Breaking down 3D printing barriers: From myths to opportunities

Recently, a reader of our blog asked for an overview of the biggest barriers to 3D printing. And since it's always good to have in mind what we are up against – and because the nature of these barriers changes as technology evolves - we asked director Jeppe Byskov to compile some of the most common challenges – and some considerations worth noting.

One of the biggest barriers preventing Danish companies from adopting 3D printing is a lack of knowledge and skills.

Many believe it is expensive or simply doesn’t make sense in their specific case. However, the problem often lies in the attempt to produce exactly the same product that is already being created through traditional manufacturing. And that is not how 3D printing is meant to be used effectively.

A good rule of thumb is that 3D printing should add new value that cannot be achieved (or would be very costly or difficult to achieve) through traditional methods. Perhaps material can be saved by eliminating excess. Perhaps less CO2 can be emitted. Perhaps functions can be added or improved. But whatever the added value is, it is clear that it is not inherent just by switching to 3D printing. The value must be integrated into the design of the item itself. 3D printing begins at the engineer's workstation – not in the production hall.

Integrating value into the design requires the necessary knowledge. Knowing the possibilities and limitations is crucial. Fortunately, there are now educational programs focused on 3D printing and skilled professionals in the industry working to promote understanding and spread knowledge. This creates ripples that we will see the effects of in the coming years.

Price: We are looking at a future where prices plummet

One thing is the printers themselves, but currently, there can also be many manual processes involved, making 3D printing resource-intensive. For instance, after a print is completed, excess parts may need to be removed by hand. Solutions to this problem exist, but they are expensive and often targeted at specific productions, meaning they are not accessible to the broader industry.

However, when we look at 3D printers alone, we are looking at a future where prices plummet. One of the biggest players in the market – 3D Systems – has predicted a Moore’s Law-like development. They believe performance will double every few years, while prices will halve. And although we are not moving at that pace yet, we can observe that 3D printers are continuously becoming cheaper and better. The market is growing, and competition is increasing. All of this is very promising and lowers the entry barrier.

You can see the development. If you needed to produce a few hundred or thousand elements, it wasn’t competitive just 5 years ago. But today, it certainly can be.

One of my personal beliefs is that 3D printing will have its industrial breakthrough when we can see it being used meaningfully and value-creating in mass production. A new technology like binder jetting is a good candidate for where we might see this first. The more industrialized it becomes, the cheaper it gets.

Limited material selection: It's coming

When we at the Danish Technological Institute talk to companies, they often want to 3D print in specific materials or alloys they are already familiar with. However, not all materials are available in a form suitable for 3D printing. This is usually not because it is impossible, but rather because the market is simply too small for material suppliers to have the economic incentive to meet requests beyond the common offerings.

However, while the limited material selection can be a hindrance, the situation is changing in the right direction. As the market grows and more large industries get involved, demand will increase. In other words, the catalog of materials available for 3D printing will grow over time.

Is the barrier real or mental?

3D printing is in constant development, and it is important not to be limited by outdated perceptions and myths. We often see that companies that take the chance and build a business case around the added value from the start discover that the expected barriers disappear. When they actively engage, the myths are dispelled, opening up new opportunities.

There are many resources available for companies wishing to delve deeper into the potential of 3D printing. For example, one can talk to experts from organizations like the Danish AM Hub or the Danish Technological Institute – or participate in courses to gain a better understanding of the technology. There are also funding opportunities available from various sources, which allow companies to engage in dialogue and explore possibilities.

So, as we continue to navigate challenges and barriers, it is clear that 3D printing is generally moving in a positive direction: barriers are becoming smaller, and opportunities are becoming more numerous and larger.