Voss&Co.

3D PU gets BMW thumbs up 

Already celebrating 25 years of 3D print technology in its production of cars and now delivering more than 10,000 3D printed components yearly, BMW is also using the technology to protect its workers.

The firm 3D-printed PU thumb guards to reduce strain when workers fit a particular component to its vehicles.

The aid is used when fitting a rubber plug into a hole left in the car’s chassis. The guard acts like support brackets for the workers’ thumbs and they are created as a custom orthotic device using a portable 3D camera. The camera captures the unique size and shape of each line worker’s thumb before a version is printed from semi-flexible thermoplastic polyurethane.

Materialise

Belgium-based Materialise posted earnings of EUR1.2b bn in 2015, a 25% hike on the previous year.  According to the company, operates one of the largest 3D printing factories in the world and has “more than 130 machines, producing on average over 2000 parts daily.”

Industrial customers can order parts direct from the firm and the business also operates an online marketplace for designers and small business to upload designs and order individual pieces or item batches for delivery.

Toon Roels, R&D manager at Materialise, told Urethanes Technology International magazine, that over the last five years laser sintering is showing the fastest growth. “The market may be small today but the projection is that it will become an attractive market.” The online marketplace currently offers 21 materials including a bio TPU modified by Lehmann&Voss&Co.

“Much of the sales is tied with honouring the individual and that is almost a movement against mass production. The efficiency of traditional manufacturing plants is because of volume. It needs a different approach. It could be that different players in the market get this difference,” Roels added.

"There is extra value in personalised products, the better fit and higher comfort achievable with 3D print processes."

Toon Roels, R&D manager at Materialise

Roels said the difference was already being felt in high end markets because of consumers’ ability to pay extra.

“There is extra value in personalised products, the better fit and higher comfort achievable with 3D print processes, especially in markets like eyewear and footwear insoles. It could be that this becomes a very usual market for TPU.”

Among the higher profile uses for Materialise’ TPU – which the firm describes to customers as a rubber-like material – was the creation of a 3D print dress by Dutch fashion designer Iris van Herpen in 2013.