By Matt Howlett, Global Polymer Group
The news is buzzing about 3D printing. There’s so much buzz, in fact, that one might think traditional molding shops are getting ready to sell their injection molding machines and replace them with 3D printers. While that might be the case in select niches, traditional manufacturing is likely here to stay for quite some time.
Various reports suggest that nearly 60,000 desktop 3D printers (3DPs) will be sold in 2014. The 3DP market is estimated to grow at greater than 100% year-over-year though 2020. This explosion is a result – in large part – of the expiration of key patents in the Fused Deposition Modeling (FDM) variant of 3D Printing. FDM[1] was originally commercialized in 1990 and, until recently, only available in commercial printers that often cost over $200,000. Today, there are dozens of 3DPs that can offer reliable print quality – some down to 0.02mm layer resolution – for under $2,500.
Resin Companies Awaken to 3DP
Why are resin companies interested? Because these printers use thermoplastics – and lots of it. The estimated market for thermoplastics in 3DP was approximately $60 million in 2013 and is expected to reach $200-220 million by 2020 – an impressive 18-20% CAGR. These numbers are expected to swell even higher as new high-performance polymers enter the market to replace metals in weight-sensitive areas such as aerospace and transportation. Already, practically every hearing aid is 3D printed to fit a specific patient. Custom medical implants suited to the needs of a given patient are becoming routine.
Today, there are a wide variety of thermoplastics currently used in 3DP, including:
The majority of these polymers are supplied unfilled (often vividly colored). However, there are a growing number of modified grades that have been custom-formulated to meet specific end-use needs. These materials are typically compounded using the following additives / modifications:
- Carbon fiber
- Ceramic
- Conductive / ESD: carbon nanotubes, carbon black
- Flame retardants
- Glass bead
- Glass fiber
- Impact modified
- Metals
- Minerals
- Plasticizers
- Wood fiber
Sources of Materials Innovation
Who will innovate? Small and medium enterprises (SMEs) will likely be the source of much of the innovation in the plastics market over the short run. Why? They don’t have the overhead of large resin companies and can make attractive profits selling thousands of pounds vs. millions. Most large resin companies are studying, evaluating, and keeping their toes in the water – but the main innovation today is coming from SMEs. As always, exceptions do apply. Larger players such as Evonik (mostly PA12), Victrex (PEEK), and Sabic (PEI) have invested heavily and are working closely with the likes of Stratasys and 3D Systems to develop materials for commercial printers. However, I expect to see most large resin suppliers wait it out a bit longer and then innovate or absorb smaller players to buy their way into the business.
What does the future hold?
The industry is still missing the ‘killer app’ that will put a 3D printer in every household, but it’s a safe bet that most engineers will have access to them. These printers will enable them to validate designs and create limited production runs of customized parts = mass customization. Tracking with Moore’s Law, the cost of printers will continue to decrease while their functionality increases. I expect innovators will effectively navigate the patent landscape and develop even lower-cost printers with ever increasing degrees of quality and functionality. And plastic materials suitable for use on all types of 3D printers will continue to evolve and offer ever-greater performance.
About the Author
Matt Howlett, President Global Polymer Group E-mail: Matt Howlett |
Matthew has been the President and CEO of Global Polymer Group (GPG) since he founded the company in 2007. His strategic marketing services assist clients who wish to enter or expand their presence in the high-performance polymer market by creating proprietary market strategies and implementation plans. Through GPG, Matthew also offers contract sales and market development support in target markets that are especially suited for high-performance polymers. Furthermore, through it’s subsidiary 3DXTech, GPG offers specialty products to the 3D Printing market. |
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