Large scale printing

Pieter Malegeer, co-founder of Footprint Inc., discussed his journey from control and automation engineering to founding a 3D print service company specializing in large objects. He highlighted the challenges of transitioning from small 3D printers to refurbishing robotic arms for large-scale printing. 

Q: Introduction: Could you briefly introduce yourself and your background in 3D technology?

Hi, my name is Pieter Maelegheer, I am a control and automation engineer. My interests have always been to mechatronics, robotics. I came in contact with 3D printing by turning an old robot arm into a 3D printer. Since then my interests grew and together with the wish to start my own a company, I have founded Footprint inc. Afterwards I came in contact with the smaller - of the shelf - printers as there is still a lot of potential to be explored there. 

Q: What do you find most fascinating about 3D printing/scanning in your field?

The creation from nothing to an object in front of you was for me like magic. Especially when it was something big, like a chair. 

Also the fact that you build it up layer by layer and that you don't destroy anything. I think that is still magnificant. Together with the quite low entry level compared to other manufacturing processes. 

Q: Can you share a specific example where 3D technology has had a significant impact?

If you think about real impact, I always think about the orthopedic aids for examle. You can really customise at a personnel level by 3D scanning and also produce it to fit for you with no change in tooling. 

Q: What new careers are emerging in this field, and what skills are essential for them?

In light of the impact described above, I think about the steps to make that customization process smoother. For example, you can do a 3D scan today and print it quite fast (for one piece), but to scale it you'll need to optimise all the steps in between as well. That often means an integration between tools from 3D scan to 3D drawing to slicing to eventuelly producing.

Another point that needs more attention is the focus on material level and the properties of an endpiece. 

How strong is the piece really in all directions. Can we simulate that in a proper way, and are we able to give guarantee some properties. 

Q: What's a common misconception about 3D technology that you'd like to address? 

You can start printing quite fast, but to do it optimally you still need to understand the materials and how everything properly works (from software to hardware). 

Another misconception is that it will replace traditional manufacturing. This is not the case, it is very complementary. Especially for the large pieces. They always win when it comes to very organic forms, but not for straight pieces. 

Q: What advice would you give to young people who want to enter this industry?

Understand materials and how the different techniques work. And find the field that interests you. It is applicable to a lot of sectors. From Aerospace to medicine to furniture...