What is in this article?:
- The Father of 3D Printing Looks Ahead
- They're All My Children
When Chuck Hull invented stereolithography in the early 1980s, he had some ideas about what it might spawn, but he could have never imagined the scope of the current 3D-printing world. Now the CTO of 3D Systems, the company he founded in 1983, Hull is the benevolent father figure of a booming industry.
Manufacturing is rapidly changing, so when we’re talking about deployment, we’re not talking about some ancient assembly line. The people we talk with are already fully into digital manufacturing."
- Chuck Hull
Title: CTO and founder
Organization: 3D Systems
Career highlights: Invented stereolithography in 1983 and is credited with the first issued patents in what is now considered 3D printing
The IndustryWeek Manufacturing Leader of the Week highlights the manufacturing leaders, executives and stars who are driving growth in today's industry and helping to shape the future of manufacturing.
HANNOVER, Germany — Where would the world of additive manufacturing be today without Chuck Hull? It would still exist, certainly, in some form or another, but it would look markedly different.
Hull invented stereolithography and founded 3D Systems back in the early 1980s, around the same time Carl Deckard invented selective laser sintering and Scott Crump invented fused deposition modeling. Hull was the first to apply for and ultimately be issued patents, though, the first of which he received in early 1986. Thirty years later, those early patents have entered into the public domain and opened the door for more development than ever.
Hull, who recently celebrated his 77th birthday and his 30th anniversary with 3D Systems, where he now works as the chief technology officer, discussed his thoughts on no longer really owning those first patents during a long conversation on the show floor at Hannover Messe in Germany. He also addressed what might be in store for the additive manufacturing industry and how its history could help it continue moving forward.
He also laughed, a lot. Hull is a champion for additive manufacturing — though that should come as no surprise — and just talking about it puts him in a great mood.
IndustryWeek: Thirty years in now, what’s new with 3D Systems?
Chuck Hull: We’re expanding into some bigger systems, some titanium-based systems, and we just showed that at the St. Louis Additive Manufacturing Users Group Conference. The other thing we’re talking about that’s new is we have a video, a technology demonstration, of a product we haven’t named yet. We’re calling it Figure 4 because it’s derived from our initial Figure 4 patent, and it’s a new development of something I thought of over 30 years ago — new materials, new methods.
IW: Still building on those early patents.
CH: It’s a programmable injection molding machine, it has the same kinds of speeds but you don’t need a mold, you don’t need to design for injection molding, you just need to send it your files and you can start producing parts. ... This kind of printer is anywhere from 20 to 50 times as fast as the currently typical stereolithography system. The other major advantage with the small material supply is that we don’t worry so much about things like vat life. A large, typical stereolithography system, the material sits there and you want it to last a year, two years, three years before it might start to lose its holding ability. With a little, small vat, you’re changing that several times a day. That lets our chemists not worry so much about traditional stability, and we can run more reactive chemistries and we can get more physical properties. We have the combination of new printer materials and high speeds, so our idea now is not to make a traditional printer.
IW: Who might put this to use in manufacturing? Is it designed to appeal and bring in new users?
CH: It really opens the door to anybody who makes plastic parts. This is not a new idea — everybody would like to make plastic parts with 3D-printing — so it’s not like a mystery as to who would use this. Lots of people have talked with us about this, and they’ve talked with every other 3D-printing company. The question is, What do you do about it? Our answer is, You can just gang as many of these together as you need — these are not as expensive as a typical stereolithography system — and then automate that. The automation, with 3D-printing, you sort of get this wet part, and the automation here takes care of that, cleans it up and so from a factory point of view now you’re just taking these parts and where do you go next with them?
IW: The industry is a little different than it was in the early 1980s.
CH: There was no industry. (Laughs) I was developing this in the back room of a little company in San Gabriel, California, and got the first 3D-print to work in 1983, a little top, and then worked on other test parts. It got to the point where we needed a patent application in ’84, and that processed and issued in ’86. So I’m at this little company, saying, OK, we need to commercialize this, and the president says, Great, but we can’t afford that. So I spun out another company, and that was the start of 3D Systems. That was really the first additive manufacturing and 3D-printing. … Of course, all those patents are expiring now.
IW: What’s the emotion there? What’s the feeling, seeing these patents go out for public consumption?
CH: There are lots of thoughts there. For lots and lots of years, we always had to explain what 3D-printing was and why people should care. Then everybody knew what it was, and we went through this hype period. We’re through that hype and now, I think, people have realistic expectations and knowledge about where it is. In terms of patents expiring, that certainly opens it up for a lot of people to work in this field — not just our patents, either. … Every new product, though, has lots of new patents associated with it — to actually advance ideas takes new patents — so there are more patent applications now. I lose track with how many patent applications are in this field now, a few hundred per quarter.
IW: How many do you have?
CH: I have about 85 (patents), I think.
IW: They’ve all helped change and evolve the industry, I imagine.
CH: It’s just a huge field now — not just patent applications, but publications, new products, research going on all around the world with government and universities. I’m supposed to keep track of all this, and I can’t anymore. I just try to find the stuff that we think has growth significance.