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Women in 3D Printing

October 18, 2020

Filed under: 3D printing,additive manufacturing — Terry Wohlers @ 06:29

Women in 3D Printing, a non-profit organization, was formed in 2014 by Nora Toure of Fast Radius. In just five years, she helped build it into a community of more than 10,000 women worldwide. From the beginning, it has been her ambition to share stories of women helping to shape the additive manufacturing industry. Based on my experience over the past 30+ years, women are dramatically underrepresented in product development and manufacturing worldwide. In fact, the ratio may be close to 10:1, although it has improved slightly in recent years. Women in 3D Printing seeks to close this gender-gap in additive manufacturing. I fully support this goal of a better balance of women and men.

I have known about Women in 3D Printing for years, but it was not until November 2019 that I attended an activity by the organization. It was a panel session as part of the 20th annual RAPDASA conference and exhibition in Bloemfontein, South Africa. (RAPDASA stands for the Rapid Product Development Association of South Africa.) The panel was led by Malika Khodja of Tiziri. She serves as the African chair of Women in 3D Printing and is also a contributor to Wohlers Report 2020. I was impressed by the enthusiasm and quality of information shared at this engaging session.

The organization is showcasing, celebrating, and profiling the work of women leaders worldwide. They include engineers, business professionals, teachers, researchers, artists, and designers. Women in 3D Printing is creating a notable list of global events, gatherings, panel sessions, and company tours. Much of the work is conducted by its local ambassadors and regional chairs, such as Malika. Its many chapters meet regularly and encourage an inclusive and diverse AM workforce. The organization has created a database of female speakers, platform for hiring, industry surveys, reports, and an annual TIPE global conference, which is January 27-28, 2021. (TIPE stands for Technology, Industry, People, and Economics.)

I applaud and endorse the work of Women in 3D Printing. Many closest to the organization are “Rock Stars in 3D Printing,” in my view. In a spirit of support, Wohlers Associates recently became a corporate member and TIPE sponsor. Women in 3D Printing has become one of the most influential and largest AM communities worldwide. I urge you to support the important work of this impressive and fast-growing organization.

Autodesk

October 3, 2020

Filed under: 3D printing,CAD/CAM/CAE — Terry Wohlers @ 05:47

In 1983, I called Autodesk and the vice president of marketing and sales answered the phone. I was employed by Colorado State University at the time. I requested free use of AutoCAD version 1.3 in a 500-level CAD course I was planning to conduct later that year. He said, “Yes” and provided the software. It turned out to be what we believe was the first university credit course on the subject worldwide.

Autodesk was launched a year earlier, so the company was small. Even so, it was vibrant, progressive, and gaining attention and traction. The IBM PC was introduced in 1981, so the software and hardware combination offered a new platform to millions that could not otherwise afford or justify CAD. I recall people saying that AutoCAD offered 60% of the capabilities of “conventional” CAD at one-tenth the price.

In 1984, I had the privilege of meeting Autodesk founder John Walker here in Fort Collins, Colorado. He attended our first International Forum on Micro-based CAD. We had one international guest, but we later found out he was from Iowa working as a theater set designer at the Malmö Stadseater theater in Sweden. The forum continued for five consecutive years, with the fourth and fifth events in North Carolina and England. I credit Autodesk as the main sponsor for helping us get it off the ground.

In the 1980s and well in to the 90s, Autodesk did not receive the respect some of us felt it deserved. Many clung to the idea of needing to invest in expensive hardware and software to get “real” CAD. Options back then were from the likes of Auto-trol, CADAM, Calma, Computervision, Intergraph, and Tektronix. Eventually, most of these companies did not survive the assault brought on by Autodesk and others offering less expensive alternatives. With Moore’s Law at work, CAD on a PC became more powerful at an exponential rate. As a result, companies offering the more expensive systems went out of business or morphed into something else.

Fast-forward 35+ years. At nearly $3.3 billion in fiscal 2020, Autodesk’s has risen to unthinkable heights. It the largest 3D modeling software company in the world, according to Autodesk. The company offers 140 products, including software for additive manufacturing and 3D printing. I certainly would not have guessed the company would become so incredibly successful, although some of us could tell it was doing something special back in the 1980s. A few things needed to line up for real change to occur. This is one case in which many elements came together and provided a new price-to-performance ratio that brought significant benefits to millions of designers and engineers worldwide. Similar benefits developed many years later when designers and engineers gained access to affordable 3D printing.

Game Day Series

September 19, 2020

Filed under: 3D printing,additive manufacturing,event,future,manufacturing — Terry Wohlers @ 15:35

America Makes’ Virtual Game Day Series with Wohlers Associates concluded last week. The four events spanned four months and covered a range of key topics related to additive manufacturing and 3D printing. In all, 728 people worldwide attended the events.

Last week’s focus on the future of AM was an excellent conclusion to the series. Top managers and executives from five major industrial sectors shared their views of the future. The immense knowledge and experience among the panelists, coupled with great chemistry among them, resulted in a wealth of inspiring comments. YouTube videos of the four 90-minute panel discussions are now available.

GAME DAY 1
America Makes COVID-19 Response

GAME DAY 2
How AM Addresses Supply Chain Gaps and Distributed Manufacturing

GAME DAY 3
The Economics, Opportunities, and Challenges of Designing for AM

GAME DAY 4
The Future of Additive Manufacturing

Thanks to everyone who attended and supported the four events, including Link3D for hosting them on the Remo conferencing platform. I hope everyone learned as much as I did.

Legend Scott Crump

September 11, 2020

Filed under: 3D printing,additive manufacturing — Terry Wohlers @ 06:51

Scott is the inventor of the most popular method of additive manufacturing (AM) and 3D printing in the world. It is called fused deposition modeling (FDM), and about nine out of 10 AM systems are based on it according to our research for Wohlers Report 2020. I first met Scott in 1990 in Eden Prairie, Minnesota. The purpose of the meeting was to learn about FDM, a process that few knew about at the time.

After 34 years, Scott spent his first day—last Friday—not working full-time for the company, transitioning from chief innovation officer to technology advisor to the board. Scott and his wife, Lisa, co-founded Stratasys in 1989. He served as CEO of the company for 25 years.

Having known Scott for 30+ years, I can say without reservation that he is one of the most approachable executives I know. His sense of humor and willingness to put himself out there is unusual in the world of business. He will do and say things that you may never see or hear from most executives, but that is what I like about Scott. I believe it is a big reason why he has been so successful and why so many people like and appreciate him.

Scott is not leaving the AM industry. He said we can expect to see him around, probably online and at in-person events when they resume. He will no doubt continue to make himself available for interviews by the media and press. To me, he is a model C-level executive that I hope others would follow. It is refreshing to hear about technology and strategy without a “sugar coating” and scripted text written by marketing groups or PR firms.

Scott has been an inspiration to many and instrumental in shaping the AM industry. Without his involvement, it would not be as vibrant in recent years. Thank you, Scott, and congratulations for what you have done.

AM Terminology

June 29, 2020

Filed under: 3D printing,additive manufacturing — Terry Wohlers @ 09:44

Standard terminology for additive manufacturing and 3D printing is critical when communicating. It puts everyone on the “same page” and more accurately conveys thoughts and ideas when conversing, presenting, and publishing. Ignoring terminology standards and using whichever terms you prefer can cause confusion or worse.

The first version of the ASTM F2792 Standard Terminology for Additive Manufacturing Technologies defined 26 terms and was published in 2009. At the time, I served as the chairman of the ASTM F42.91 Terminology Subcommittee, so the subject is near and dear to my heart. This work led to today’s ISO/ASTM 52900 Standard Terminology for Additive Manufacturing, which is recognized worldwide. It includes nearly five pages of terms, along with additional pages of diagrams and information.

I cringe when I hear non-standard terms when formal industry standard versions are available and were established after a tremendous amount of work by many organizations and bright people worldwide. An example is “selective laser metal (SLM),” a term that some will use instead of metal powder bed fusion (PBF), the correct phrase according to the ISO/ASTM 52900 standard. One problem with using SLM is that it is a part of a company name (SLM Solutions), which offers metal PBF systems. The incorrect use of SLM could lead to a serious blunder when negotiating a legal agreement, for example.

The following are seven key terms and definitions from the ISO/ASTM 52900 standard. They represent the major processes that most AM systems fall within.

  • Material extrusion—an additive manufacturing process in which material is selectively dispensed through a nozzle or orifice
  • Material jetting—an additive manufacturing process in which droplets of build material are selectively deposited
  • Binder jetting—an additive manufacturing process in which a liquid bonding agent is selectively deposited to join powder materials
  • Sheet lamination—an additive manufacturing process in which sheets of material are bonded to form a part
  • Vat photopolymerization—an additive manufacturing process in which liquid photopolymer in a vat is selectively cured by light-activated polymerization
  • Powder bed fusion—an additive manufacturing process in which thermal energy selectively fuses regions of a powder bed
  • Directed energy deposition—an additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited

If you are not using these and other industry standard terms, I strongly urge you to do so. It will help with your communication, demonstrate your recognition of international standards, and reduce the possibility of errors and other problems.

3D-Printed Bike Saddle

June 14, 2020

Filed under: 3D printing,additive manufacturing,life,review — Terry Wohlers @ 07:20

On June 3, 2020, Specialized announced the commercial availability of the first 3D-printed cycling saddle, the S-Works Power Saddle with Mirror Technology. A major part of the saddle is made with technology from Silicon Valley-based Carbon. The lattice-structure design is said to improve rider comfort and performance by absorbing impact and improving stability.

I received the saddle on Friday and the new design exceeded my expectations. I had read about it and saw pictures previously, but holding and studying it provided a far better appreciation for what went into the product. After shooting images of the new saddle, I mounted it to one of my new bikes from Fezzari, a relatively small but excellent consumer-direct manufacturer in Utah. Bikes from Fezzari have received many favorable reviews from the likes of Bike Magazine, Bikerumor, and Mountain Bike Action. I absolutely love my Signal Peak mountain bike and Catania road bike, both from Fezzari. I highly recommend both.

My first ride using the new saddle was short, but I found it exceptionally comfortable. I was told the saddle is designed for road bikes, but since my Catania it currently about two hours away, I tried it with the Signal Peak. It may handle the rigors of rocky trails, but I do not know, so I am checking with both Specialized and Carbon. Meanwhile, I plan to use it on one or more long road bike rides later this week in the Rocky Mountains of Colorado. I will try to share more after then.

With the new 198-gram (7-oz) saddle, Carbon and Specialized reduced the overall development process from a typical 18-24 to 10 months, while creating and testing more than 70 designs. Carbon’s 3D-printing technology reduced the design process from six to two months. Design iterations occurred in as little as one day. These are among the benefits of using 3D printing to develop a new product.

The new saddle is Carbon’s third production application in sporting goods, after running shoes from adidas and custom football helmets from Riddell. The S-Works Power Saddle sells for $450 and the company is currently sold out of them. In recent months, I have found that bikes and bike accessories have been difficult to get. Biking is an activity that people believe is safe, healthy, and fun, especially during a pandemic. If you’re looking for a comfortable bike saddle that is believed to improve performance, take a close look at the S-Works Power Saddle. Based on what I have read, seen, and experienced, it is a special product.

Distributed Manufacturing

May 31, 2020

Filed under: 3D printing,additive manufacturing,education,event,future,manufacturing — Terry Wohlers @ 08:08

Most mass manufacturing is done at centralized locations. Many produce millions of products annually. Envision a future where this capacity occurs in many more locations much closer to the customer. Deliveries occur faster and less expensively. Relatively small quantities of products are tailored to the needs of the geographic area. Inventories are smaller, with true just-in-time delivery closer to reality for a greater number of companies and products. Functionality, quality, and value improve.

This development is slowly and quietly underway. It is being made possible from the flexibility and responsiveness of companies running additive manufacturing systems and ancillary processes. The diffusion of this approach is still small compared to the opportunity. Even so, it is real and exciting to watch develop. Most large manufacturing sites are not breaking up into smaller ones. Instead, entirely new products and businesses, such as custom eyewear, footwear, jewelry, spare parts, and after-market products are developing. Production runs are a small fraction of what a large factory produces.

How AM Addresses Supply Chain Gaps and Distributed Manufacturing is the subject of the second in our Virtual Game Day Series brought to you by America Makes and Wohlers Associates. This 90-minute panel session is on June 18 and is free of charge. Four experts will answer questions and address important issues associated with supply chain challenges and how distributed manufacturing and other factors can help address them. I have the pleasure of moderating the session. Virtual networking opportunities will occur before and after the 12:00 Noon ET panel.

Plan to be a part of shaping the future of our supply chains and distribution manufacturing by attending this event. Your questions and participation are welcomed. I hope to see you there.

Response to Pandemic

May 16, 2020

Filed under: 3D printing,additive manufacturing,event,future,life — Terry Wohlers @ 16:27

On Monday of this week, an important event occurred. It was the first in the recently announced Virtual Game Day Series with Wohlers Associates. Monday’s virtual event, titled America Makes COVID-19 Response, attracted about 250 people. The panelists included:

  • Matthew Di Prima, PhD, Materials Scientist, FDA
  • Meghan McCarthy, PhD, Program Lead, 3D Printing Biovisualization, NIH/NIAID/OD/OSMO/OCICB
  • Beth Ripley, MD, PhD, Chair, VHA 3D Printing Advisory Committee, Veterans Affairs Health Administration, Innovation Ecosystem
  • John Wilczynski, Executive Director, America Makes
  • Moderator: Terry Wohlers, Principal Consultant and President, Wohlers Associates, Inc.

Additive manufacturing (AM) is playing an important role in the pandemic, especially where supply chains are disrupted. Thousands of AM systems are operating across the U.S., so local responses to the need for personal protection equipment (PPE) are occurring where traditional manufacturing is more involved. “We’ve seen it play a significant role in face shields and it’s filling a gap in the conventional supply chain for them,” Wilczynski said. Not all of it is for healthcare providers. Some has gone to the broader community, such as those working at grocery stores, restaurants, municipalities, and in shipping. Riply said that tapping into this manufacturing capacity is big, especially at a time when traditional manufacturers are pressed to deliver products. Distributed manufacturing models could become increasingly interesting in the future as local and regional disasters occur, Di Prima explained.

As of Monday, more than 523 PPE designs were submitted to the National Institutes of Health (NIH) 3D Print Exchange, a repository of designs hosted by NIH. Eighteen designs have been reviewed for clinical use and 14 have been optimized for community use, McCarthy said. She went on to say the site has seen more than 200,000 page views and a lot of interaction among users. This capability is central to the response and has had an impact.

America Makes brought together the FDA, NIH, and VA and launched the initiative just eight weeks ago. It has come a long way in a short time. The group, made up of the four panelists, have talked every day since the beginning.

The initiative is helping manufacturers understand where they can help. The group is providing clarification around complex questions on how to make products that can be used safely. A lot is based on a risk-benefit analysis, especially where few alternatives are available, Riply explained. The biggest thing to come out of this response is a trusted resource, explained Wilczynski. Di Prima has found that hospitals are showing increased interest in 3D printing parts because of the pandemic.

Will this response to COVID-19 create a change in the adoption of AM in the medical industry? For years, the industry has adopted AM in a substantial way for surgical planning models, drill and cutting guides, orthopedic implants, hearing aids, and dental parts. The medical industry has already been a large adopter of AM, Di Prima clarified. Even so, the work and learning surrounding the response to the coronavirus will help both the AM and medical industries better and more quickly respond to supply chain gaps when widespread emergencies occur in the future, McCarthy stated.

Will we look at this time as a turning point in the AM industry? Wilczynski said, “Yes.” It will open the eyes to the capabilities of the technology, he said. This experience is teaching us how to mobilize quickly in response to emergencies, with people ready to do the work, McCarthy explained. This initiative could not have happened without these four organization coming together. One of the groups on its own could not have done it, she said.

Following the panel was an interesting opportunity for virtual networking, which worked exceptionally well. Up to six people could “sit down” to a theme-based table or join a virtual lounge to discuss specific topics related to the pandemic and AM. Among the labeled tables were face shields, face masks, swabs, ventilators, designers, manufacturers, health care community, medical devices, maker community, and member mobilization. The networking on these and other topics was about as close as you can get to actual in-person meetings. Link3D supported the event by sharing its experience with Remo, an online platform for conferencing, meetings, and other activities.

Remarkable Struggles

April 5, 2020

Filed under: 3D printing,additive manufacturing,future,life — Terry Wohlers @ 06:58

Our nation’s healthcare providers are doing extraordinary work. They are risking their lives to help many of us. We cannot provide too much support to them. I’m hopeful they receive the personal protection equipment (PPE) they deserve. To date, many have not, and that’s unbelievably sad, especially given the sacrifices they are making.

Several organizations have stepped up to try to fill this void. One of hundreds of efforts underway stands out. America Makes, also referred to as the National Additive Manufacturing Innovation Institute, is a public-private partnership launched in 2012 by the White House. The organization, based in Youngstown, Ohio, is focused on the nation’s development and adoption of additive manufacturing (AM), more popularly known as 3D printing. The organization is largely supported by the U.S. Department of Defense, other government agencies, and 180 members. In the interest of full disclosure, Wohlers Associates has been involved with it from the very beginning, so I will admit some bias.

On or around March 19, John Wilczynski, executive director and others at America Makes made the decision to launch a nation-wide initiative to help healthcare providers with desperately needed PPE and other equipment, such as ventilators. The effort, fully described here, is fighting COVID-19 with 3D printing. It is bringing together designers, manufacturers, and healthcare providers in close collaboration with the U.S. Food and Drug Administration, Department of Veterans Affairs and, and National Institutes of Health. An online repository is connecting the needs of healthcare providers with the capabilities of some of our nation’s best designers and manufacturers.

Many individuals and small companies are also doing great work. One example is Avid Product Development of Loveland, Colorado. The 18-person service provider has designed and manufactured 1,500–2,000 parts for face shields in its effort to fight the deadly virus. The company expects to produce tens of thousands. Separately, Olaf Diegel, an associate consultant at our company, has designed a face shield that can be laser cut and assembled in less than three minutes. His latest development is a ventilator, which uses MIT’s E-Vent design as the starting point. Olaf believes it could be manufactured for about $150, including the 3D-printed parts, a motor, electronics, and ventilator bladder.

Many of the hundreds of initiatives are nothing short of remarkable. They are are bringing out some of the very best in people and organizations. I urge you to do what you can to help support them so that our precious front-line healthcare professionals are protected and receive the support they deserve.

Extraordinary Times

March 21, 2020

Filed under: 3D printing,additive manufacturing,future,life — Terry Wohlers @ 13:21

Countless organizations have shut down indefinitely. The economy is tanking while the stock market declines to unthinkable levels. United Airlines cut 95% of its international flights and most business travel has halted. Meeting with others, even close friends and relatives, is discouraged. Except for getting out to pick up food and medicine, we are mostly trapped in our homes. Most of the world is in various levels of chaos, with no end in sight.

I cannot remember a time when life was so uncertain. So much has changed in a few short days. As a nation, we were slow to recognize the threat, so we may pay a very high price. My wife and I consider ourselves lucky because we have a warm home and enough supplies. I cannot imagine the fear among those who are less fortunate. All of us need to see some light—and hope—at the other end.

The crisis did not slow us down in the last few days of developing Wohlers Report 2020, a project that began to ramp up in December 2019. We published it on Wednesday—a week earlier than the past two years. I owe tremendous gratitude to our core team of nine consultants and authors, and our 79 co-authors and contributors in 33 countries. So many great people pulled together to make it happen.

Now, we need to pull together for other reasons. In today’s edition of The New York Times, I read about a group of volunteers who are working day and night to develop an open-source ventilator to help save lives. A crisis will sometimes bring out the best and worst in people, and this is an example of the best. Others in the U.S. and abroad are 3D printing masks and other devices to help reduce the risk of spreading the virus.

If you have ideas on how we can work together to combat the virus and support our healthcare providers, please contact me. We stand ready to help.

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