Layer by Layer

With 3-D printing, manufacturers can make existing products more efficiently—and create ones that weren’t possible before

From my article in the January 2012 issue of Technology Review

GE thinks it has a better way to make jet-engine fuel injectors: by printing them. To do it, a laser traces out the shape of the injector’s cross-section on a bed of cobalt-chrome powder, fusing the powder into solid form to build up the injector one ultrathin layer at a time. This promises to be less expensive than traditional manufacturing methods, and it should lead to a lighter part—which is to say a better one.

The innovation is at the forefront of a radical change in manufacturing technology that is especially appealing in advanced applications like aerospace and cars. The 3-D printing techniques won’t just make it more efficient to produce existing parts. They will also make it possible to produce things that weren’t even conceivable before—like parts with complex, scooped-out shapes that minimize weight without sacrificing strength. And the technology could reduce the need to store parts in inventory, because it’s just as easy to print another part—or an improved version of it—10 years after the first one was made. An automobile manufacturer receiving reports of a failure in a seat belt mechanism could have a reconfigured version on its way to dealers within days…read more

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