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3D Printing I 020516 3d_printing

The specter of counterfeit products is always a concern for any company that relies on other facilities to actually manufacture and assemble their products. From fake Rolex watches to fake iPhones to fake Louis Vuitton purses, large companies often spend millions to protect their intellectual property from criminals who copy and sell fake products to often unsuspecting consumers.

While it can be easy to be anti-corporate and turn a blind eye to this kind of theft, especially when the companies are large and extremely profitable, their concern goes far beyond the potential loss of profits. The fact is, most counterfeit products are vastly inferior to the real thing, and if a consumer doesn’t know that they are purchasing a fake then the company not only has a lost sale, but their reputation will take a hit based on something that they didn’t even produce.

Even as 3D printing continues to grow into a valid and profitable alternative manufacturing method to injection molding or large-scale mass production, there are still companies that see the threat of counterfeiting as a reason to stall the adoption of 3D printing technology. Realistically there is not much that can be done about pirated 3D models and individuals using home 3D printers to make fake products. Combating individual piracy has been woefully ineffective for the entertainment industry, and probably only encouraged more users to download electronic files illegally. It stands to reason that going after individual pirates will work just as well if the 3D printing industry makes an attempt to over-regulate and control the flow of 3D printable files.

DRM on 3D printable files is probably not going to be an effective deterrent.

DRM on 3D printable files is probably not going to be an effective deterrent.

Many of the solutions that are being floated as counter-counterfeiting measures don’t really seem especially feasible or sustainable. Adding DRM (digital rights management) or unlock code requirements to 3D files may slow down some users, but just as with DRM efforts on movies and video games, if someone can put a lock on something, someone can take that same lock off and teach others how to do it as well. These efforts may work in the short term, as the pool of users who are capable of breaking DRM on 3D printable files is smaller, and there isn’t really an outlet to disperse those illegal files yet. But as the industry grows it is going to be harder and harder for companies to control their intellectual property using these methods. I’m not really sure that there is much to be done on this end of the industry. Besides, there is an even greater counterfeiting problem brewing on the manufacturing side of the industry and it is far more important than individual piracy ever could be.

Counterfeit bolts.

Counterfeit bolts.

As with fake mass-produced consumer goods, mass-produced industrial parts are also counterfeited quite frequently. It may be more interesting to talk about fake purses, but a greater threat is products like fake screws, bolts, fittings and individual components. Many of the parts that are used to build our homes, businesses, vehicles and personal electronics use mass-produced components that manufacturers simply purchase in extremely large quantities. And all of those parts are held to very strict manufacturing guidelines that dictate how they can be used, what their maximum stress tolerances are and how they can be expected to perform.

When these types of components are forged, they are rarely made with the same quality of materials and often don’t even come close to performing as required. If these fake parts find their way unknowingly into the hands of manufacturers, who design products with these components’ manufacturing guidelines in mind, then the results could be catastrophic. There have been instances of airplanes and automobiles that have crashed due to the failure of lower quality, counterfeit parts. Buildings and homes are also at risk due to poor quality and counterfeited construction materials being used. It may seem odd, but cheaply made products that do not pass strict regulations are a huge business and lives can be lost to it.

3D printed Nike shoes with embedded InfraStructs.

3D printed Nike shoes with embedded InfraStructs.

With 3D printed components becoming more common, and eventually expected to be extremely common, counterfeit parts will pose a real risk. Using DRM, even if it was effective on a small scale, to prevent machines from making unauthorized parts is not going to matter when these parts can simply be 3D scanned and reproduced without the need for the original 3D model. The methods that need to be developed to combat this type of industrial counterfeiting will need to work in ways that DRM never will and identify the specific physical object as authentic. There are a few different methods that are currently being proposed, with varying probabilities of success.

The most likely option will be including RFID tags on 3D printed components that will identify an object as the real thing. The idea is that any part that doesn’t have an embedded RFID device in it — and they can easily be made small enough to easily be inserted inside of a 3D printed part — will automatically be identified as fake. The downside of this method is price, as the RFID tags themselves would be costly, as would the labor involved in inserting them. Testing for tags will also require specialized equipment that adds more cost to the authentication process. It is possible that a 3D printable material that would act as a tag called InfraStructs could be developed, but that would mean developing multiple materials that will be RFID reactive, which will be quite costly on the development side.

Subsurface fingerprinting with InfraTrac.

Subsurface fingerprinting with InfraTrac.

Another authentication option would be chemically tagging materials that can be detected with a handheld spectrometer. There are multiple companies providing these types of materials, but the most promising is a technique developed by InfraTrac. The Maryland-based company has developed a chemical that can be discreetly added to virtually anything without altering the chemical makeup of the material. For instance, parts can be 3D printed with a small subsurface “fingerprint” hidden in a discrete location. That mark alone would be printed with the material that has been treated with the chemical, and would easily identify the part as genuine. The material could also be printed as a single layer of the print with no mark, and no risk of altering the integrity of the part. Of course again this comes with it the need for specialized equipment in the form of the spectrometer and an actual machine that can 3D print with the standard material and the second, tagged material.

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3D Printed Model of a Human Heart

One thing is very clear, there is a desire for additive manufacturing to be developed as an alternative to other mass production methods. That means the companies looking to use 3D printing to manufacture parts, and the 3D printing industry itself, are going to need to address the problem sooner rather than later. Determining which of these options is the ideal solution will not be an easy choice, as they both bring with them additional costs and challenges, but doing nothing simply isn’t an option.

 

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GE Desal 111015 greenville5_extra_large-1024x1024The mini desalination system combines 3D printing with GE’s deep reservoir of knowledge of turbo-machinery and fluid dynamics. GE scientists Doug Hofer and Vitali Lissianski used them to shrink a power generation steam turbine that would normally barely fit inside a school gym.

Not too long ago, Lissianski, a chemical engineer in the Energy Systems Lab at GE Global Research, was chatting with his lab manager about new ideas for water desalination. This type of “small talk” happens thousand times a day at the GRC.

Their lab tackles a lot of technical challenges coming from GE’s industrial businesses including Power and Water, Oil and Gas, Aviation and Transportation, and they quickly hit on a possible solution.

It led them to Hofer. As a senior principal engineer for aero systems at GRC and a steam turbine specialist, he was part of another team of GE researchers working on a project for Oil and Gas to improve small scale liquefied natural gas (LNG) production. A key part of the project focused on using 3D printing to miniaturize the turbo expander modeled after a GE steam turbine. (A turbo-expander is a machine that expands pressurized gas so that it could be used for work.)

Hofer was the perfect person in charge. He led the steam turbine aero team at Power and Water before coming to GRC eight years ago. Few people in the world have the kind of expertise and knowledge of steam turbine technology that Doug brings. “In traditional steam turbines, steam condenses and turns to water,” he says. “We thought maybe the same principle could be applied to water desalination.”

The only difference, Hofer explained, would be in using flows through the turbine to freeze the brine, or salt water instead of condensing the steam to water as in a steam turbine. Freezing the brine would naturally separate the salt and water by turning salt into a solid and water to ice.

A 3D printed mini-turbine . Image credit: GE

Lissianski and Hofer compared notes and today they are working on a new project with the US Department of Energy to test their new water desalination concept.

The reality today is that 97.5 percent of the world’s potential clean water drinking supply essentially remains untapped, locked in salty oceans and unsuitable for human consumption. This is in the face of growing global water shortage. According to the United Nations, water scarcity impacts 1.2 billion people, or one fifth of the world’s population.

Not even the United States has been spared. California, which has one of the country’s longest coastlines bordering the ocean, has been suffering through a severe water shortage crisis.

Technology inspired by a miniaturized steam turbine could help change all that. And there’s no reason to believe that it can’t. Advances in miniaturization have proven to have great impact time and time again.

For example, the application of Moore’s Law in the semiconductor world has shrunk the size of computer chips to enable mobile phones that pack more computing power than a roomful of mainframe supercomputers that were state-of-the-art just a few decades ago.

In ultrasound, miniaturization technologies have shrunk consoles to the size of a phone screen and can fit neatly into a doctor’s coat pocket. Doctors today can deliver high quality care in regions where access was previously limited or non-existent.

And steam turbines? They already have proven to be one of the key innovations that spread electricity to virtually every home and business. Miniaturized, they just might hold the key to spreading water desalination around the world.

Top image: Doug Hofer, a GE steam turbine specialist, and Vitali Lissianski, a chemical engineer in GE’s Energy Systems Lab, holding the mini-turbine in front of an actual size power generation steam turbine. Image credit: GE Reports

Treating Cancer with nanotechnologiesScientists at the Univ. of Sheffield have succeeded in using a 3-D printed guide to help nerves damaged in traumatic incidents repair themselves.

The team used the device to repair nerve damage in animal models and say the method could help treat many types of traumatic injury.

 

The device, called a nerve guidance conduit (NGC), is a framework of tiny tubes, which guide the damaged nerve ends towards each other so that they can repair naturally.

Patients with nerve injuries can suffer complete loss of sensation in the damaged area, which can be extremely debilitating. Current methods of repairing nerve damage require surgery to suture or graft the nerve endings, a practice which often yields imperfect results.

Although some NGCs are currently used in surgery, they can only be made using a limited range of materials and designs, making them suitable only for certain types of injury.

The technique, developed in Sheffield’s Faculty of Engineering, uses computer aided design (CAD) to design the devices, which are then fabricated using laser direct writing, a form of 3-D printing. The advantage of this is that it can be adapted for any type of nerve damage or even tailored to an individual patient.

Researchers used the 3-D printed guides to repair nerve injuries using a novel mouse model developed in Sheffield’s Faculty of Medicine, Dentistry and Health to measure nerve regrowth. They were able to demonstrate successful repair over an injury gap of 3 mm, in a 21-day period.

“The advantage of 3-D printing is that NGCs can be made to the precise shapes required by clinicians,” says John Haycock, professor of bioengineering at Sheffield. “We’ve shown that this works in animal models, so the next step is to take this technique towards the clinic”.

The Sheffield team used a material called polyethylene glycol, which is already cleared for clinical use and is also suitable for use in 3-D printing. “Further work is already underway to investigate device manufacture using biodegradable materials, and also making devices that can work across larger injuries,” says Dr. Frederik Claeyssens, senior lecturer in biomaterials at Sheffield.

“Now we need to confirm that the devices work over larger gaps and address the regulatory requirements,” says Fiona Boissonade, professor of neuroscience at Sheffield.

Source: Univ. of Sheffield


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