The Ice Breaker collection was inspired by the complex geometry and symmetry of ice as it cracks and splinters. By using the DMP process, 3D Systems is able to print an entire set of flatware at the same time with a shape that would not be possible with traditional metal manufacturing methods. The DMP process works like most metal 3D printing processes, a thin layer of metal powder is laid down on a printing bed, only rather than a laser simply sintering (melting the outside layer of the grains of metal to each other) the metal powder, the high-precision fiber laser melts each layer, completely fusing each grain together. Because the laser is so intense and the metallic powder melted so completely, each subsequent layer will bond directly on top of the previous layer without the need of bonding agents or any sort.
The metal objects created with DMP are fully dense with a homogenous microstructure and all of the produced parts have a density of 99.98%. With relative density levels that high, objects manufactured using DMP are essentially the same as objects produced using standard subtractive or casting methods. Because 3D printing is not restricted to the use of molds or the axes of metal milling machines, it can create objects with virtually any recesses, ribs, cavities or internal features. Essentially, designers are limited only by their imaginations and the capabilities of their CAD software.
Because the parts are literally assembled from small grains of metal powder, once a complete part is printed it will have a rough, sandpaper like finish. However the parts can easily be polished, making them completely smooth and indistinguishable from traditionally manufactured metal parts. The Ice Breaker collection is meant to be used with food, so for obvious reasons 3D Systems and Kyttanen chose to 3D print the flatware in stainless steel. However, the DMP process is also capable of printing complete parts in both Aluminum and Titanium, with several new materials on the horizon.
But before you get excited about the idea of custom 3D printed flatware, the DMP process is still pretty new, and at the moment quite pricey. While 3D Systems didn’t provide a cost to have the complete Ice Breaker set printed with their Quickparts service, it probably isn’t going to be cheap. The metal 3D printed sink faucets that I wrote about back in June were expected to range in price from $12,000 to $20,000, so an entire set of flatware is probably going to be priced well beyond most of us. However you can certainly request a price quote if you find yourself with a few thousand extra dollars to spend on silverware.
As with any technology, the more that it is developed, the faster that its price is going to drop. It isn’t out of the realms of possibility that in a few years anyone will be able to design their own customized flatware with complex geometries and have it affordably 3D printed for them. Let us know what you think of metal 3D printing technology and the Ice Breaker Metal 3D Printed Flatware Collection over at 3DPB.com.