The U.S Department of the Navy (DoN) has revealed plans to use a blockchain to control its 3D printers.

The U.S Navy is increasing its implementation of 3D printing and earlier this year ordered its first Concept Laser metal 3D printer and also recently produced its first 3D printed aircraft part.

Lieutenant Commander Jon McCarter has now revealed in a blog post that the DoN will begin trialling blockchain this summer before issuing a report in September on the proof-of-concept.

Decentralized network

Blockchain is an example of a decentralized network which means data is shared across the network and not secured in one location. By having a distributed network in this way the Navy can “both securely share data between Additive Manufacturing sites, as well as help secure the digital thread of design and production.”

The digital thread is the data concerned with manufacturing a part and is all the data that defines the manufactured part across its development – from design to final part production.

By outlining a component’s life in this way, the U.S Navy can assert greater security and control over the manufacturing process. Security is increasingly gaining attention within the 3D printing industry as the technology is used to make critical parts.

North Dakota State University’s (NDSU) Jeremy Straub explored this topic recently and outlined a process for enabling greater security during the printing process.

Why implement a blockchain system?

As the DoN advances its manufacturing supply chain with 3D printing, allowing it to be faster and closer to deployed forces, this simultaneously opens the door to a new attack vector.

This heightens “the need for a cryptographically secure, traceable, immutable, and controllable data flow.” The DoN’s LCDN Jon McCarter believes blockchain and Naval additive manufacturing are a perfect match since,

The ability to secure and securely share data throughout the manufacturing process (from design, prototyping, testing, production, and ultimately disposal) is critical to Additive Manufacturing and will form the foundation for future advanced manufacturing initiatives.

Demonstrating this, the U.S DoN recently held a 3D Print-a-Thon at the Pentagon in which 40 different Navy and Marine projects presented their innovative use of the technology.

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The ultrasonic 3D printing technology was demonstrated by the company’s Ultrasound Research Group and has particular potential for electronics. Research engineer and project lead for Neurotechnology’s Ultrasound Research Group, Dr. Osvaldas Putkis explains the patent-pending 3D printer will use a variety of materials in order to produce electronic objects that are entirely 3D printed.

Putkis says the 3D printer is “capable of printing virtually anything” and points to the example of a smartphone with all its components printed from a single device.

Gif shows suspension of small material using ultrasonic transducers. Images via Neurotechnology.

Ultrasonic transducers

Using ultrasonic transducers, the research group manipulated small materials and even electrical components to a high degree of accuracy. The prototype device can transport electronic components to a specific location and then solder them with a laser. The process is enabled by a camera which determines the position of the substrate and materials.

Ultrasonic technology has been used for 3D printing prior to this with Ohio-based company Fabrisonic. However, Fabrisonic’s patented technology uses ultrasonic sound waves to weld thin layers of metal sheets together. The company was recently granted a new patent to incorporate the technique into hybrid machinery.

Gif shows the manipulation of foam material. Images via Neurotechnology.

Materials and components

Dr. Osvaldas Putkis, who is listed as the inventor of the technology, explains the potential,

Ultrasonic manipulation can handle a very large range of different materials, including metals, plastics and even liquids. Not only can it manipulate material particles, it can also handle components of various shapes. Other non-contact methods, like the ones based on magnetic or electrostatic forces, can’t offer such versatility.

The non-contact nature, combined with high accuracy, means the system can control very small and sensitive particles without damaging them or affecting their electrostatic forces. The scale of component sizes can be from a number of millimeters down to sub-millimeters. Similarlly, we’ve seen how 3D printing has been used to create a tractor beam device that can suspend materials with transducers housed in a 3D printed cup.

Non-contact printing

By offering such versatility, Neurotechnology intends to develop a unique 3D printer device which could 3D print a wide range of materials and possibly allow for the creation of 3D printed objects with embedded components and electronics.

According to Neurotechnology, the Lithuanian company is currently inviting other organizations to support development of the project and ultrasonic particle manipulation technology.

If you’d like to 3D print your own acoustic tractor beam then you can download the files here.

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With many companies within the 3D printing industry looking at how to advance their machines for mass manufacturing, Blackbelt has a novel approach of bringing the conveyor belt to the 3D printer. 3D printing bureau Voodoo Manufacturing has similarly had this brainwave recently as it has incorporated a robotic arm and conveyor belt to automate its 3D printer factory.

3D printing of “endless length”
The Blackbelt 3D printer houses its 3 print heads on an X-Y actuation system, with the Z-axis in the form of a conveyor belt. This allows for theoretically infinite sized horizontal parts. The idea of infinite size is something Stratasys is addressing with its Infinite Build 3D printer. The device is currently undergoing testing at Ford Motors.

Continuous printing
Not only does the machine’s conveyor belt enable endless horizontal size, its functionality as a moving print bed allows for continuous printing. The printer can hold a container, as shown, that can collect finished parts enabling the machine to keep running.
This function is appropriate for series production since Blackbelt claims it is “not necessary to remove the prints manually.” Blackbelt believe this is enabled because the conveyor belt is made from “carefully selected and well tested carbon fiber composite.”


Support free overhangs
Due to the X-Y actuation system’s print angle it is possible to print support-free overhangs. The machine is by default set to print at 45° but this can be adjusted to be lower at 15°, 25° or 34°. However, Blackbelt do explain that some prints may require a starting geometry in order to do this, as shown.


Large format printing
As mentioned earlier, the conveyor belt allows for endless length and the ability to create large-scale printed parts is a major benefit of the device. In order to facilitate this, Blackbelt have incorporated a roller table for support. The company explains that, “for prints of 1300mm or longer, we recommend using the roller table to provide additional support while the printing process.”
The Blackbelt 3D printer will release in two formats, a desktop version and a stand-alone version which includes standing frame and roller table to realize the large-scale possibilities of the device.

Specifications
– Interchangeable print heads
– Industrial linear guides
– Building volume: 340 x 340 x ∞ mm (13” x 13”x ∞”)
– Print angle adjustable: 15°/ 25°/ 34°/ 45° – 45° by default, some parts come out better at lower angles.
– Filament diameter: 1.75mm
– Print heads: nozzle sizes 0.4/ 0.6/ 0.8 mm come with the printer. Further sizes will be available.
– Retail price: 9,500 EUR Desktop version. 12,500 EUR with standing frame and roller table
The Blackbelt 3D printer will launch on Kickstarter, with further details expected to be announced on Friday May 12th.

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Corey Clarke from 3D Printing Industry
French researchers from Grenoble Alpes University have evaluated the environmental impact of 3D printing with a case study focused on the production of orthotic insoles.

The paper, available here, was presented as part of the 12th International Congress of Industrial Engineering. The researchers assessed the production of orthotic insoles with a conventional method in compared to the method used by a 3D printing startup company.

Life Cycle Assessment
To understand the environmental impact of the two processes, the researchers undertook a life cycle assessment (LCA). An LCA is a technique to analyze the environmental impacts of a product through all stages of its life, from raw material extraction to it’s final disposal or recycling.
Through the comparison, the researchers found that,

In Human Health and Climate Change, a 3D-printed insole is about 20% and 25% less impactful respectively. In Resources category, 3D Printed insole overcomes by 35% the impacts of a classic insole.

Relating to materials, the team report the “impacts from 3D printed insole are 65% less than a classic one in the four impact categories.” The four impact categories are Human Health, Ecosystem Quality, Climate Change and Resources.

Results of the LCA
Concluding the research, the team states the 3D printing process “impacts less than a Classic manufacturing considering Material, Distribution, and Usage phases.” While the two processes have similar end of life phases, “in the Production phase, the impacts of 3d-printing manufacturing overcome the other one.”
The research team notes that the length of time the insole takes to print is a considerable factor in relation to environmental impact, and one that varies drastically regarding the 3D printer that is used. The paper notes therefore that, “the way to reduce the environmental impacts of AM for this type of use is reducing the printing time investing in better performance 3D printers and choosing the best energy source.” The paper concludes that the 3D printing process itself is the most environmentally impacting element.

3D printed footwear
The 3D printing of footwear is a growing market and there are a number of companies exploring the industry, including Carbon who have most recently collaborated with sportswear manufacturer Adidas to produce 3D printed midsoles.
While elsewhere, Canadian 3D printing startup, Wiivv has developed the process of 3D printing insoles with proprietary software. The company raised over $500,000 in its latest kickstarter campaign for 3D printed sandals.
The research was carried out by Kléber Da Silva Barros, (Phd Student) Akhmal Ikhan Mansur, (Master Student) and Peggy Zwolinski, (Professor). The full paper can be read here.

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