IZMIR INSTITUTE OF TECHNOLOGY-DEPT.

OF INDUSTRIAL DESIGN
ME 323 INDUSTRIAL DESIGN MANUFACTURING TECHNOLOGIES ▪ 2023-2024
FALL
Instructors:
Lecturer Dr Büşra Karaş

Final Examination Report

Student:
Ceyda Olgun
280303003

1. Introduction

This report aims to analyze and understand the comprehensive manufacturing process of a
custom-made additively manufactured product. The focus will be on IKEA's 3D-printed
hands from the OMEDELBAR collection. This analysis will cover the journey from raw
material selection to the final finishing operations. The objective is to gain insights into the
additive manufacturing process and to assess how design considerations such as strength,
weight, and aesthetics are integrated into the manufacturing workflow.

2. Product Overview

The OMEDELBAR series, a collaboration between IKEA and Bea Åkerlund, who has
previously worked with famous artists Madonna, Beyoncé, and Lady Gaga, features bold and
unconventional designs that emphasize individuality and creativity. This series includes a
variety of unique items, among which are 3D-printed hands. These hands were produced
using Selective Laser Sintering (SLS), a powder-based 3D printing process. They are notable
for their mesh-inspired stylistic design and can be used as wall decorations or decorative
jewelry hangers. The material used for these hands, Nylon 12, is known for its durability,
flexibility, and resistance to UV radiation, and the hands can be easily colored, although they
initially come out white from the printing process. The use of 3D printing technology in this
collection highlights IKEA's commitment to embracing modern manufacturing processes.

Image 1: 3D Printed Hands From IKEA's Omedelbar Collection

 3. Design Process

The Omedelbar collection, featuring 3D printed hands, is the outcome of a collaborative effort
between IKEA and Swedish artist Bea Åkerlund. This alliance signifies a major milestone for
IKEA in integrating 3D printing into their manufacturing methods. [1]

Image 2 : IKEA Omedelbar 3D Hands And Bea Akerlund

4. Material Choice

The material used in this process, Nylon 12, is particularly notable for its robustness and
adaptability, as explained by industry expert Sami Mattila. It stands out for being chemically
stable, resistant to stress cracking, and able to withstand high UV exposure. An important
feature of Nylon 12 is its sustainability; both unused printing powders and the printed
products themselves are recyclable. While these items are naturally white, they can be easily
colored, offering a range of customization options. [2]

5. Manufacturing Collaborations

In 2017, IKEA, a leading furniture manufacturer, embarked on a groundbreaking 3D printing

mass production project in collaboration with Wazp, an Ireland-based company recognized as
one of the largest producers of 3D printed objects globally. Their initiative led to the creation
of a metal-mesh, artistically deconstructed human hand, a key item in the IKEA
OMEDELBAR collection. This item, which can serve as an ornamental jewelry holder or
distinctive wall art, boasts a complex design that would have been unachievable with
conventional injection molding technology. [3]

6. Manufacturing Process

The production of the 3D printed hands for IKEA's Omedelbar series by Materflow serves as
a cutting-edge example of leveraging 3D printing technology in large-scale manufacturing.
This method stands out for its fusion of high-end technology and efficiency, essential for
producing complex, high-quality designs for consumers. [4]
Utilizing the Selective Laser Sintering (SLS) technique, Materflow fabricates these hands.
This powder-based approach, pioneered by Dr. Carl Deckard and Dr. Joe Beaman at the
University of Texas at Austin in the 1980s, involves a laser to sinter powder material,
meticulously forming the product's design in successive layers. The distinctiveness of SLS
lies in its capacity to fabricate detailed and complicated shapes, which would be difficult with
conventional production methods.

Image 3: For time efficiency you try to print as many items as possible in one build.

The Selective Laser Sintering (SLS) process in 3D printing primarily involves a laser shaping
the powder into the desired structure. The procedure starts with the machine distributing a
uniform layer of plastic powder onto the platform within the printing chamber. The laser then
solidifies this powder. After the layer is completed, the platform descends to the thickness of
one layer, and a fresh layer of powder is applied for the laser to fuse. This cycle is repeated
until the component is fully formed.

Throughout this process, the excess powder around the forming structure provides support,
resulting in the finished product being encased in a block of unused powder, often referred to
as a "powder cake." After the printing is complete, this excess powder is extracted, filtered,
and reused. The final product typically undergoes additional post-processing steps to enhance
its surface quality, which initially appears somewhat coarse. Techniques like vibratory
finishing are employed to refine the surface of the printed parts, enhancing their texture and
appearance. This method is celebrated for its efficiency in manufacturing runs and its ability
to produce intricate designs.[5]

In this process, a laser bonds with powder material within a printer set at a high temperature
of 177°C. Post around 40 hours of printing, the powder block encompassing the printed
objects is extracted and placed into a sealed wooden box for cooling, for about 24 hours or
until the temperature lowers to 60°C. This innovative cooling method, devised by Materflow,
is key to maintaining the integrity and quality of the prints and allows for the immediate start
of a new print cycle, bypassing the need for the machine to cool down. [6]

Once the cooling phase concludes, the block is dismantled, and the individual hands are
extracted from the remaining powder, which is then recycled. The hands undergo a blasting
process to eliminate any leftover powder, followed by a thorough cleaning and drying. They
are subjected to stringent quality control checks to ensure they adhere to the high standards
set by both Materflow and IKEA.

Image 4: The build is taken apart, and items are separated.

Crafted from Nylon 12, known for its robustness, flexibility, chemical resistance, and
resilience to UV radiation, these hands exemplify the effectiveness of 3D printing in mass
production. This method exemplifies a sustainable manufacturing approach, reducing waste
and allowing for just-in-time production. The hands in the Omedelbar collection represent not
only decorative elements but also a significant innovation in home decor manufacturing,
marrying artistic design with state-of-the-art technology.

In the post-production phase of the 3D-printed hands for IKEA's Omedelbar collection, the
items are sent to DyeMansion in Germany for further processing. This stage is integral to
ensuring the quality of the final product. It begins with an extensive cleaning to eliminate any
leftover materials from the printing process. After cleaning, the hands are dried completely to
prevent any moisture-related issues. The last step in this phase is a detailed quality check,
ensuring each hand aligns with the high standards set for the Omedelbar series. [7]
 Image 5: Sami Mattila placing newly printed items in the automatic blasting machine to remove powder residue.

7. Why SLS printing?

Opting for 3D printing technology was imperative for the production of Bea Åkerlund’s
sophisticated hand-shaped hangers, due to the intricacies of the design. These hangers are
crafted using SLS technology, with IKEA also having the option to use HP’s MJF technology.
The production is outsourced, and while exact numbers are not public, IKEA's widespread
market suggests production is in the high thousands.[8]

The primary benefit of 3D printing is its reduction in material waste, a stark contrast to the
traditional subtractive manufacturing process. This additive approach is especially beneficial
for large manufacturers like IKEA, which recently reported a decrease in profits due to rising
costs of raw materials. The ability of Additive Manufacturing to produce quickly with
minimal waste is, therefore, a key advantage for IKEA.

Benefits of 3D Printing include:

Eco-Friendliness: Printing near markets cuts down transport needs and waste production is
below 5%, with most reusable or recyclable materials.
Cost-Effectiveness: Printing based on demand reduces the need for large inventories and
lowers the risk of excess stock.
Tailored Products: The technology allows for creating distinct products suited to specific
customer or market demands without extra costs.
Design Innovation: It facilitates the production of complex designs and complete structures
that were impossible before, eliminating manual assembly requirements. [9]
 8. Conclusion

The development and manufacturing of IKEA's Omedelbar series' 3D-printed hands

represent a significant stride in applying additive manufacturing in large-scale production.
This case study illustrates the advanced capabilities of 3D printing technologies, such as
Selective Laser Sintering (SLS), and highlights the creative possibilities they unlock in design
and manufacturing.

The collaborative efforts between IKEA, Bea Åkerlund, and manufacturing partners like
Materflow and Wazp have paved the way for intricate and highly customized products,
previously unattainable through traditional manufacturing methods. The use of Nylon 12 as
the material choice underscores a commitment to durability, flexibility, and sustainability,
echoing the modern consumer’s demand for eco-friendly and resilient products.

The success of this project lies not just in the aesthetic appeal or the novelty of the
technology used, but also in the practical benefits it offers. These include reduced material
waste, cost-effectiveness, and the ability to tailor products to specific market needs without
incurring significant additional costs. The environmentally friendly aspect of this production,
with minimal waste generation and recyclability of materials, aligns well with IKEA’s
growing focus on sustainability.

The Omedelbar series’ journey from concept to market introduction demonstrates the
potential of additive manufacturing in revolutionizing product design and manufacturing. It
offers valuable insights for future endeavors in this field, suggesting a shift towards more
personalized, sustainable, and technologically advanced manufacturing processes. This case
study is an encouraging example for other industries exploring the possibilities of 3D
printing, marking a noteworthy point in the evolution of additive manufacturing.

References
[1] OMEDELBAR – a collaboration with Bea Åkerlund. (n.d.). IKEA | IKEA Singapore.
https://www.ikea.com/sg/en/ideas/its-bold-and-its-here-the-new-omedelbar-range-
pub00197c70
[2] Designboom. (2017, July 14). IKEA announces 3D printed omedelbar line by bea
åkerlund. Designboom | Architecture & Design Magazine.
https://www.designboom.com/design/ikea-3d-printed-omedelbar-line-bea-akerlund-07-11-
2017/
[3] S. Saunders. 3D Printing in Mass Production: IKEA Announces the Upcoming Release of
Its Unique 3D Printed Collection.[online] 3Dprint.com 11 July 2017. Available at:
https://3dprint.com/180726/ikea-3d-printed-collection/
[4] P, A., & P, A. (2018b, May 22). IKEA unveils its first 3D printed collection. 3Dnatives.
https://www.3dnatives.com/en/ikea-3d-printed-omedelbar180720174/
[5] Smattila. (2023b, April 23). SLS – Selective Laser Sintering. Materflow.
https://www.materflow.com/en/sls-selective-laser-sintering-2/
[6] S. Saunders. 3D Printing in Mass Production: IKEA Announces the Upcoming Release of
Its Unique 3D Printed Collection.[online] 3Dprint.com 11 July 2017. Available at:
https://3dprint.com/180726/ikea-3d-printed-collection/
[7] Cd3d, & Cd3d. (2022, March 9). German IKEA introduces decorative items printed on
demand in 3D. 3DPC | We Speak 3D Printing. https://3dprintingcenter.net/german-ikea-
introduces-decorative-items-printed-on-demand-in-3d/
[8] Annija. (2023, July 24). IKEA to Airbus - Five examples of mass production using 3D
printing. PLM Group EU. https://plmgroup.eu/articles/examples-mass-production-3d-
printing/
[9] Brave new 3D world - IKEA Global. (n.d.). IKEA.
https://www.ikea.com/global/en/stories/design/brave-new-3d-world-170709/