“For instance, we have to qualify manufacturing, be able to repeat it, secure strength and study the material, costs and effects on the environment. There are many questions for us researchers,” says Anton Wiberg, who is project manager for part of this area.
Additive manufacturing is the term for what is often known as 3D printing. The manufacturing process is completely different from traditional manufacturing industry. There are plenty of advantages:
Accessibility is important. A ready-to-use product can be made in a relatively short time. Although this manufacturing may not be better for the environment, reducing transports can make a difference and lead to lower total cost. Objects can be manufactured one at a time, with individually tailored details.
It’s important to have a lab environment that can inspire othersOn the minus side, there are uncertainties as to quality, and a general scepticism. Additive manufacturing is on the increase, but has not yet matured.
“Traditional manufacturing processes are very mature. People know very well how to use a milling machine to get the right shape. With 3D printing, completely new methods are introduced. This becomes a huge uncertainty factor. But there are numerous indications that the new methods will mature too,” says associate professor Joakim Holmberg.
“You get used to that. It’s important to have a lab environment that can inspire others. We want this space to become available as a testbed for researchers, students and industry,” says Anton Wiberg.
The metal printer consists of a building chamber with an adjacent powder chamber from where thin layers of metal powder are successively applied to a build plate. The electron cannon shoots electrons at the metal powder bed. Its beam can be directed with very high precision and extremely quickly at various positions to melt the powder, layer by layer, according to the pre-set geometries. Electromagnets guide the beam to the right location.
In 3D printing, the material, the product and its geometry are created simultaneously. This places very high demands on the entire process, from metal powder to geometric shape.
The geometry, i.e., the shape of the product, impacts the entire manufacturing process, and also the quality of the final material. Anton Wiberg holds up a plate with examples of various shapes.
“In principle, all materials can be 3d printed if you choose the right technology. But the consequences of additive manufacturing span over the entire life cycle of a product, forcing us to reconsider the design, manufacture, use and recycling of products,” says Johan Moverare, professor and research leader in the area of additive manufacturing.
Medical applications is one of the areas they focus on. Anton Wiberg has worked on printing of hip bones, together with Joakim Holmberg and research engineer Jinghao Xu and orthopaedist Jörg Schilcher, researcher at the Faculty of Medicine and Health Sciences. This is done using a plastic material resembling the structure of a human skeleton. From CT scan images, they print a natural size model that looks very much like the hip joint to be operated on.
“The purpose of this is to train the surgeons on the procedure before the operation. We have developed a software that transforms the CT scan images, and is easy to use. You can print using a normal hobby printer. This keeps the costs down,” says Anton Wiberg.
In this way, surgeons can discuss the procedure beforehand. They can practice drilling and screwing into the printed “bone material”, as well as use screws to attach implants to it – before the actual operation. They can also practice new methods and more advanced procedures.
“Training can reduce surgery time and give better results,” says Anton Wiberg.
What scientific gains can collaboration with businesses and organisations bring?
“Huge gains, as we can ask questions in our research that are relevant to future applications,” says Anton Wiberg.
Johan Moverare summarises:
“There are many good examples of how additive manufacturing contributes to making products more effective, cheaper and more environmentally friendly. But this has to be done in the right way and there are pitfalls. There are still many challenges that we need to solve together with industry and other organisations in society.”