How can the production of the future be decarbonized? For the first time, three speakers took the stage at a Future Lecture to shed light on the focus topic from as many perspectives as possible. Additive Manufacturing (AM), commonly known as 3D printing, was the central keyword of the tenth edition of the Future Lectures on November 19th in Audimax 2 at TU Hamburg. Where does this technology currently stand, what can it do – also regarding a more sustainable industry – and what are the challenges or brakes?
What a Mars Mission and a Sneaker Have in Common
Prof. Ingomar Kelbassa, head of the Fraunhofer IAPT in Hamburg and professor for the industrialization of smart materials at TUHH, gave a comprehensive insight into the current state of additive manufacturing. He took the audience through an impressive range of current applications of 3D printing – from the Mars mission, life sciences, and the automotive industry to locally produced sneakers. Using concrete cases, he demonstrated the advantages and thus the future viability of additive technology – in terms of product quality, production time, costs, and sustainability. “3D printing is a key factor for next-generation parts and components that drive change,” said Kelbassa. In his estimation, “bio-printing,” i.e., printing organs, could be possible in ten to fifteen years, at least theoretically.
“We Are Still at the Beginning”
Prof. Frank Piller from RWTH Aachen, one of Europe’s leading scientists in digital industrial transformation, gave a rapid historical overview of “3D printing.” He discussed factors that influence the scaling, diffusion, and long-term adoption of technologies, making clear: “We are still at the beginning.” The vision of local, decentralized production existed already twenty years ago. The leap from “early adopters” over the chasm to the “early majority” has not been achieved; hardly any private person owns a 3D printer, the cost factor is still high – and is critically weighed against the expected benefits. This hesitation also shows in industry. Although many companies have announced switching to AM, they have not implemented it. The future is unknown. A mistake, as Piller believes, looking at his shoes, a 3D-knitted model. Sixty percent of all shoes made do not please or fit consumers, while highly demanded models sell out. 3D production could provide quick relief here and is particularly customizable and promising for local markets.
Getting to the Shoe
The third speaker of this Future Lecture, Lennard Stoever, co-founder and president of Zellerfeld Shoe Company Inc., arrived on strikingly red, springy soles and thus introduced the actual hero of the evening: completely 3D-printed sneakers, made in Hamburg. Sustainability was especially important to him when founding the company. Because billions of shoes are produced annually, a high proportion of which ends up unworn in incinerators. According to estimates (for example Greenpeace), this proportion is around 30 percent; others speak of over 90 percent (Wirtschaftswoche) of all produced shoes. “Less waste starts with not producing waste,” emphasizes Stoever, highlighting a crucial advantage of AM. With AM, production can always be on demand, thus excluding overproduction. The red model on his feet was developed in cooperation with Nike. The hype around the recyclable, individually foot-fitting sneakers made in one piece is now so big that Stoever and his team urgently need to expand, preferably decentralized and close to the customer. The vision: a truly circular platform – for far more than just shoes, to create a better system for the Earth and consumers through the combination of design and sustainability. In response to a question from the moderator and Vice President for Research at TUHH, Irina Smirnova, about what the greatest challenge is for science despite all the innovation and sustainability potential of AM technology, the three speakers agreed: Systematic changes are necessary, both within companies and especially in the cumbersome regulations and laws in Germany, which often cause delays of years.
