Professional Documents
Culture Documents
opportunity
primer
The basics
of additive
manufacturing
A Deloitte series on
additive manufacturing
A Deloitte series on additive manufacturing
Contents
Foreword | 2
Endnotes | 14
1
The 3D opportunity primer: The basics of additive manufacturing
Foreword
2
A Deloitte series on additive manufacturing
An overview of additive
manufacturing (3D printing)
“
then slices the data file into individual lay-
A process of joining materials ers, which are sent as instructions to the AM
to make objects from 3D model device. The AM device creates the object by
adding layers of material, one on top of the
data, usually layer upon layer, other, until the physical object is created.
as opposed to subtractive
”
Once the object is created, a variety of finish-
manufacturing methodologies.2 ing activities may be required. Depending
on the material used and the complexity of
In common practice, the terms “AM” and the product, some parts may need secondary
“3D printing” are used interchangeably.3 processing, which can include sanding, filing,
3
The 3D opportunity primer: The basics of additive manufacturing
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A Deloitte series on additive manufacturing
1 2 3 4 5
CAD-based .STL file Sliced layers AM system End-part
3D model finishing
FINAL PRODUCT
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The 3D opportunity primer: The basics of additive manufacturing
‘86 ‘87 ‘88 ‘89 ‘91 ‘92 ‘93 ‘94 ‘96 ‘97 ‘98 ‘99
First-generation acrylate
resins commercialized by New resins developed and Materials developed to
3D Systems and commercialized for use in a withstand tougher
Ciba-Geigy wide range of 3D printers conditions
Focus on developing
capabilities to process
newer materials (e.g.,
composites and metals)
Source: Deloitte analysis; Wohlers Associates, Additive manufacturing and 3D printing state of the industry, 2012; The University of Texas at
Austin, "Selective laser sintering, birth of an industry," December 7, 2012, http://www.me.utexas.edu/news/2012/0712_sls_history.php,
accessed January 25, 2014.
apparatus.6 Selective laser sintering (SLS), processing, the complexity of design, and the
another AM technology, was first commercial- variety of materials used.
ized in the late 1990s; just like SLA, its appli-
cations grew from prototyping to end-part AM versus traditional
production over the years, driven by lower
system costs.7
manufacturing:
AM processes were largely geared toward Understanding trade-offs
prototyping applications in the 1990s. AM creates 3D structures by adding materi-
However, since the late 1990s, AM technolo- als layer upon layer. In contrast, traditional
gies and processes have increasingly been manufacturing practices (such as drilling or
deployed to large-scale industrial, medical, and machining) are often “subtractive,” as they
consumer end-market applications. Significant remove material from areas where it is not
developments since the early 2000s include desired. Additive manufacturing and tradi-
AM applications in the production of parts tional manufacturing face different trade-offs,
for unmanned aircraft, automobiles, con- with each process likely to play a role in the
sumer products, and organ and tissue printing deployment of manufacturing capabilities.
systems.8 As shown in figure 3, AM technol- Below, we list some of the respective advan-
ogy continues to improve in the speed of tages of AM and traditional manufacturing.
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A Deloitte series on additive manufacturing
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The 3D opportunity primer: The basics of additive manufacturing
AM processes, technologies,
and applications
Vat photopolymerization
In vat photopolymerization, a liquid photopolymer (i.e., plastic) in a vat is selectively cured by light-activated polymerization.
The process is also referred to as light polymerization.
Related AM technologies: Stereolithography (SLA), digital light processing (DLP)
Material jetting
In material jetting, a print head selectively deposits material on the build area. These droplets are most often comprised of
photopolymers with secondary materials (e.g., wax) used to create support structures during the build process. A UV light
solidifies the photopolymer material to form cured parts. Support material is removed during post-build processing.
Related AM technologies: Multi-jet modeling (MJM)
Material extrusion
In material extrusion, thermoplastic material is fed through a heated nozzle and deposited on a build platform. The nozzle
melts the material and extrudes it to form each object layer. This process continues until the part is completed.
Related AM technologies: Fused deposition modeling (FDM)
Binder jetting
In binder jetting, particles of material are selectively joined together using a liquid binding agent (e.g., glue). Inks may also
be deposited in order to impart color. Once a layer is formed, a new one is created by spreading powder over the top of the
object and repeating the process. This process is repeated until the object is formed. Unbound material is used to support the
object being produced, thus reducing the need for support systems.
Related AM technologies: Powder bed and inkjet head (PBIH), plaster-based 3D printing (PP)
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A Deloitte series on additive manufacturing
Sheet lamination
In sheet lamination, thin sheets of material (e.g., plastic or metal) are bonded together using a variety of methods (e.g., glue,
ultrasonic welding) in order to form an object. Each new sheet of material is placed over previous layers. A laser or knife is
used to cut a border around the desired part and unneeded material is removed. This process is repeated until the part is
completed.
Related AM technologies: Laminated object manufacturing (LOM), ultrasonic consolidation (UC)
AM
Technology Typical materials Advantages Disadvantages
process
Stereolithography Vat Liquid photopolymer, Complex geometries; Post-curing required;
polymerization composites detailed parts; smooth finish requires support structures
Digital light Vat Liquid photopolymer Allows concurrent Limited product thickness;
processing polymerization production; complex shapes limited range of materials
and sizes; high precision
Multi-jet modeling Material jetting Photopolymers, wax Good accuracy and surface Range of wax-like materials
(MJM) finish; may use multiple is limited; relatively slow
materials (also with color); build process
hands-free removal of
support material
Fused deposition Material Thermoplastics Strong parts; complex Poorer surface finish and
modeling extrusion geometries slower build times than SLA
Electron beam Powder bed Titanium powder, cobalt Speed; less distortion of Needs finishing; difficult to
melting fusion chrome parts; less material wastage clean the machine; caution
required when dealing with
X-rays
Selective laser Powder bed Paper, plastic, metal, Requires no support Accuracy limited to powder
sintering fusion glass, ceramic, structures; high heat and particle size; rough surface
composites chemical resistant; high finish
speed
Selective heat Powder bed Thermoplastic powder Lower cost than SLS; New technology with
sintering fusion complex geometries; no limited track record
support structures required;
quick turnaround
Direct metal laser Powder bed Stainless steel, cobalt Dense components; intricate Needs finishing; not suitable
sintering fusion chrome, nickel alloy geometries for large parts
Powder bed Binder jetting Ceramic powders, metal Full-color models; Limited accuracy; poor
and inkjet head laminates, acrylic, sand, inexpensive; fast to build surface finish
printing composites
Plaster-based 3D Binder jetting Bonded plaster, plaster Lower price; enables color Limited choice of materials;
printing composites printing; high speed; excess fragile parts
powder can be reused
Laminated object Sheet Paper, plastic, metal Relatively less expensive; Less accurate; non-
manufacturing lamination laminates, ceramics, no toxic materials; quick to homogenous parts
composites make big parts
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The 3D opportunity primer: The basics of additive manufacturing
Figure 4. AM technologies, corresponding base materials, and advantages and disadvantages (cont.)
AM
Technology Typical materials Advantages Disadvantages
process
Ultrasonic Sheet Metal and metal alloys Quick to make big parts; Parts with relatively less
consolidation lamination faster build speed of newer accuracy and inconsistent
ultrasonic consolidation quality compared to other
systems; generally non- AM processes; need for
toxic materials post-processing
Laser metal Directed Metals and metal alloys Multi-material printing Relatively higher cost of
deposition energy capability; ability to build systems; support structures
deposition large parts; production are required; need for
flexibility post-processing activities to
obtain smooth finish
Sources: Deloitte analysis; Wohlers Associates, Additive manufacturing and 3D printing state of the industry, 2012; Troy Jensen and Pipar Jaf-
fray, 3D printing: A model of the future, March 2013; Justin Scott, IDA Science and Technology Policy Institute, Additive manufacturing: status
and opportunities, March 2012.
Graphic: Deloitte University Press | DUPress.com
Stereolithography
Digital light processing
Multi-jet modeling (MJM)
Fused deposition modeling
Electron beam melting
Selective laser sintering
Selective heat sintering
Direct metal laser sintering
Powder bed and inkjet head
printing13
Plaster-based 3D printing
Laminated object manufacturing14
Ultrasonic consolidation
Laser metal deposition
Sources: Deloitte analysis; Wohlers Associates, Additive manufacturing and 3D printing state of the industry, 2012; Phil Reeves, 3D printing &
additive manufacturing: Extending your printing capability in true 3D, Econolyst, June 12, 2012; Justin Scott, IDA Science and Technology Policy
Institute, Additive manufacturing: Status and opportunities, March 2012.
Graphic: Deloitte University Press | DUPress.com
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A Deloitte series on additive manufacturing
as polymers and metals are widely used in numbers of companies use the technology not
AM systems. To a lesser extent, ceramics and just for producing prototypes, but to manufac-
composites also support AM processes. Use of ture parts and full-scale products.15 The tech-
varied materials in AM is an area of focus for nology will act as a particularly strong catalyst
R&D in the future. for substantive research developments in the
health care and manufacturing industries.16
AM applications: The Figure 6 summarizes some current applications
of and potential future developments in AM in
technology’s inherent select industries. The breadth of current and
benefits will drive increasing likely future applications suggests that there is
penetration across industries strong growth potential for AM going forward.
in the next decade
Application of AM technologies is expected
to grow across industries as increasing
Sources: Deloitte analysis; CSC, 3D printing and the future of manufacturing, 2012.
Graphic: Deloitte University Press | DUPress.com
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The 3D opportunity primer: The basics of additive manufacturing
Market opportunities
and challenges
OPPORTUNITIES CHALLENGES
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A Deloitte series on additive manufacturing
Deloitte Consulting LLP’s supply chain and manufacturing operations practice helps companies
understand and address opportunities to apply advanced manufacturing technologies to impact
their businesses’ performance, innovation, and growth. Our insights into additive manufacturing
allow us to help organizations reassess their people, process, technology, and innovation
strategies in light of this emerging set of technologies. Contact the author for more information
or read more about our alliance with 3D Systems and our 3D Printing Discovery Center on www.
deloitte.com.
13
The 3D opportunity primer: The basics of additive manufacturing
Endnotes
1. Mark Cotteleer and Jim Joyce, “3D op- 12. A blue dot indicates that a given material is po-
portunity: Additive manufacturing paths tentially used with a given technology. It does
to performance, innovation, and growth,” not indicate the extent of that material’s use.
Deloitte Review 14, January 2014, http:// 13. In addition to the categories of materi-
dupress.com/articles/dr14-3d-opportunity/. als listed, powder bed and inkjet head
2. ASTM International, Standard terminol- 3D printing also uses sand molds.
ogy for additive manufacturing technologies, 14. In addition to the categories of materi-
designation F2792 − 12a, 2013, p. 2. als listed, laminated object manu-
3. The terms “additive manufacturing” facturing also uses paper.
and AM will be used throughout this 15. Wei Jun, Singapore Institute of Manufacturing
report to refer to the technology set. Technology, Opportunities and applications of
4. Laser Institute of America, The his- 3D additive manufacturing, April 11, 2013.
tory of laser additive manufacturing, 16. 3D Printing Industry, “The possi-
January/February 2012, p. 6. bilities of nanoscale additive manufacturing,”
5. T. Rowe Price Connections, http://3dprintingindustry.com/2013/11/20/
3D printing, May 2012. possibilities-nanoscale-additive-manufactur-
6. Ian Gibson, David W. Rosen, and Brent ing/, accessed November 21, 2013; CSC, 3D
Stucker, Additive Manufacturing Technologies: printing and the future of manufacturing, 2012.
Rapid Prototyping to Direct Digital Manufac- 17. For a detailed analysis of AM’s implications
turing (New York: Springer, 2009), p. 34. in the aerospace and defense industry, refer
7. The University of Texas at Austin, Selec- to our report 3D opportunity in aerospace
tive laser sintering, birth of an industry,” and defense: Additive manufacturing takes
December 7, 2012, http://www.me.utexas. flight, Deloitte University Press, June 2,
edu/news/2012/0712_sls_history. 2014, http://dupress.com/articles/additive-
php, accessed January 25, 2014. manufacturing-3d-opportunity-in-aerospace/.
8. Gibson, Rosen, and Stucker, Additive 18. For a detailed analysis of AM’s implications
Manufacturing Technologies, p. 34. in the automotive industry, refer to our
report 3D opportunity for the automotive
9. AM equipment providers are constantly industry: Additive manufacturing hits the
introducing new systems at a variety of road, Deloitte University Press, May 19, 2014,
price points, including professional-grade http://dupress.com/articles/additive-manu-
and consumer models that occupy price facturing-3d-opportunity-in-automotive/.
points ranging from a few hundred to
several hundred thousand dollars. 19. For a detailed analysis of AM’s implica-
tions in the medical technology industry,
10. ASTM International, Standard Terminology refer to our report 3D opportunity in medical
for Additive Manufacturing Technologies. technology: Additive manufacturing comes
Designation: F2792 − 12a, 2013, p. 1. to life, Deloitte University Press, April 28,
11. We acknowledge the ongoing and rapid evolu- 2014, http://dupress.com/articles/additive-
tion of the AM technology marketplace. Our manufacturing-3d-opportunity-in-medtech/.
goal here is to provide an overview of the major 20. “The National Additive Manufacturing
process types used to fabricate full components Innovative Institute in Youngstown: What
in use at this writing. A variety of other process is it?,” The Plain Dealer, February 12, 2013,
approaches may also be identified that, in http://www.cleveland.com/metro/index.
particular, enable features to be additively ssf/2013/02/the_national_additive_manu-
created on traditionally manufactured com- fact.html, accessed January 25, 2014.
ponents (e.g., direct write processes). For the
purposes of this analysis, we adopt the seven
major AM process types identified by ASTM.
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A Deloitte series on additive manufacturing
15
The 3D opportunity primer: The basics of additive manufacturing
Jonathan Holdowsky
Jonathan Holdowsky is a manager within the Brand & Eminence group of Deloitte Services LP. In
this role, he manages a wide array of strategic research projects on behalf of clients within the con-
sumer and industrial products industry.
Monika Mahto
Monika Mahto is a senior analyst with Deloitte Support Services India Pvt. Ltd. Over the last six
years, she has been involved in various strategic research assignments for clients in the consumer
and industrial products industry.
Contact
Mark Cotteleer
Director
Deloitte Services LP
+1 414 977-2359
mcotteleer@deloitte.com
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A Deloitte series on additive manufacturing
17
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