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Shore Hardness = 75D
Suggested Applications: braces, fasteners, gears and protective covers
Automotive giant General Motors has partnered with 3D software expert Autodesk in order to create 3D printed parts for new cars. The manufacturer is looking to develop a new line of alternative energy vehicles in the upcoming years, and 3D printing will be used in order to fabricate more lightweight parts for the new cars, in a more cost-effective way. The company’s eventual goal is to have 20 new alternative energy cars added to its product lineup by 2023.
With the use of fossil fuels and carbon emissions being linked to climate change, alternative ways of powering cars are increasingly being sought out across the industry, and General Motors is hoping to ride the wave of these changes. Advances in manufacturing technology have made new developments progressively more feasible and cost-effective for production, and Chief Executive Mary Barra has made a bold promise to General Motors investors that the Detroit-based manufacturer will be making money from the sale of electric cars by 2021.
The electric cars will be powered from fuel cells or batteries that can be charged at dedicated power points, much like filling stations. The new designs for GM’s electric car range will require a whole host of new parts, and 3D printing technology will prove useful as a way to get these pioneering designs to the production phase. The key will be to produce parts that are as light as possible to maximize fuel efficiency, as well as implementing new production methods in a way that is affordable for the company.
GM recently demonstrated a 3D printed stainless steel seat bracket that was developed using Autodesk’s 3D technology. The two companies made use of cloud computing and artificial intelligence-based algorithms in order to rapidly explore multiple permutations of a part design, before settling on the optimal structure.
With the use of conventional manufacturing methods, a part like this would have required eight different components, sourced from several suppliers. With this new system, the visually-striking seat bracket was made up of just one part, fabricated directly from the digital 3D model. This method has made it 40 percent lighter and 20 percent stronger than it would otherwise have been, with joints and fixtures increasing the total weight and adding to the number of weak points.
GM’s director of additive design and manufacturing, Kevin Quinn, has predicted that 3D printed parts will be appearing in the company’s high-end motorsports vehicles by sometime next year. Repeatability and robustness are currently the main issues that are holding the technology back from final-phase production applications on a larger scale. Within five years, GM is hoping to produce thousands or even tens of thousands of parts for mass production, as the technology continues to improve. “That is our panacea,” said Quinn. “That’s what we want to get to.”
Other automotive manufacturers, such as BMW and GM’s major U.S. competitor Ford, have been taking advantage of what 3D printing has to offer, with 3D printed tools and 3D printed prototypes becoming increasingly widespread. Ford is now in the process of testing lightweight 3D printed parts for mass production.
A Chinese doctor successfully implanted the world’s first artificial vertebra produced by a 3D printer into the spine of a 12-year-old boy.Reuters
A 12-year-old bone cancer patient named Minghao was recently the first recipient of a new, 3D-printed vertebra in the top of his spine. The Aug. 18 surgery took place at Peking University, where surgeons cut out the cancerous mass and replaced it with a durable artificial replacement.
3D printing is quickly becoming the innovating surgeon’s leading means of repair. Tiny blood vessels all the way up to entire portions of a human face can now be produced with little more than a digital scan and some new-age materials. As the field grows, scientists are beginning to feel more confident with doctors implanting these devices regularly, and not just in the lab but in the operating room.
Using traditional methods, doctors would have had to prop up Minghao’s head with stabilizing pins, Dr. Liu Zhongjun, the director of orthopedics at No. 3 Hospital, Peking University, told Reuters. “But with 3D printing technology, we can simulate the shape of the vertebra, which is much stronger and more convenient than traditional methods.”
Because of a cancerous tumor in one of the axes, doctors had to replace it with an implant, one that was stronger than traditional titanium tubes. Reuters
Doctors first spotted the tumor after an injury Minghao sustained while playing soccer. According to his mother, the boy went up for a header during one of his games and came down complaining of a neck injury. Later tests confirmed the tumor’s presence.
Minghao could barely stand, let alone walk, prior to his five-hour surgery; he lay in the hospital’s orthopedics ward for two months. As Liu told Reuters, standard protocol for a vertebra replacement calls for a hollow titanium tube. The problem with this method is it takes time. Minghao’s head wouldn’t be able to touch the pillow for three months, in order to keep the tube sturdy.
Dr. Liu Zhongjun successfully implanted the world’s first artificial axis produced by a 3D printer into the spine of a 12-year-old boy. Reuters.
The new vertebra spans the entire width of his spine, as opposed to the tube thinly bisecting it through the center. His recovery will still take time, doctors say. Five days after his surgery he continued to have trouble writing and couldn’t speak. He is on the path toward recovery, however, and doctors suspect he’ll make a full return to health.
Like normal vertebrae, the 3D model allows room for nerves to be threaded through and carries enough strength to support the bone that sits on top of it. With the advanced technology, Minghao’s recovery will be shorter and hopefully less inconvenient.
Late last month, doctors broke new ground when they gave a 6-year-old a 3D-printed prosthetic arm. And in March, a surgical team implanted 3D-printed windpipes splints to help a baby with a condition known as tracheomalacia, in which the boy’s windpipe collapses under minimal stress, breathe new life back into his lungs. Dr. Glenn Green, who co-designed the implant, said at the time his team’s project was only a week-old when it saw surgical use.
“It had worked just the way we had hoped,” he told NPR. “I said, ‘This is going to change this boy’s life and his family’s life forever.'”