September 27, 2015

Last Week’s Euromold 2015

The 22nd annual Euromold event was held last week in Düsseldorf, Germany. Other than a few companies missing from the exhibition floor, it could not have gone better. More than 450 exhibitors from 33 countries showed their latest products and services. More than one-third of them were from the additive manufacturing and 3D printing space, giving visitors a lot to see and learn. A fashion show on Friday featured models with stunning 3D-printed accessories.

Large crowd in awe by the work shown at the Euromold fashion show

This year’s Euromold conference program was expanded to three days, with the support of USA-based SME. Jeff Kowalski, senior vice president and chief technology officer at Autodesk energized a packed room at the opening keynote. His comments were inspiring, and people were discussing them days after his presentation. Kowalski said that quality and reliability are holding back 3D printing. He also explained how we are entering the “imagination age,” but it will require completely new software capabilities to help propel the industry forward. His fresh and forward-thinking ideas gave hope to those who feel that CAD software currently hinders their ability to unlock the full potential of 3D printing.

Left: Jeff Kowalski of Autodesk. Right: Lively panel session on 3D printing software tools and data with Wilfried Vancraen of Materialise, Scott White of HP, Chris Romes of Autodesk, Emmett Lalish of Microsoft, and session chair Tim Caffrey of Wohlers Associates

Dr. Jules Poukens, a cranio-maxillofacial surgeon, was keynote speaker the second day of the conference. He shared video footage of his team implanting a cranial plate, as well as the world’s first complete mandible (jaw) replacement. Both were custom-designed and 3D-printed in titanium. The full room of people were amazed by this work.

On the final day, Stephen Nigro of HP took center stage as keynote speaker. Nigro is senior vice president at HP and responsible for company’s printing business, which is valued at more than $20 billion per year and involves tens of thousands of employees. On November 1, 2015, he becomes president of HP’s new 3D printing business. Similar to the previous two days, the room was completely packed, with people lining the walls and queued in the doorways. Nigro said the 2D printing business is $230 billion annually, but 3D printing has the potential to exceed it in size. I was flattered when he used Wohlers Associates’ data to illustrate his point. If 3D printing penetrates just 5% of the global manufacturing economy, it will surpass 2D printing by nearly three times.

The three-day conference concluded with an outstanding keynote by Jason Dunn of Made In Space. The company successfully designed, produced, and placed the first 3D printer on the International Space Station. The excellence of Dunn’s information, along with that of the other speakers and panelists, coupled with the number and quality of people in attendance, were, by far, the best in 17 years of running the conference. Thanks to everyone in attendance, and to the teams at DEMAT and SME, for their involvement. We look forward to Euromold 2016, again in Düsseldorf, which is a great place to spend a few days. Please add December 6–9, 2016 to your calendar. I look forward to seeing you there!

September 12, 2015

HP’s Stephen Nigro

Filed under: 3D printing,Additive Manufacturing,Future,Manufacturing — Terry Wohlers @ 11:38

Stephen Nigro is senior vice president of PPS Imaging and Printing at HP. He has worldwide responsibility for the company’s printing business, which includes HP InkJet, HP LaserJet, and HP Graphics. This business is roughly $20 billion per year and involves tens of thousands of employees. One can easily conclude that Nigro is very important to HP.

Stephen Nigro

It was announced last week that Nigro will focus entirely on 3D printing on November 1, 2015. This news was first reported in an article by Fortune. In my opinion, this is very big news for the company and 3D printing industry. The announcement speaks volumes about the importance of HP Multi Jet Fusion technology and how the company believes it will develop in the future.

Dion Weisler, CEO of HP Inc. (beginning November 1), has stated more than once that the 3D printing industry has not solved the major problems of speed, quality, and cost. HP hopes to address these problems with Nigro’s help. He will continue to report to Weisler as the company expands into 3D printing. “Over the next 5-10 years, I think [3D printing] will be a really big core part of our business,” Weisler stated recently. Nigro will be a key to making it happen.

Update: After the above was originally published, Nigro was named president of HP 3D Printing.

August 30, 2015

LASIK Nine Years Later

Filed under: Life — Terry Wohlers @ 18:36

One of the most important medical-related decisions of my life was made more than nine years ago. In July 2006, I had LASIK surgery on both eyes. I documented the experience a few days after the procedure. A year later, I reported on how my eyes were doing.


My eyesight has regressed some, but little. I’m still seeing better than 20/20 when using both eyes. My right eye is considerably weaker than my left, which was the case hours after surgery. However, it has enabled me to see small print without the need for reading glasses. In fact, I still don’t own a pair.

If you require corrective lenses and would rather not bother with them, consider LASIK surgery. Carefully research your options and go with the very best ophthalmologist in your region, if you choose to move ahead. It’s not something you want to rush, and do not shop for the best price because your eyesight is priceless.

August 15, 2015

Kill Decision

Filed under: Entertainment,Future,Review — Terry Wohlers @ 10:15

A good friend recommended Kill Decision and I’m glad he did. Author Daniel Suarez knows how to get and keep your attention. Many compare him to Michael Crichton and Tom Clancy. The techno-thriller grabs you early in the book and has you on the edge of your seat most of the way through it. As odd as it may sound to some, I do not read novels for the pure sake of enjoyment. However, if the book provides interesting perspective into future, I’ll make an exception.

I chose the audio version of Kill Decision so that I could exercise while taking in something good. Also, narrator Jeff Gurner tells a story spectacularly. I’ve heard him before and he’s excellent. He nails foreign accents and characters (for example, a hard-nosed army general) better than anyone I’ve heard and his emphasis on certain points and phrases is flawless.


The book is focused mostly on drones and how they may develop to control the world around us. The tension-filled plot brings together many technical ideas in ways that are not only fascinating, but believable. At times, I could not put it down. The story builds and the plot thickens as swarming autonomous drones communicate and organize attacks. The drones and their “behavior” are modeled after swarms of weaver ants, which are very organized, even deadly, as a colony.

If you are looking for a good book to round out the summer, assuming you’re in the northern hemisphere, consider Kill Decision. You won’t regret it. And, if you like to walk, run, or go to the gym, take the audio version with you. Listening to narrator Jeff Gurner, alone, is worth the price.

August 2, 2015

Frisco, Colorado

Filed under: Life,Review,Travel — Terry Wohlers @ 17:16

Frisco is a mountain town of about 2,700 people, located 114 km (71 miles) west of Denver. It is situated at an elevation of 2,766 meters (9,075 feet) and surrounded by mountains. Ten Mile Creek runs through the town and empties into Lake Dillon, which touches the northeast border of Frisco.

Repeatedly, Frisco has been named the top ski destination without a ski resort. Four major ski mountains are within 26 km (16 miles), with Copper Mountain—our favorite—being just 11 km (6.7 miles) away. A fifth is Vail Mountain Resort, which is 42 km (26 miles) away and the largest ski area in the USA.

Frisco is not known to as many as one would expect, especially given its proximity and charm. Many bypass it on their way to somewhere else without knowing much about it. Consequently, it is not as busy and crowded as neighboring Breckenridge—a short 16 km (10 miles) away.

Frisco’s Main Street

Dentist and friend Ted Mioduski once said, “Summer time in Frisco is a best kept secret.” I could not agree more. Temperatures are in the low 20s C (70s F) during the day and much cooler at night. This makes it perfect for hiking, biking, climbing, fishing, taking a stroll down quaint Main Street, or having a bite or drink at one of the many local restaurants, pubs, or coffee shops.

Frisco and nearby Copper Mountain host many musicians, festivals, and exhibits in the summer. Just last night, we stumbled across an excellent acoustic guitarist and singer while waiting for the Saturday night fireworks at Copper. Returning to Frisco was a quick ride on the complimentary Summit Stage Shuttle.

On Friday, my wife, Diane, and I biked to Vail Pass, located at 3,250 meters (10,662 feet), and then back to Frisco—a 42-km (26-mile) round trip. (Diane turned around a few miles short.) Yesterday, friend Paul Carlton and I climbed Peak One, which is 3,901 meters (12,800 feet) in height. I felt like I might not survive after the seven-hour round trip. Although tired, I’m feeling better today.

At the top of Peak One, with Copper Mountain in the background

Frisco is small and quiet, yet it offers plenty of activity to keep things interesting. Some joke that the town has more pets, mostly dogs, than people. I doubt it’s true, but it certainly is dog-friendly. The people are open and friendly too. Frisco grows on you the more you spend time there. I can say without reservation it’s one of my favorite places to escape. Just don’t tell anyone.

July 18, 2015

AM in Aerospace

Filed under: 3D printing,Additive Manufacturing,Future — Terry Wohlers @ 14:39

The world of additive manufacturing is experiencing an interesting time in the aerospace industry. The technology holds tremendous promise for the production of both polymer and metal parts. Many aerospace companies are currently qualifying AM processes and materials and certifying designs at an unprecedented pace. What’s more, we expect it to accelerate in the coming months and years. This rapid growth could result in a demand for AM products and services that outpaces the supply, especially for metal parts.

Airbus has said that it plans to 3D print 30 tons of metal parts monthly by 2018, which is less than 30 months away. Already, the company has flown 3D-printed metal on commercial aircraft, and has built many impressive and complex parts that reduce material and weight by 40-50%, and sometimes more. Meanwhile, GE Aviation is working toward the production of tens of thousands of metal parts annually for jet engines with the construction of a $50 million manufacturing facility in Auburn, Alabama.

3D-printed sheet metal parts, which flew on the A350

The demand for AM becomes especially interesting when considering all of the other aerospace companies. Among them are BAE Systems, Bell Helicopter, Boeing, Bombardier, Embraer, General Dynamics, GKN Aerospace, and Honeywell Aerospace. Other companies include Lockheed Martin, Northrop Grumman, Pratt & Whitney, Raytheon, Rolls-Royce, SpaceX, and United Launch Alliance. Most of them have built infrastructures within their corporations to evaluate and implement AM.

The aerospace industry is a natural for the series production of parts by AM. The volumes are relatively low and the part complexity and value are high. With new designs that consolidate many parts into one, coupled with methods of reducing material and weight, AM becomes very compelling. Consequently, we can expect an exciting and thriving future for AM in the aerospace industry.

July 4, 2015

Cheap 3D Printers

Filed under: 3D printing,Additive Manufacturing — Terry Wohlers @ 10:28

Low-end, desktop 3D printers are becoming surprisingly inexpensive and they continue to decline in price. Some say that it’s a race to the bottom. At least three models are priced at under $400, with one—the QB-3D OneUp—selling for $199. The other two are the da Vinci Jr. from XYZprinting for $349 and the Play product from Printrbot for $399. All three are material extrusion “FDM clone” 3D printers.

We have not worked with any of the three, so we can’t say how easy they are to set up and use. And, we hesitate to comment on the quality of the parts they produce. We do know that you more or less get what you pay for. However, with the sub $2,000 3D printers, we see a lot of similarity in the quality of output, compared to the differences in the much higher-priced industrial-grade machines, which have an average selling price of $87,140. Some desktop 3D printers offer surprisingly good quality, considering the price.


Companies are buying many of these low-cost products for early design concepts. In the past, these same companies would spend 10-30 times more for a machine to produce basic concepts models. Put another way, they can purchase 10-30 machines for the same money they spent previously on one machine.

Indeed, the market has changed, and it’s causing many to rethink their modeling and prototyping strategy. At the low-end of the cost spectrum, companies, educational institutions, and hobbyists have an unprecedented number of options. We believe that more than 300 brands of under $5,000 3D printers are now available, with most of them priced at under $2,000. For a review of several 3D printers priced under $1,000, see this product review.

June 21, 2015

3D Printing in Australia

Filed under: 3D printing,Additive Manufacturing,Event,Manufacturing — Terry Wohlers @ 07:20

Last month, the Australian government announced the funding of a new program that could give 3D printing and additive manufacturing (AM) a boost in the country. On May 26, the Honorable Ian Macfarlane, Australia’s Minister for Industry and Science, announced the Innovative Manufacturing Cooperative Research Center (IMCRC). Much of the program is expected to center on AM and related methods and technologies. The focus on AM may have been partly inspired by America Makes, coupled with the investments and alliances associated with the U.S. initiative.

The IMCRC is a collaboration of 14 manufacturing companies, 16 universities, and CSIRO, which is Australia’s top federal agency for scientific research. Four industry bodies will help recruit more than 300 additional small and medium-sized enterprises to serve as “portal partners.” As part of the program launch, the Commonwealth is providing A$40 million (US$31 million). An additional A$210 million (US$163 million) is expected in cash and in-kind contributions from industry, research institutes, and state governments, bringing the total investment to A$250 million (US$194 million).

The announcement lingered for about nine months, so many people welcomed the long-awaited news. Senior consultant Tim Caffrey and I were in Australia when the announcement was made, with the IMCRC being the center of attention. We believe that it will indeed provide a much-needed lift to advanced manufacturing in the country, but as the saying goes, “the devil is in the details.” It will be interesting to observe how Australia sorts through the maze of challenges associated with coordinating so many people, organizations, and agendas. As with America Makes and other national efforts, the challenge and opportunity is to make a difference, and that’s easier said than done.

The day before the announcement, CSIRO officially launched its new and impressive Lab 22. Tim and I were present to participate in the festivities and meet many of the talented researchers and scientists at CSIRO. Lab 22 was established as center of excellence for organizations wanting to explore metal AM, so it welcomes participation by organizations of all types.

Lab 22’s Voxeljet VX1000 installation

Equipment in the new lab includes an Arcam A1 electron beam melting machine, a Concept Laser M2 laser-based machine, and a Voxeljet VX1000 machine for producing sand casting molds and cores. The lab was established as a center of excellence for organizations wanting to explore metal AM, so it welcomes participation by organizations of all types. CSIRO also has an Optomec LENS MR-7 directed energy deposition machine and a cold spray plasma additive process.

Australia is establishing a strong foundation in AM. The adoption of the technology in the private sector may not be as great as it is in some advanced countries, but the pieces are coming together for it to close the gap. The Melbourne area, alone, may well have the highest mix of metal AM systems in the world (in an area of this size), with nine direct metal AM systems. Among them are machines from Arcam, Concept Laser, EOS, Optomec, SLM Solutions, and Trumpf. The Concept Laser Xline 1000R at Monash University, and two Trumpf TruLaser 7040 machines, one each at Monash and RMIT University’s Advance Manufacturing Precinct, are very large, both in size and investment.

June 6, 2015

Jobs from 3D Printing

Filed under: 3D printing,Additive Manufacturing,Manufacturing — Terry Wohlers @ 14:47

Government officials have been asking how 3D printing will create jobs in their part of the world. The subject came up again last week in Melbourne, Australia when meeting with people at the state government of Victoria. We explained that some companies and businesses would not exist if it wasn’t for 3D printing. An example is Align Technology, makers of the Invisalign plastic aligners that replace metal brackets and wire to straighten teeth.

Invisalign manufacturing, courtesy of Align Technology

Align takes advantage of additive manufacturing to produce parts used to thermoform sets of custom plastic aligners. The company involves many additional processes, including CT scanning, special software, 5-axis CNC milling, robotics, polishing, and other methods of manufacturing and packaging. Seeing it in action is impressive. Much of it involves a great deal of sophisticated automation, which has dramatically reduced manual labor, but has also created many jobs. The company employs 3,580 people. Consider also all of the people needed to design, produce, sell, and service the machinery and systems that make everything tick at the company. And, consider the many dental professionals that are impacted by the Invisalign product.

As 3D printing penetrates production applications more deeply, it will involve many upstream and downstream processes. Among them: new methods of design and redesign, data management and IT, and cloud computing and web services. Also, it will involve thermal processes and machining operations, materials and material handling equipment, surface treatment and methods of coating, and inspection and process improvement. Consider all of people and jobs behind these machines and processes.

3D printing is what made it possible for Align Technology to create personalized plastic aligners. It is the enabling technology that will help launch many other new companies and businesses. Organizations of all types and sizes will put 3D printing to work to manufacture custom, limited edition, and even relatively high volumes of products, especially in the future. When viewing it from this perspective, it will create many jobs. A manager at GE put it best when he said, “Additive manufacturing won’t create thousands of new businesses; it will create tens of thousands.” And, behind them will be countless jobs.

May 22, 2015

Apple iPrint

Filed under: 3D printing,Additive Manufacturing,Future — Terry Wohlers @ 21:03

Apple has pioneered many industries. Among them: desktop computing, desktop publishing, music, smart phones, tablet computing, and smart watches. Could the high tech giant also get into 3D printing? It’s possible, given that other IT and technology companies have entered the space. Autodesk and HP have made big commitments, and Adobe, Amazon, Dell, eBay, Intel, Lenovo, and Microsoft are dabbling in it.


In a presentation I gave yesterday at RAPID 2015 in Long Beach, California, I mentioned the idea of Apple’s potential interest, with “iPrint” being a good name for a 3D printer. Lucas Mearian of Computerworld was in the audience and picked up on it. See the story titled Is Apple Planning a 3D Printer?

I honestly don’t know whether Apple has an interest and is working on anything at this time. However, it could be a fit, given the company’s success in producing winning products across a range of industries. However, Apple is best at producing products for consumers and not for industrial customers and manufacturers. For now and the foreseeable future, that’s who will be purchasing and using most 3D printers and systems for the additive manufacturing of parts and products. Consequently, Apple will probably not launch a product any time soon, unless it develops the unimaginable, which it has done in the past.

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