GreenTech3D - New Generation Green Technology for Post-Processing of 3D Printed Parts

Covid-19 and geopolitical uncertainties are bringing significant changes into the global manufacturing, logistics and free trade. This has increased uptake of the on-demand 3D printing manufacturing in UK, USA and Europe, especially for the manufacture of medical articles, Covid-19 testing devices, PPE and personal accessories \[Nature, _The global rise of 3D printing during the COVID-19 pandemic, 12 August 2020\]._

3D printing offers the capability to rapidly create necessary medical articles locally within the UK. This ability is of strategic national importance, especially in the times of crisis and shortage of vital components as seen during Covid-19 epidemic. In many cases it is faster for the local hospitals and institutions to receive specialised parts by 3D printing them at the point of use rather than from the central government. Nationwide, there are many 3D printing systems both in commercial and academic capacity and this resource must be utilised.

Due to the layer-by-layer nature of 3D printing, the printed articles result in rough, powdery and porous surfaces. This causes the accumulation and growth of bacteria, fungi and increases the risk of the loose polymer particles attacking the respiratory system as noted by the World Health Organisation (WHO) and FDA guidelines for 3D printing. This issue prevents any further use of 3D printed articles for oral/respiratory medical purposes.

Current methods for the post-processing of 3D printed surfaces involve mechanical abrasion techniques, that do not seal the surface and create polymer micro-fibres that can attack the respiratory system. Furthermore, these methods discharge hundreds of litres of micro-plastic polluted freshwater. Therefore, current post-processing techniques are not adequate for the smoothing of articles to be used for medical respiratory purposes. Fully green and sustainable post-processing technology would provide a massive boost to the general adoption of industrial 3D printing in medical market.

Additive Manufacturing Technologies (AMT), a Sheffield-based developer and manufacturer of smart Additive Manufacturing systems, has developed a new generation green technology to be used in its vapour-based BLAST smoothing process.

The adaptation of such technology would replace traditionally pollutant post-processing methods thus increasing the sustainability and environmental factor in the whole 3D printing process cycle. This follows multiple announcements, policy changes and numerous grants for the industry to move towards clean sustainable technologies and replace old polluting equipment.