How High Volume 3D Printer Operators Address Sustainability

3D Printing: From Prototyping to Production

Originally seen as a prototyping tool, 3D printing has evolved into a vital manufacturing method. This transformation has given rise to 3D printer farms, where groups of printers operate simultaneously to enhance production rates of printed parts. 

High-volume operations of 3D print farms provide a scalable solution from prototype to mass production, handling up to 10,000 parts. This method offers significant cost advantages over traditional manufacturing, like injection moulding, which requires expensive setup costs for mould tools. 3D printing's affordability, flexibility, and speed facilitate rapid project starts and easy adaptations to design changes without new moulds. It also allows for customisations and reduces time to market by avoiding delays associated with overseas parts delivery.

However, 3D printing is a double edged sword - the growing adoption of 3D printing brings environmental considerations to the forefront.

“Material sustainability is an issue that can no longer be ignored due to wide adoption of 3D printing”. 

Poll Insights and High-Volume Filament 3D Printing

In order to understand the diversity in material usage among operators, a LinkedIn poll was created to gauge the volumes of 3D printer filament being used in order to understand the demand for plastic in 3D printing and therefore it’s potential environmental impact.

The LinkedIn poll on filament usage among 3D printing operators reveals insightful data on the scale of high-volume 3D printing and material consumption. A significant 51% of respondents report using between 1 to 15 kilograms of filament each month, indicating a wide adoption of 3D printing technology across various scales of operation, from small to moderate production levels. Interestingly, 22% of operators are in the 16 to 30 kilograms range, showcasing a notable segment of the market operating at a higher capacity, likely catering to more extensive project demands or commercial productions.

The absence of users in the 31 to 49 kilograms range could suggest a gap in the market or a jump in scale that fewer operators currently bridge. However, the substantial 26% of respondents using 50 kilograms or more of filament monthly underscores the significant presence of high-volume 3D printing operations.

Sustainability Challenges of High Volume 3D Printing

Following the poll, we identified several users operating high-volume 3D printers and sought their insights on the sustainability challenges they face in their large-scale 3D printing operations. There responses have been included below and categorised into wider sustainability topics.

Material Usage and Sustainable Filament Benefits

Sustainable filament, particularly recycled materials, offers numerous benefits in 3D printing.

Ken Pearce of Lunia 3D highlights the importance of sustainable material sourcing: 

"At Lunia 3D, sustainability is important to us. We prioritise it in our operations, especially understanding the plastics industry's environmental impact. Working with Filamentive ensures our 3D printing materials are sustainable, offering our customer's peace of mind that their products and prototypes are made responsibly."

The Importance of Sustainable Design Principles

The role of design in achieving sustainability is just as critical as the choice of materials. Oliver Landau-Williams of Printotype elaborates:

"Material selection is only part of the solution; equally important are sound design principles... A holistic approach to both material and design is essential for the most sustainable outcomes."

Economic and Environmental Costs of Inferior Materials

James Birkett founder of Protogen 3D, raised the very real prospect of a false economy when it comes to buying lower cost material and the potential far-reaching consequences on both operational efficiency and the environment:

"The unseen cost of cheap and unethically sourced filament is the amount of quality issues, additional finishing time, and waste management problems. A better margin on paper can result in containers full of plastic reels, and expensive machines blocked up or damaged, which ultimately leads to missed deadlines, more repair bills, and unhappy customers”

End-of-Life Considerations and the Plastic Stigma

Paul Moloney , of UK 3D Printing Service, Midlands 3D, highlighted the stigma around the use of plastics as well as the growing expectations from customers for 3D-printed products that need to be recyclable at the end of their lifecycle:

“The use of plastics still carries a stigma of waste and non-re-usability so education is key… Our customers range from individuals to global organisations, and industries from medical to industrial, consumer products to automotive… Increasingly we are asked for recyclability at the product’s end-of-life too”

How do these Perspectives inform Sustainable Solutions?

Lunia 3D's commitment to sustainable materials reflects a growing industry trend towards responsible production. Enhancing environmental credentials is not only a win for the planet but can also positively impact commercial performance.

“Talking steps to reduce plastic waste is not only environmentally friendly, but a savvy business practice, too, as more consumers seek out companies making a commitment to sustainability.” Barbara Estrada, All3DP.com (2021)

James Birkett's insight on the pitfalls of inexpensive, unethical filament use stresses the importance of reevaluating material sourcing to encourage a sustainable industry shift. This perspective is validated by findings from a Sculpteo State of 3D Printing Report which evidenced the growing demand for sustainability - according to the report, nearly half of the respondents (47%) emphasised the necessity for sustainable materials and technologies as essential for the growth of the 3D printing sector.

Oliver Landau-Williams' advocacy for integrating value engineering with sustainability highlights the potential for reducing waste and prolonging product life. This approach is closely aligned with Filamentive's commitment to fostering a Circular Economy within the 3D printing industry. As highlighted in a blog post discussing recycling empty spools, the emphasis is on encouraging designers to rethink their design processes and product lifecycle management to support environmental sustainability.

The lack of an established end-of-life (EoL) processing system for 3D printed plastic parts poses a significant sustainability challenge in additive manufacturing. Paul Moloney emphasises the urgent need for solutions that address both the stigma of plastic use and the rising demand for product recyclability. This perspective not only underlines the urgency of developing EoL solutions but also aligns with the broader industry movement towards sustainable practices. In line with this, Filamentive explored the practical recycling options available to 3D printing users in this post.

The Road to Sustainable, High Volume 3D Printing

These industry insights highlights the need for a comprehensive approach to sustainability in high volume 3D printing. This includes not only selecting sustainable materials but also adopting innovative design principles to minimise waste and extend product lifecycles.

The role of collaboration among operators, material suppliers, designers, and customers is key in driving the industry towards more sustainable practices.

Reflecting on the insights shared by high volume 3D printer operators emphasises the multifaceted nature of sustainable 3D printing and the collective responsibility of the 3D printing community to address environmental challenges.

Sustainability is an ongoing journey where the aim is continual improvement rather than perfection. The practical strategies adopted by 3D print farm operators highlighted in this post offer a glimpse of hope and serve as a guiding light for the future of sustainable, high-volume 3D printing.

Their efforts underline a positive shift towards more eco-friendly practices, inspiring optimism for the environmental-responsible evolution of the industry.

Open-minded to 3D printing more sustainably?

Filamentive is a UK-leading sustainable 3D printing materials brand. The company was founded to address the environmental need to use more recycled plastics in 3D printing, and also alleviate market concerns over quality and long-term sustainability. Filamentive materials are trusted by educators, engineers and makers globally, helping thousands of 3D printing users to reduce their environmental impact.

Learn more about Our Commitment to Sustainability at this link.