3D Printing
Certain types of 3D printing have already been in existence for over 20 years. The basic concept behind 3D printing is that it is an additive manufacturing process that creates three dimensional objects using a digital file. In relation to subtractive processes which “remove undesired materials to achieve desired forms” (Brown, 2012), additive manufacturing “has to do with combining multiple elemental components, each of which is usually obtained through subtractive processes” (Brown, 2012).
The elemental components may be made up of different metals, plastics and composite materials. The elemental components take a powdered form that is first placed on a building platform. As the platform moves upward more layers are added and a laser beam is used to fuse the layers together, eventually producing a prototype (For Technology-Interested, 2015). These prototypes “let you discover performance issues and correct them before you invest in product documentation, tooling and manufacturing” (Functional Prototypes, 2015). They allow for changes to be made efficiently without the additional cost.
The design for the prototype is generated in a computer aided design file that uses either a 3D modeling program or a 3D scanner. The use of either one depends on whether a new object needs to be created or if an existing one is being copied. Regardless, the object design is put into a 3D modelling program and the software slices the object into horizontal layers that the printer will copy layer by layer (What is 3D printing?, 2015). There are several forms of 3D printing. Selective Laser Sintering and Fused Deposition Modelling use softening materials to make the layers and Stereolithography uses liquid layers.
Specifically, Selective Laser Sintering “requires very little additional tooling once an object is printed, meaning that objects don’t usually have to be sanded or otherwise altered once they come out of the SLS machine” (Palermo, 2013). Fused Deposition Modelling is the “the only professional 3D printing technology that uses production-grade thermoplastics, so parts are unrivaled in mechanical, thermal and chemical strength” (FDM Technology, 2015). Lastly, Stereolithography “employs a vat of liquid ultraviolet curable photopolymer resin and an ultraviolet laser to build the object’s layers one at a time” (What is 3D printing?, 2015).
An example of the more commonly used 3D printing process, Selective Laser Sintering, can be seen in the image below:
3D Printing in Healthcare
Three dimensional printing is changing the world of medicine. In the healthcare system 3D printing is being used to create end-use medical devices, a variety of implantations and to create realistic surgical models to practice on before operation (Groopman, 2014). It has also aided in the development of prosthetic parts and in cancer research as “printing cancer cells is a way of growing these cells on tissue in a lab to study, test drugs on and to eventually find a cure for” (Honigman, 2015). This is only the beginning as researchers are working on new ways 3D printing will improve the healthcare sector in the future.
As an example, in 2012 a 3 month old boy had “Tracheobronchomalacia: the tissue of one portion of his airway was so weak that it persistently collapsed. This made breathing very difficult, and it regularly blocked vital blood vessels nearby … triggering cardiac and pulmonary arrest” (Groopman, 2014). The doctors were able to use 3D printing to create a “splint—a small tube, made of the same biocompatible material that goes into sutures—that would fit snugly over the weakened section of airway and hold it open” (Groopman, 2014). The splint was flexible and lasted 3 years which gave it enough time for the cells to build over and dissolve it. As a result the boy was fine and grew up with no issues regarding the splint.
Benefits
The two main benefits of 3D printing in the healthcare industry are savings in cost and time. Starting with the medical product manufacturers, they are now able to deliver clinical trial products effectively and efficiently to the market. 3D printing enables them to evaluate products and make changes immediately, cutting down the time it would normally take to do so and the costs associated (Medical, 2015). Costs reduced include external failure costs and prevention costs because there are less operational procedures and training required.
Manufacturers can also make any medical device necessary, regardless of their size, which used to be a problem due to the intricate detail involved. As for surgical teams, 3D printing improved the way they treat patients. They can now develop alternatives for complex surgical procedures in order to predetermine the best possible outcome (Medical, 2015). In a sense, 3D printing is just in time delivery and one of the leanest examples of managing inventory because it reduces the stock on hand and can be made for delivery right away (Scott, 2015). Any alternatives not used can be kept on hand to use as models for future patients and personalized to their needs, similar to delayed differentiation.
This recognizes another benefit of 3D printing and its ability to improve the quality of life for patients in the healthcare industry. Shahid N. Shah, chair of the HealthImpact Conference, states “3D printing allows personalization and customization to the extreme and there’s nothing that requires more customization or personalization than devices connected to or replacement parts of any human body” (Diana, 2014). Tailoring parts to the needs of any individual makes the process much more simple, fast and inexpensive.
Challenges
Although 3D printing saves money in the early stages of production it makes it more difficult to expand in the long run. In the likelihood of mass customization and production, both are possible in the medical field using 3D printing, however there are challenges accompanying each one. Only products with a single purpose can be customized which means limited materials can be produced commercially. Furthermore only unique products that can’t be manufactured through traditional methods can be mass produced, large products surpass the capabilities of a 3D printer. It can also be more costly to produce in high quantities, using 3D printing, so it is hard for manufacturers to achieve economies of scale (Halmes & Pierreu, 2015).
With the progress 3D printing has made in the past 20 years it can still pose as a risk “because people are still trying to figure out what exactly it means and how 3D printing works. Another risk to consider … is that the technology is catching up to the point where commercialized products can be scanned to 3-D print knock-off products, which could mean bad products reaching the market” (Pedersen, 2014). This challenges the Food and Drug Administration (FDA) to continue to build well developed assessments of future product submissions. This also challenges the laws regarding intellectual property and questions the liability of manufacturers or services in the industry if a consumer makes a faulty product or part (Sherman, 2015).
Ethically, 3D printing contradicts the values of the healthcare system. It is used to better the quality of life for patients through lower costs, less time delays and innovative recovery devices but it imposes harm on those who use it. According to researchers at the Illinois Institute of Technology “the emissions from desktop 3D printers are similar to burning a cigarette or cooking on a gas or electric stove” (Gilpin, 2014). The researchers were the first to test the emissions and also found that “while heating the plastic and printing small figures, the machines using PLA filament emitted 20 billion ultrafine particles per minute, and the ABS emitted up to 200 billion particles per minute. These particles can settle in the lungs or the bloodstream and pose health risk” (Gilpin, 2014). This may pose as a challenge to managers in finding solutions that prevent these health risks from effecting their employees.
Future of 3D Printing
Three dimensional printing is revolutionizing the healthcare industry and growing at a high rate. A study done by Visiongain, one of the fastest growing business intelligence providers, recorded that “in 2013, there was a $1.2 billion market for 3D printing in healthcare; by 2018 that will increase to over $4 billion” (Diana, 2014). It will advance to develop skin grafts, knee cartilage and small heart valves. This will be done through bioprinting which will use a blend of living cells known as bioink to print living tissues (Lee, 2014). The next step will be the printing of human organs including kidneys, pancreases and hearts which will have a huge impact on the industry by “reducing the lengthy transplant lists, improving the chances of recovery and possibly even controlling or curing chronic diseases, like diabetes (Lee, 2014).
One last step added to the operations of 3D printing may be to add in electronics. Markus Fromherz, Xerox’s chief innovation officer in healthcare explained “artificial knees could include sensors to measure the pressure and health of the knee, connected wirelessly to an app or provider software” (Doyle, 2013). Not only will 3D printing change the scope of operational capability it will also change the framework of operations. It is predicted that with its “flexibility to build a wide range of products, coupled with the fact that 3D printing can be done near the point of consumption, implies a serious change to supply chains and business models. Many steps in the supply chain can potentially be eliminated, including distribution, warehousing and retail” (Koff & Gustafson, 2015).
Manager’s Responsibility
Managers in the healthcare industry will need to ensure they are maintaining three aspects of their workplace in order to successfully fulfill their roles and responsibility. The three aspects to be aware of are:
- Time-to-market for products shrinks
- Open design is here to stay
- Internal barriers
The time-to-market will shrink due to the rapid prototyping cycles as a result of 3D printing. There is also no need for factory set up or tooling meaning that the competitive advantage of agility is an advantage no more. Managers will need to maintain an agile workplace to stay alive in the industry. The open design suggests that the consumer will have more say in the design of products and parts. What is most suited to them will matter more so consumer insight is key for managers to recall during the manufacturing process to stay ahead of competitors.
Lastly, internal barriers such as culture need to be managed going forward. Traditional manufacturing processes need to change to fit the needs of 3D printing in the healthcare supply chain as new entrants will have new methods in comparison to existing market holders. Internal barriers can prevent necessary change and it is up to the managers to identify and monitor these barriers (Koff & Gustafson, 2015).
Midterm Question
What three factors do managers in the healthcare industry need to be aware of in order to facilitate a successful workplace amidst the influence of 3D printing?
Works Cited
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Doyle, K. (2013, August 22). 3 Ways 3-D Printing Could Revolutionize Healthcare. Retrieved from Forbes: http://www.forbes.com/sites/xerox/2013/08/22/3-ways-3-d-printing-could-revolutionize-healthcare/
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Groopman, J. (2014, November 24). Print Thyself. Retrieved from The New Yorker: http://www.newyorker.com/magazine/2014/11/24/print-thyself
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