Development of Additive Manufacturing

Technology
Implications on the design process and the transportation industry, moving
from prototyping to production

Erik Stre
Department of Product Design
Norwegian University of Science and Technology

ABSTRACT
As additive manufacturing continuously is gaining momentum and its technology is rapidly developing
designers are being enabled to make better products faster and cheaper, without worrying about the
constraints of traditional manufacturing processes. This paper reviews the development of the additive
manufacturing technology with a focus on its impact on the design process, and how it is moving from
prototyping into production. There will also be an emphasis on how additive manufacturing is affecting
the automotive and aerospace industry. The results of this paper show that the use of AM in product
development is necessary for companies to compete with industry standards. However a shift can be
seen in the manufacture of production parts as 3D printing is emerging. Future implications of 3D
printing are also explored.

KEYWORDS: additive manufacturing, automotive industry, design process, 3d printing, rapid

manufacturing

1. INTRODUCTION concept models, functional prototypes, factory

tooling and finished goods. Materials used in 3D
It proliferated years ago because of its usefulness printing include resins, plastics and metals
in building prototypes. Ever since then, (Stratasys 2012). Many believe that it will shape
companies have increasingly used the the future of production and help to liberate the
manufacturing method to make production established engineering and manufacturing
parts. It is rapidly changing the industry, and the processes. It has been claimed that AM can cut
way we design and manufacture. By disposal of new product costs by up to 70% and the time to
tooling costs and reducing development time and market by 90% (Waterman 1994) (DDM at BMW
material usage it makes for a faster turnaround 2013) (Stratasys 2012).
and a more profitable design process.
AM is enabling companies to do what otherwise
Additive manufacturing refers to the process that would be impossible. To competitors confusion,
automatically builds objects layer by layer from the Aston Martin racing team managed to
computer data, better known as 3D printing. The develop the LMP1 racing car for the 2011 Le
Technology is utilized in many sectors including Mans competition in just six months due to
Transportation, aerospace, industrial, health highly advanced 3D printing in the conceptual
care, military and education. Uses include mock up stage (Rapid Prototyping 2013).

Development of Additive Manufacturing 1

To ensure an efficient development process total growth over 24 years (26,4%) (Wohler
when designing the Mars rovers, NASA turned to 2012).
3D printing. In all, 70 AM parts where produced
for its test vehicles.
Recently, a company called SelectTech
Geospatial, an advanced manufacturing facility
for commercial and defense applications, earned
the distinction of producing the first 3D printed
Unmanned aerial system (UAS) to take off and
land on its own gear (Hiemenz 2013).
EADS (European Aeronautic Defense and Space
Company) with their subsidiary Airbus has
earmarked the prospect of growing a full sized
airliner wing with AM sometime beyond 2020
(Excell 2010).

This paper will give an overview of the
development of additive manufacturing Figure 1: Additive manufacturing overview table
technology and where it stands today. And In (Thompson 2007).
addition take a closer look at how additive
manufacturing is continuously evolving the 2.1 Stereolithography
design process and how the technology is
changing the role of the designer. An Emphasis SLA is built one layer at the time by an UV laser
will be put on its impact on the transportation beam directed by a computer-guided mirror onto
industry, and how its implementation is the surface of the UV sensitive liquid epoxy resin.
gradually moving from prototyping and into The UV light solidifies the resin it touches and
production. Additive manufacturing also has a each layer is applied by submersion of the build
profound impact on the consumer market. platform into the resin. SLA is the technique that
However, this paper is solely industry focused. produces the finest surface finish and
dimensional accuracy. It requires a support
2. ADDITIVE MANUFACTURING (AM) structure under production, which has to be
removed post-production.
Additive manufacturing (commonly referred to as
either rapid prototyping or 3D-printing) is used to 2.2 Selective Laser Sintering (SLS)
construct simple and complex geometries by
fusing together very fine layers of powder or SLS is a similar powder-based process where a
liquid. The process starts with a CAD model sliced CO2 laser fuses fine nylon powder in layers,
into cross-sections. Each cross-section is mapped directed by a computer-guided mirror. The build
onto the surface of the rapid prototyping platform progresses downwards as each layer is
material by a laser, which fuses or cures the built. Delivery chambers rises to provide a roller
particles together (Thompson 2007). The layers with fresh powder that is being uniformly spread
are in the XY plane while the part is being built in over the build area. The non-sintered powder
the Z direction. Each of these cross-sections encapsulates and supports the sintered model.
represents a layer in the build. The model is then This eliminates the need for support material
tessellated and exported out as an STL file, the being printed along with the part.
industry de facto file format. Having a growth of
29,4% in 2011 alone, it notched the industrys

Development of Additive Manufacturing 2

 uphold overhangs and complicated geometries. It
is easily removed by hand and with water. Multi-
material printing is possible.

Figure 2: SLS process (Thompson 2007)

Figure 3: 3D printed models shown with soluble
2.3 Direct metal laser sintering (DMLS)
support material (dark) intact, and after removal.


Similar to SLS, a CO2 laser is used to sinter metal
alloy powder. An expendable first layer of the
3. AM IN PRODUCT DEVELOPMENT

part is anchored to a steel plate to stop
With an increasingly competitive market, getting
distortion, which makes for easier removal when
products out faster is crucial. The longer a
the build is complete.
product stays in the design cycle, the longer It

takes to get it to market, meaning less potential
2.4 Fused deposition modeling (FDM)
profit for companies. For that reason AM has

become standard practice for product
FDM produces 3D parts by melting and advancing
development across manufacturing sectors and
a fine ribbon of production grade thermoplastic
continents. Prototyping is an essential part of the
materials through a computer controlled
product development and manufacturing cycle
extrusion head, producing parts that are ready to
required for assessing the form, t and
use. This extrusion nozzle moves in the horizontal
functionality of a design before a signicant
XY plane while the build platform moves down,
investment in tooling is made (Pham 1997).
building the part layer by layer. This method
Additive manufacturing is an enabler for
requires a supportive structure to be printed, but
designers and it is changing the way design is
the strength to weight ratio is very high. Raw
being designed. The process of adding material
FDM parts have visible layer lines, which can be
layer by layer allows designers and engineers to
removed with several post processes.
develop complex geometries, which would be

prohibitively expensive or physically impossible
2.5 Jetting Systems
to produce with other manufacturing methods

(Lane 2013). The technology is giving designers
Utilizes Inkjet technology by jetting layers of
close to limitless freedom, removing the
liquid photopolymer onto a build tray and then
constraints of traditional manufacturing methods
curing them with UV light. Fully cured models can
(Excell 2010).
be handled and used immediately, without

additional post-curing. The 3D printer also jets a
gel-like support material specially designed to

Development of Additive Manufacturing 3

Cost savings alone is one of the main reasons and mechanical properties they require careful
Additive manufacturing have managed to get optimization. Maintaining a uniform temperature
mainstream attention in industry. After Stratasys` is a challenge with the SLS process, which can
key patents on FDM expired in 2009, there was results in variation in mechanical properties on
an explosion of open-source FDM printers on the different builds (Excell 2010).
market. In a few years the lowest price of an FDM
printer dropped from $14 000 to $300 (Mims FDM is taking on increased importance as an
2013). Another significant drop in price is likely alternative manufacturing method for
to play out again as key patents to the low-cost, components made in small numbers. Additive
high-res laser sintering is expiring in February components are more than strong enough to be
2014. Others claim that this turning point will not used for highly stressed load-bearing
be as radical as when the FDM patents expired, it applications. On paper, metallic additive parts
will have beneficial impact and generate a more printed with the DMLS technology, have
competitive market (Lewis 2013). Only the core mechanical properties that are better than cast
patents from the 1980s will expire, while the and getting towards wrought standards. The
advancements made subsequent are still on the limitation for expansive use is the lack of agreed
books. In addition to that, SLS is a more complex standards for material and process quality. Once
and sensitive process compared to FDM and will there will be recognized standards for testing,
be harder to adopt. then people will commit to the technology and
start utilizing it for load-bearing applications
There is a potential environmental benefit to 3D (Excell 2010).
printing due to it being an additive
manufacturing process. This is the opposite of An intersection of great importance is the one
traditional subtractive manufacturing processes, between AM and luxury automotive production.
which produce objects by cutting material away Noting that a company like Audi may claim it
from a block to create the desired shape produces 7 million individual cars, there is an
(Hiemenz 2011). On-demand production may elaboration on the possibility for AM to make
lead to reduced raw material requirements and a luxury design more individual and exclusive by
reduction in number of raw materials needed, allowing customers to create variations on
reduced wastage originating from the process interior design or entertainment components.
and also cuts in CO2 emissions resulting from the Traditional manufacturing would make this type
savings in the distribution phase. However the of customization too expensive for all but the
process of printing is very energy consuming. wealthiest of customers, but AM can make the
Research shows that the laser process that either process both less expensive and faster (Lane
melts or solidifies plastics consumes up to 100 2013). Pointing at moldless rapid manufacturing
times more electrical energy than traditional utilizing AM, Laurens Van den Acker, at the time
mass manufacturing to make an object of the head of Mazda design, said that the future of car
same weight. The actual energy usage per item design is that everyone has his own individually
is very high. The process does not use less energy styled car. (Van der Wiel 2012).
at the production stage, its the material
production stage that sets AM apart due to the 3.1 In the design studio
amount of material saved (Choudhury 2013).
Trends towards affordability and ease of use are
It is known that AM produces impressive results bringing professional 3D printing technology into
when it comes to part precision and complexity the lives of many designers and engineers. The
(Thompson 2007) (Lane 2011). Despite these growing expectation that a CAD drawing can
qualities a major issue is the sensitivity of current become a real three-dimensional object in a
machines. To be able to achieve desired material

Development of Additive Manufacturing 4

matter of hours is altering how companies see precision and ability to facilitate the creation of
the design process (Stratasys 2012). complex components (Brooke 2013). It is
believed that with both time and the huge
Purchasing a reliable 3D printer with good amount of funding the field is receiving (Atkins
accuracy and low tolerance suitable for the needs 2013), manufacturers will see AM making a
of small design studio, as of today is rather tremendous impact on the automotive,
expensive. Therefore outsourcing services aerospace and many other manufacturing sectors
suitable for 3D printing (conceptual form models, (Lane 2013).
prototypes, tooling etc.) to a dedicated 3D At Present time the first OEMs (Original
printing firm is common practice. This likely Equipment Manufacturer) are starting to fit 3D
ensures both competitive pricing and good print printed components onto their production cars
quality. On the other hand product development (Meadowcroft 2013).
is dependent on the previously mentioned rapid At the BMW AG plant in Regensburg, Germany,
iterative design process where designers can get FDM continues to be an important component in
immediate feedback, prevent mistakes and make vehicle design prototyping, and beyond. BMW is
design changes. Having this opportunity in house extending the application of FDM to other areas
eliminates shipping delays and reduces and functions, including direct digital
administrative slowdowns that can accompany manufacturing. BMW are also utilizing AM
sourcing prototypes from external services. indirectly to their automotive process. Even tools
(Stratasys 2012) and devices that aid the workers are made with
FDM (DDM at BMW 2013). BMW are in
possession of internal guidelines regarding
whether to utilize Additive manufacturing or not.

Both Bentley Motors Ltd. And Jaguar Land Rover
(JLR) are committing to another AM technology,
Jetting systems. Their studios are equipped with
Objet500 and Objet30 3D printers from Stratasys.
Utilizing multi-material 3D printers gives JLR a
competitive advantage in the market (Modelling
luxury 2013). To broaden their in-house
prototyping capabilities, enhance styling and
provide better testing, the use of 3D printers
became the answer. This resulted in more rapid
development of complex multi-material parts.
As well as producing working prototypes quickly
in a single process for immediate style, fit and
Figure 4. Time saved prototyping with in-house function testing.
3D printing vs. other methods. Based on The technology enables the Bentley design team
customer experience. (Stratasys 2012) to easily produce small-scale models as well as
full-size parts, for assessment prior to production
4. TRANSPORTATION INDUSTRY on the assembly line. Virtually every part is
prototyped in miniature scale. 3D printing has
4.1 Automotive sector revolutionized the design process, and enables
exact simulation of how the car will look. This
Additive manufacturing and its related more or less ensures for no retooling costs
technologies are being used by car (Modelling Luxury 2013).
manufacturers all over the world for their

Development of Additive Manufacturing 5

Jim Kor, a pioneer of 3D printing within
automotive design is developing a fully electric
3D printed urban city car. The goal is to design a
model that can travel across the US in just 2 days
by using an electric engine supplemented by 10
gallons of biofuel within 2015. Kor and his team
at Kor Ecologic are utilizing 3D printing (SLA) to
make the vehicle. This ensures a light, strong and
safe chassis. By building the actual chassis out of
molten polymer enables Kor to imagine what
might be instead of worrying about limitations of Figure 5: Prodrive MINI John Cooper Works RX
materials and traditional manufacturing. Kor race with over a dozen FDM parts.
Ecologic are trying to develop parts that cant be
designed any other way except for on a 3D Among other motor sporting branches that utilize
printer (Clancy 2013). additive manufacturing are Formula 1 and
Nascar. In F1, all the teams build 60% scale
4.2 Motor sports models for aerodynamic testing in designated
wind tunnels. For a sped-up process, all of these
The Motor sport industry is using AM for direct models are fully produced with AM. Also here
digital manufacturing (DMM) of production parts. minor production/race parts are starting to be
This demonstrates that additively manufactured manufactured additively.
parts have the quality and durability to meet The 3D printing of parts have become so
some of the toughest demands there are essential In F1 that the Red Bull racing team in
Kreemer 2011). The motorsport sector is the 2011 season decided to start bringing two 3D
composed of people with a versatile background. printers around on-site to every race (Rapid
They are used to working with high-tech prototyping 2012).
processes and materials. On the other hand, the
sector contains people with expertise within 4.3 Aerospace/aviation sector
mass production and the concrete problems and
short deadlines they deal with. It acts as a bridge The aerospace industry, being at the forefront of
between the aerospace and automotive supply technology has a long history of utilizing additive
chain (Excell 2010). manufacturing both for prototyping and
It is impossible to get a fully transparent image production parts. Boeing already put laser-
when it comes the scope of AM usage in motor sintered cooling ducts on the F18 10 years ago
sports as guarding valuable secrets is a tradition, and the 787 Dreamliner also features a number
and can give a competitive edge. Unless you are of non-critical laser sintered components (Excell
apart of the team, you wont know the full extent 2010). The most critical features of AM
of additive manufacturing used for production implementation for aerospace is the advantage
racing. of weight reduction. Equally important is the
UK-based Prodrive is one of the worlds largest reduction in storage space for stock and material
vehicle technology businesses. During design and resources. The reduction in maintenance costs is
testing of their successful MINI John Cooper rally also significant.
car, FDM was vital in design assessment and
testing. Now that the car is racing, and the FDM NASA is implementing 3D printing for more
parts proved strong enough, Prodrive uses its efficient manufacturing, a total of nine centers
FDM machine nearly full time for production are equipped with 3D printers (Eitel 2013). NASA
parts that include gauge pods, wheel arches and recently successfully tested a 3D printed rocket
hood vents. injector. Liquid oxygen and gaseous hydrogen

Development of Additive Manufacturing 6

passed through the component into a would be costly early in the process. Being able
combustion chamber and produced 10 times to produce prototypes increases the chances of
more thrust than any injector previously finding flaws in a design during testing, which
fabricated using 3-D printing. The component ensures for a better product and can lead to
was manufactured utilizing DMLS, building up bigger profits. If these problems were to be
layers of sintered nickel-chromium alloy. This discovered later in the process or after market
type of injector manufactured with traditional launch it could be costly or result in product
processes would take more than a year to make, failure. Additionally, AM can significantly reduce
but with AM processes it can be produced in less lead times through rapid turn-around cycles
than four months, with a 70% reduction in cost. between design and production.
One of the keys to reducing the cost of rocket The technology allows R&D departments to make
parts is minimizing the number of alterations quickly, refit or change the design
components.(NASA1 2013). This injector had only based on digital input. This accelerates the design
two parts, whereas a similar injector tested process by getting products to market faster.
earlier had 115 parts. Fewer parts require less An optimized design process with more iterations
assembly effort, which means complex parts can help minimize risk of product failure
made with 3-D printing have the potential for (Stratasys 2012).
significant cost savings. NASA seeks to advance
3D printing to make every aspect of space 5.2 Cost and productivity
exploration more cost-effective (NASA2 2013).
It is generally believed that cost and faster
SelectTech is another innovative company that turnaround are among the primary drivers in
utilizes additive manufacturing. They developed a industry, as for incorporating 3D printing in the
3D printed Unmanned Aerial system (UAS) product development process.
without funding or aeronautical expertise and Additive manufacturing eliminates tooling, and
succeeded. Additive manufacturing offered the with that the cost and time related to creating it.
flexibility to iterate, and was used in a trial and The amount of material used can also drastically
error approach to avoid delays for analysis and be reduced. While traditional subtractive
simulation (Hiemenz 2013). manufacturing processes often remove up to
95% of the raw material to arrive at a finished
5. DISCUSSION component, additive machines only use the
material needed to make the part (Excell 2010).
Additive manufacturing is changing both how and The savings in material usage and rapid turn-
what we can manufacture. It is enabling around cycle saves on additional storage and
designers and engineers to create in a new way. maintenance costs.
The technologys impact on the automotive and
aerospace industry is unquestionable. Even so The lowering of investment cost and
there are unresolved issues and challenges to development time allows businesses to adapt
overcome. more easily and faster to the market. This new
logistics model where files are getting shipped
5.1 Prototyping digitally and manufactured on demand locally
close to the end user, allows for fast and fairly
Research shows that by using additive risk free production. On the other hand these
manufacturing methods in the design process, transactions of digital files and intellectual
designers can quickly get to a point of producing property comes with the risk of valuable
working prototypes. This serves as an effective information being stolen or misused illegally by
validation tool both functionally and others (Stratasys 2012). In house printing can
aesthetically, when before having a prototype

Development of Additive Manufacturing 7

eliminate that risk as well as speed up the the ecological footprint. It is believed that when
iteration process considerably. material production is factored into the equation,
Additive manufacturing is to prefer over
5.3 Complexity traditional methods for the transport industry,
which is under tight environmental and emission
The elimination of tooling also means that regulations.
designers are freed from the constraints of
traditional manufacturing and assembly. By 5.6 Moving towards production
creating layer by layer the geometrical
complexity of printed components are almost Between design and production there are many
limitless. Components that had to be stages were the utilization of additive
manufactured in hundreds of parts can now be manufacturing can be beneficial. The use of AM
3D printed into one or several-part components is speeding up the design process and getting
(NASA1 2013). The technology also allows products to market faster.
shapes to be structurally optimized for increased
performance. The implementation of 3D printed production
components in motor sports and aerospace
5.4 Customization proves that additive manufacturing can move
from prototyping to production, and arguably
It has been long known that the trend towards mass-production in the near future. Research
customized products is accelerating. Consumers shows that AM is producing parts at lighter
are looking to have their personal taste reflect in weights than traditionally manufactured
what they are doing and using (Bryson 2011). For components at equal strengths (Lane 2013).
Instance a personal vehicle becomes your avatar, Reduction in weight for the transport industry
the way you portray yourself to the world around equals more effective shipping, less cost and
you. This becomes even more true when AM is emissions. On the other hand 3D printing is
incorporated into the product development known for being a sensitive process where the
cycle. It is believed that the technology can slightest change in production conditions can
democratize the luxury of customized design, and alter the mechanical properties of manufactured
make it more individual and exclusive by allowing components.
customers to create variations on elements and
design components. AM can make this process The limitation on build size is also a concern for
both less expensive and faster (Lane 2013). This many researchers. However, most believe that
is especially of interest to high-end luxury its a minor one that can be solved and should be
manufacturers, with a relative small production subsequent to the likes of machine sensitivity.
volume and demanding customers who want,
and are willing to pay that price. Users have to be certain that components will
perform. Formal types of validation and quality
5.5 Environmental impact controls have to ensure that parts will function.
At present time there are no agreed standards or
It is proven that AM produces less material waste regulations for material and process quality of
than traditional manufacturing methods, only additively manufactured parts. Once that will be
using material needed for production of in place along with general awareness of the
components. However there has been some technologys capability, it is believed that its use
discussion regarding the energy consumption of within production will expand rapidly.
3D printing. As the laser process consumes much
more electrical energy than under traditional Another obstacle for AM to overcome is the
manufacturing, questions are raised regarding limitations regarding materials. As of now it is

Development of Additive Manufacturing 8

improbable to produce some parts with complex components. It is rapidly growing into a large-scale
geometries, since the array of materials available industry.
is more compacted than with traditional
manufacturing techniques. (Lane 2013). Additive manufacturing gives the flexibility to iterate
while facilitating for faster turnaround resulting in

products arriving the market sooner, while keeping
6. FUTURE OF AM costs down and thus increasing profit.

Many believe that 3D printing will revolutionize The role of 3D printing in manufacturing is an
manufacturing and its industries. With NASA important ecological factor. Due to less material
printing engine parts to rockets and Boing prepared and wasted in the process of manufacture,
planning to print fully functional airplane wings AM is beneficial to the environment when compared
its hard to argue. It is also easy to get carried to traditional processes. As of today, the process of
away, imagining a futuristic sci-fi world where printing itself is to energy consuming and has to be
everything needed around us will be printed developed further.

without taking the earlier addressed limitations
The manufacturing technologys success and
into the equation.
widespread use throughout the transport industry is
inevitable. Aerospace and motor sports are leading
The futures of additive manufacturing will likely the way, using AM for small production parts. The
involve significant sharing of production facilities technology is producing components with good
(Eitel 2013). As files are transferred digitally, material properties at lighter weights resulting in
production can happen locally as close to the end better performance. The evolution of 3D printing
user as possible. This eliminates global shipping wont happen over night, as there are problems yet to
and the damage it brings upon the environment. figure out. Today, AM within production is used
mainly for non-critical parts. For the technology to
facilitate the production of load bearing components
Aerospace is the industry other industries look to
there has to be developed validation standards for
for a glimpse of what the future might bring.
material and process quality. The sensitivity of current
They were the earliest adopter of carbon fiber machines is an issue and has to be dealt with. When
and the first to integrate CAD/CAM into the printing a component several times the mechanical
design process. Both of these implementations properties have to be stable from one print to the
are now commonplace throughout industries and next.
doesnt require financial justification (Hiemenz
2013). There are many other examples that show Additive manufacturing might very well become the
that trends in aerospace predict the future, de facto method of industrial manufacture in the
which is reassuring for the additive future. While its historical underpinnings date several
decades back its only in recent years the technology
manufacturing industry. I am confident when
has been widely implemented in product
saying that AM will dictate manufacturing in
development, completely altering how and what can
industry in the future. be made. The direct connection between designer and
manufacturing is re-established. It is believed that we
7. CONCLUSIONS will se a remarkable shift from use limited to
prototyping over to production.
This paper has studied the impact of the rise in
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Development of Additive Manufacturing 10