Articles in this issue include some examples from key industries such as textiles, footwear, eyewear, cosmetics, sports and automotive, to demonstrate the breadth and variety of applications of 3D printing in various industries present in the market today.
Custom 3D printed glasses
When it comes to consumer products, one of the most exciting customizations enabled by 3D printing is the ability to tailor products to your own body. In the eyewear industry, customizing your own 3D printed glasses or sunglasses means that by scanning your face you can create a personalized, one-of-a-kind frame. Glasses manufacturers offering this technology are the Spanish company Horizons Optical or the German company Youmawo. The process is simple. Both manufacturers scan customers’ faces in 3D to collect biometric data. Customers can then use the software to virtually try on the glasses and choose from a range of color and frame design options. The selected glasses are then 3D printed, with Horizons Optical using HP’s MJF technology, while Youmawo relies on EOS’ SLS technology. The advantages of using additive manufacturing in this field are products that can be obtained in a short time, more complex designs and lighter and stronger materials.
△Horizons Optical and HP Multi Jet Fusion produce fully customized glasses
3D printed shoes
The first thing to notice when it comes to our shoes is the uniqueness of each foot and the importance of wearability and comfort. Feet, in particular, come in countless shapes and sizes, making it difficult for some people to find the right shoe. That’s where 3D printing comes in, allowing shoes to be personalized – and there are already some examples of how important this is to our feet. For example, a group of Spanish students from the Elisava Design Institute designed the Athos hiking shoe to provide better performance and comfort for amateur and professional climbers, taking into account the specific needs of the wearer. Still in classical dance, act’ble has released a shoe made from 3D printing. The idea is to transform dance shoes, which already break down quickly, from a disposable product into a durable, hard-wearing shoe that also responds to the personality of the wearer. In the field of insoles, Wiivv and foot care market leader Dr. Scholl have made inroads with their smartphone apps. Here, customers can scan their feet directly at home and order a personalized 3D printed insole measured at 400 points on their foot.
△3D printing is used to produce personalized insoles (Photo source: Dr. Scholl)
3D printed clothing offers unique high-end pieces
Fashion is an industry known for eccentric pieces, where designers and consumers are constantly looking for originality. With the rise of “fast fashion” and overconsumption, 3D printing could offer an alternative. Both parties can use technology to express their creative personalities by creating unique objects. Spanish designer Miranda Marquez, for example, believes consumers should be able to print their own clothes at home using this technology, and that’s exactly what her website offers.
3D printed dresses based on customers’ body scans are also available in the market. The Museum of Modern Art (MoMA) in New York has made available a 3D printed design called “Kinematic Dress” by Jessica Rosenkrantz and Jesse Louis-Rosenberg. Once the customer’s body is scanned, fabric is digitally inlaid onto the body and a garment is created using selective laser sintered (SLS) elastic nylon material. In this way, clothes can be made according to the aesthetic needs and body proportions of the customer. Another example of the couple’s high-end fashion is the “Sporting Petal Dress” project commissioned by the Museum of Fine Arts (MFA) in Boston. The dress, like the Kinematics dress, offers a customizable fit and features 1,600 unique pieces connected together by more than 2,600 hinges. Despite its intricate design, the dress straight from the printer is completely wearable.
△The KinematicPetals dress was created in 2016 using nylon and SLS technology. (Image source: NERVOUS SYSTEM)
Additive manufacturing in personalized watchmaking
Another area where 3D printing allows greater customization is that of watchmaking. With the significant growth of 3D printing in recent years, many watch designers have turned to 3D printing to design and manufacture consumer products faster while maintaining good quality. But why print in 3D? As we have seen in other areas, 3D technology allows watchmakers to use fewer materials, thereby minimizing waste and making their production processes more sustainable. Depending on the objective and the degree of customization sought by the consumer, one or another additive manufacturing method must be used.
For example, the Swiss company SevenFriday used Multi Jet Fusion to create FREE-D – an original watch with an eye-catching appearance and unique design. Through the use of PA11 material, the company is able to create organic, lightweight and durable parts while maintaining high quality. For its part, the Italian brand AionWatch is developing the lightest automatic watch in the world. Weighing just 26 grams, these 3D printed watches have an internal honeycomb structure that allows them to maintain the necessary rigidity and reduce weight by 200%. In addition to the lightness and high mechanical resistance of the watch, the properties of carbon fiber include high thermal insulation. This highlights the opportunity to use performance materials to enhance the properties of customized products.
△3D printed watch. Photo credit: Aion
3D technology in cosmetics
3D printed cosmetics are already starting to emerge, particularly in terms of personalization. This is done in different ways. To give an unexpected example: Formula 1, a pillar of motorsport, has also started to develop 3D printed cosmetics. In 2020, Formula 1 began using 3D printing to create distinctive perfume bottles. All three bottles were inspired by the automotive industry, known at the time for its complex and interesting designs, demonstrating the endless possibilities of additive manufacturing. But packaging and bottles aren’t the only ways cosmetics are adopting 3D technology. Another example we can give comes from Dior. In this case, beauty brands are turning to 3D scanning to help each customer get the right skin care products. This is done using a device called Eve V, which allows each person to have their skin analyzed individually, including measuring areas such as sagging skin, bags under the eyes and wrinkles. This analysis is then used to determine an appropriate skincare regimen (focusing on the two biggest skin concerns) using AI technology. This level of customization for each user is only possible thanks to 3D scanning.
△Image source: Lovegrove Studio
Additive manufacturing improves sports performance
In recent years, additive manufacturing has repeatedly proven the usefulness of this technology for athletes. Equipment for any sport can be customized to meet the needs of the athlete and provide a higher level of comfort. In addition, 3D printing also helps reduce the weight of equipment. This is especially beneficial in sports where speed is crucial. So overall this technology helps in improving performance.
Carbon’s example is a great example of how additive manufacturing can be used in sports. The company prints custom helmet shells for NFL players from sporting goods manufacturer Riddel. They differ from traditional helmets by their lattice structure. In addition to the customization options, the elastomers used protect against impacts because most of them are absorbed. Another example is that of the Californian bicycle manufacturer Superstrata, which in 2021 launched a carbon fiber frame weighing 1.7 kilograms. It is not only extremely lightweight, but also very durable. Bicycle frames are said to be 61 times stronger than steel. The part was printed in a single process using Arevo’s DED technology. Depending on the manufacturer, up to 500,000 different configurations are possible and can be chosen in the company’s online store.
△ The Superstrata: personalized 3D printed carbon fiber bike
3D printing of personalized vehicles
In the automotive world, the use of additive manufacturing to personalize vehicles is commonplace. As you might expect, adding accessories, upgrades or replacing parts to a vehicle is often very expensive, making the use of 3D printing the best option to achieve this. These technologies allow car owners to create unique and personalized parts for their vehicles, from decorative accessories to functional parts, in addition to greater portability and extreme flexibility in design, shape and precision of details . It is an affordable, easy-to-use and durable solution that improves the driver experience.
An example of this can be found at the Ford brand, which has made 3D files available to personalize its Maverick models, allowing all drivers without exception to 3D print parts of its “FITS system”. Depending on the user’s needs and preferences, they offer eight storage locations for mounting accessories in the central area or under the seat. Peugeot, for its part, follows suit and also offers vehicle personalization solutions through accessories that are comfortable to the touch, light and easy to use, sold in its LIFESTYLE stores, studying the needs of its customers and choosing to offer them to them using 3D technology The car is as comfortable as possible.
△3D printed consumer products may include cars. Photo credit: Ford
3D printed furniture: food waste and optimized comfort
In the world of 3D printing, there are always new ways to create objects. Whether it’s new technologies or new materials, the industry is always looking for innovation. Krill Design is a great example of this. In fact, the Milan-based startup has successfully 3D printed furniture from orange peels, lemon peels and coffee grounds. Yes, it’s true: this startup uses food waste to design interior furniture, including lamps, magazine racks and even flower pots. The recycling process for any type of waste is the same, they are ultimately transformed into a material called Rekrill. The first step in the recycling process involves drying the waste and then grinding it to make it micronized. Finally, the resulting pellets were heated and extruded into filaments via Prusa and Creality’s FDM 3D printer. This manufacturing technique is an example of green production because it limits the use of plastic and all materials are 100% recyclable, biodegradable and compostable.
Steelcase is one of the major players in office furniture. The company turned to additive manufacturing to create a new version of its SILQ office chair. It is designed to better adapt to the user’s shape, increasing comfort. The company has partnered with Fast Radius and Carbon to benefit from 3D technology. Thanks to these technologies, it is possible to 3D print handrails with a grid structure. In detail, they are divided into four zones, each designed to adapt to user behavior. So, depending on the person’s position, the chair will be more comfortable. For example, if the user lowers their elbows or fully extends their arms, SILQ will adjust the user’s sitting posture. In addition, the use of 3D printing in the manufacture of office chairs saves 70% of materials.
△3D printed consumer products. Photo credit: Krill Design
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Daguang focuses on providing solutions such as precision CNC machining services (3-axis, 4-axis, 5-axis machining), CNC milling, 3D printing and rapid prototyping services.
