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3D Printing and the Future of Manufacturing 3D PRINTING AND THE FUTURE OF MANUFACTURING Technology Program Fall 2012 3D Printing and the Future of Manufacturing ABOUT THE LEADING EDGE FORUM As part of CSC’s Office of Innovation, the Leading Edge LEF TECHNOLOGY PROGRAM LEADERSHIP Forum (LEF) is a global community whose programs William Koff help participants realize business benefits from the use Vice President and Chief Technology Officer, of advanced IT more rapidly. Office of Innovation The LEF works to spot key emerging business and tech- A leader in CSC’s technology community, Bill Koff nology trends before others, and identify specific prac- provides vision and direction to CSC and its clients tices for exploiting these trends for business advantage. on critical information technology trends, technol- The LEF draws from a global network of thought lead- ogy innovation and strategic investments in leading ers and leading practitioners, proven field practices, and edge technology. Bill plays a key role in guiding CSC a powerful body of research. research, innovation, technology leadership and alli- ance partner activities, and in certifying CSC’s Cen- The LEF Technology Program gives CTOs and senior ters of Excellence and Innovation Centers. technologists the opportunity to explore the most press- [email protected] ing technology issues, examine state-of-the-art prac- tices, and leverage CSC’s technology experts, alliance Paul Gustafson program and events. The reports and papers produced Director, Leading Edge Forum Technology Program under the LEF are intended to provoke conversations in the marketplace about the potential for innovation Paul Gustafson is an accomplished technolo- when applying technology to advance organizational gist and proven leader in emerging technologies, performance. Visit csc.com/lef. applied research and strategy. Paul brings vision and leadership to a portfolio of LEF programs and The LEF Executive Programme is a premium, fee-based directs the technology research agenda. Astute at program that helps CIOs and senior business executives recognizing how technology trends inter-relate and develop into next-generation leaders by using technol- impact business, Paul applies his insights to client ogy for competitive advantage in wholly new ways. strategy, CSC research, leadership development Members direct the research agenda, interact with a and innovation strategy. network of world-class experts, and access topical con- [email protected] ferences, study tours, information exchanges and advi- sory services. Visit lef.csc.com. In this ongoing series of reports about tech- CoveR: The Urbee from KOR EcoLogic is the nology directions, the LEF looks at the role world’s first 3D–printed car. The entire car of innovation in the marketplace both now body is 3D–printed using Stratasys printers, and in the years to come. By studying tech- and there are plans to 3D print the car’s inte- nology’s current realities and anticipating its future rior. The car is designed to be highly energy shape, these reports provide organizations with the efficient, including manufacturing processes, necessary balance between tactical decision-making and could be in low-volume production by and strategic planning. 2014. www.urbee.net CSC LEADING EDGE FORUM 3D Printing and the Future of Manufacturing 3D PRINTING AND THE FUTURE OF MANUFACTURING CONTENTS 2 Remaking Manufacturing 5 The Rise of 3D Printing 9 3D Printing at Work 14 3D Printing at Home 17 Democratization of Manufacturing 21 Impact on Commercial Manufacturing 24 Technology Advances On the Horizon 26 Platform for Innovation 29 Notes 32 Appendix: Further Reading 33 Acknowledgments Access this report via the LEF RSS feed (csc.com/lefpodcast) or the LEF website (csc.com/3dprinting) 3D Printing and the Future of Manufacturing CSC LEADING EDGE FORUM REMAKING MANUFACTURING Who would have thought that modern manufacturing manufacturing as we know it. The Economist calls 3D could be done without a factory? Since the Industrial printing the third Industrial Revolution, following mecha- Revolution, manufacturing has been synonymous with nization in the 19th century and assembly-line mass pro- factories, machine tools, production lines and economies duction in the 20th century.1 of scale. So it is startling to think about manufacturing without tooling, assembly lines or supply chains. However, CLASSIC DISRUPTION this is exactly what is happening as 3D printing reaches individuals, small businesses and corporate departments. 3D printing is a classic disruptive technology accord- ing to the disruption pattern identified by Harvard Busi- Today you can make parts, appliances and tools in a wide ness School professor Clayton Christensen.2 It is simpler, variety of materials right from your home or workplace. cheaper, smaller and more convenient to use than tradi- Using a computer, simply create, modify or download a tional manufacturing technology. Current 3D printing tech- digital 3D model of an object. Click “print,” just as you nology is “good enough” to serve markets that previously would for a document, and watch your physical 3D had no manufacturing capability at all (e.g., small busi- object take shape. No longer the stuff of science fiction, nesses, hospitals, schools, DIYers). However, the technol- 3D printing is a new reality. ogy is not expected to flourish in traditional manufacturing markets for a number of years, so it is unlikely that an entire While this new reality is exciting, it also poses significant commercial passenger airplane will be 3D–printed any time questions for the future of how we manufacture goods. soon. Still, traditional manufacturers need to take notice; Factories will not disappear, but the face of the manufac- there are many examples of “good enough” technologies turing industry will change as new entrants, new prod- that eventually disrupted and dominated their industry, ucts and new materials emerge, and mainstay processes including transistor radios and personal computers. like distribution may no longer be needed. Today’s con- sumers clamor for customized products and services and for speed of delivery. Yet customization and immediacy 3D printing changes the — right here, right now — are not economical with tradi- tional manufacturing processes, which are optimized for calculus of manufacturing by large volumes of consistent output in a factory far away. optimizing for batches of one. 3D printing changes the calculus of manufacturing by optimizing for batches of one. 3D printers are being used to economically create custom, improved and sometimes All disruptive technologies start out inferior to the domi- even impossible-to-manufacture products right where nant technology of the time. When the first experimental they will be used. A single printer can produce a vast 3D printers emerged 20 years ago, they were nowhere range of products, sometimes already assembled. It’s a near the production quality of traditional manufactur- factory without a factory floor and it has created a plat- ing processes. However, as Christensen observed in his form for innovation, enabling manufacturing to flourish in research, the new technologies find a market that is uncommon areas and spawning a new generation of do- underserved by the current technology (which is often it-yourself (DIY) manufacturers. The new players, with focused on the higher end of the market). 3D printing their innovative processes and technology, will disrupt found rapid prototyping, which was an extremely costly 2 CSC LEADING EDGE FORUM 3D Printing and the Future of Manufacturing and labor-intensive process using traditional manufactur- relationships through collaboration with customers to ing techniques. 3D printing enabled cheap, high-quality, create products (“co-creation”). one-off prototypes that sped product development. It is easy to dismiss the impact of 3D printing if you focus As 3D printing technology evolved, it started to be used only on the capabilities of today’s 3D printers compared to directly manufacture niche or custom goods in low to the capabilities of modern, highly automated facto- volumes. According to Christensen, a disruptive technol- ries. Today, and for the near future, 3D printing cannot ogy continues to evolve to the point where it can serve produce entirely finished products on an industrial scale. the needs of the higher-end market at a lower cost, at However, to dismiss 3D printing’s impact is to ignore the which point it takes over the dominant players. impending disruption, just like the minicomputer makers did when personal computers appeared. This is the path 3D printing is on today. 3D printing is evolving rapidly, with practical examples in numerous industries including defense, aerospace, automotive and Flexibility to build a wide healthcare. Although 3D printing has been applied mainly to low-volume production, the products can be far supe- range of products, coupled rior (lighter, stronger, customized, already assembled) with the fact that 3D printing and cheaper than if created with traditional manufactur- ing processes. That is because 3D printing can control can be done near the point exactly how materials are deposited (built up), making of consumption, implies a it possible to create structures that cannot be produced using conventional means. serious change to supply chains and business models. Another disruptive element of 3D printing is the fact that a single machine can create vastly different products. Com- pare this to traditional manufacturing methods, where the production line
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