Design

3D printing: let’s print a house

Do 3D printing technologies signal the start of a new industrial revolution? Will we soon be able to 3D-print our own toothbrushes? We take a look at the real potential offered by this much-hyped production process and the possibilities it holds for the years ahead.

By
Marie-Sophie Müller

EOS and New Balance: customized running shoes

No two runners are alike. But for elite athletes, winning is measured in hundredths of a second. So for personal-best times, it pays to make sure the spike plates on running shoes are individually customized. Using an EOS 3D printer and a specially developed nylon blend, New Balance has come up with a technique to produce runner-specific spike plates based on each athlete’s biomechanical data, including mechanical forces and pressure values, which are then printed out using 3D printing technology. In the manufacturing of a traditional sports shoe, each plate requires several injection molds of varying sizes. The mold is expensive and used to manufacture thousands of identical spike plates. But with 3D technology, the printed spike plate is resource-efficient and can be quickly replaced or modified if necessary – which means individually customized running shoes on demand.

Joris Laarman: footbridge in Amsterdam

Dutch Designer Joris Laarman has been experimenting with 3D technologies for several years. He achieved worldwide fame in 2006 with his computer-generated Bone Chair, a design inspired by the growth principle of bones. Now, he has discovered a way to print free-form structures in midair – which, in theory, could reach infinite proportions. Robotic arms equipped with welding guns are programmed to shape droplets of molten steel into stable, complex structures. The first bridge to be built using this technique will span one of Amsterdam’s canals by 2017.

BigRep’s 3D printer

With a print volume of 30 cubic feet, this is the world’s largest mass-produced 3D printer. BigRep One from Berlin carries a price tag of nearly $60,000 – still a fraction of the cost of the more powerful industrial models. The printer has been on sale worldwide since 2014. An Australian bus manufacturer, for example, uses it to “print” front ends. And in the medical technology industry, prostheses can be manufactured quickly to meet individual requirements. But the printer is used mainly for prototyping in the design phase, enabling designers to generate new developments faster, cheaper and using fewer materials.

i3 Berlin printer

The i3 Berlin was developed and perfected in workshops by a community over a two-year period. Measuring just 20 cm per side, the 3D printer is much smaller in format than the BigRep One, but works on the same principle. An open-source construction manual is now available on the internet. The printer comes with one or two print jets and can be bought in kit form for home construction or preassembled for around $1,500 (workshop included) from retailers such as the 3D print shop Youin3D in Berlin.

Oak Ridge National Laboratory and Skidmore, Owings & Merrill: 3D-printed building AMIE

Dental prostheses, building components and scale models are all well and good – but is it possible to 3D-print an entire building? No problem, says SOM, the Chicago-based firm of architects. At the International Builders’ Show held in Las Vegas in January 2016, the designers collaborated with the Oak Ridge Natural Laboratory to create AMIE (Additive Manufacturing Integrated Energy), a building measuring 13 feet high by 13 feet wide, and almost 40 feet long. Made from 3D-printed skeletal structural components, AMIE is capable of generating its own energy from integrated solar panels to power a hybrid-drive vehicle (likewise built using 3D-print technology).

The future has arrived in an inner courtyard in Berlin. On the third floor of an industrial building in the Kreuzberg district, computer-controlled printer heads run almost silently back and forth across the base of a man-sized skeletal cube, creating an object, layer by layer, out of fine plastic threads. “It’s a part for a drone,” explains Jasmin Ribouni of BigRep, the company that makes the world’s largest mass-produced 3D printer. Founded in 2014, the young company initially focused on printing molds, scale models and prototypes for designers, architects and artists. Today, BigRep One is increasingly an industrial machine. “You could say that 3D printing is now at the same stage of development as the Internet was in 1996,” says Ribouni. “We have the basics, but the technique is far from delivering the full potential benefits. With the right software, for example, printers can build networks and print mini-series in different locations. I also like the social element of this technology: with a 3D printer, I can set up a business in any country on earth and produce objects that would not otherwise be available so easily.”

The company sold over 100 printers in 2015 alone, most of them to North America, some even to Australia. It is ironic to think that the very machine that will one day liberate us from complex distribution channels is now being shipped all over the world from Berlin. Although BigRep is far from your average copy shop, here in Kreuzberg, potential buyers can make test prints of objects like the drone part.

There is a growing trend towards 3D workshops that allow anyone interested in the technology to have an object printed – or even try printing it for themselves. In Berlin, for example, there’s FabLab, where customers can print objects using the i3 Berlin, an open-source 3D printer that came about as a result of many workshops, and for which an open-source construction manual is available on the Web. Designers can use the i3 Berlin to print micro-production series, prototypes or molds for use with other materials. This means they are less dependent on large manufacturers.

Annika Frye does not believe the technology will soon be turning us all from consumers into manufacturers, printing Lego bricks for our children in the playroom, as predicted by Chris Anderson in 2013 in his book Makers: “The 3D printer isn’t some magic box,” she explains. “3D printing is only useful in furniture design when the parameters are right, for example, or when objects need customizing: a shelf that has to fit a certain corner, or to create variation in details, such as ornamentation. It’s still much too expensive for series production. But 3D printing has a future wherever individual customization is required – for example, in the luxury industry.”

Last year, Frye designed a table for BigRep. The aesthetic of her Woven Table derives from the possibilities and limitations of FDM (fused deposition modeling) printing: “My aim was to create something specifically for this printing technique, to develop a formal idiom that worked with the conditions imposed by the machine.” Just as wood has a grain, so a 3D print has a structure created by the thin layering process. The finished 3D print can be left in its raw form, treated, or laminated. The conference room at BigRep Studios houses a concrete-coated version of her Woven Table.

Other additive manufacturing techniques exist alongside FDM. Laser sintering involves the selective fusion of powder layers (ceramic, metal or plastic), for example, and by means of stereolithography (or “SLA” printing), objects are formed by laser in a vessel of liquid photopolymer.

Joris Laarman from Amsterdam has developed a way to “print” free-form, self-supporting and, theoretically, infinitely large structures in midair. Robotic arms equipped with welding guns are programmed to shape droplets of molten steel into stable, complex structures. In 2017, the first bridge using this futuristic technique will be built across one of Amsterdam’s canals.

In his 2013 State of the Union address, President Barack Obama predicted that “3D printing has the potential to revolutionize the way we make almost everything.” Just four years later, Obama may be able to walk across the first 3D-printed bridge – although to do so, he’ll have to travel to Europe.

Annika Frye: 3D-printed tables

How do you design an object for a specific manufacturing technique? What kind of formal idiom works with the possibilities and limitations of 3D printing? These were the questions facing designer Annika Frye in 2015 when she created a one-piece table for BigRep to match the characteristics of FDM (fused deposition modeling) printer BigRep One. What she came up with was a circular latticework structure, the diameter of which got smaller throughout the printing process. The object was then turned upside down to create a table. The Woven Table design uses both the layered and textile looks typical of FDM prints.

08/07/16