High-speed 3D Printer & IoT Could Really Revolutionize Design & Manufacturing

Posted on 10th August 2016 in 3-D printing, automotive, design, environmental, Internet of Things, logistics, management, manufacturing, marketing, supply chain

There’s a new high-speed 3D printer on the horizon which, coupled with the IoT, could really revolutionize product design and manufacturing.

I’ve raved in the past about 3D printing’s revolutionary potential, but I’ll admit I was still thinking primarily in terms of rapid prototyping and one-off repair parts.  Now, according to Bloomberg, HP is going to transfer its ink-jet printer expertise to the 3D printer field, with a $130,000 model set for release later this year that, for the first time, could make 3D printing practical and affordable for large-scale manufacturing, with “parts at half the expense and at least 10 times faster than rival printers — and likely [using] lower-cost materials.”

Combined with the IoT, that would go a long way toward making my “precision manufacturing” vision a reality, with benefits including less waste, streamlined products (a single part replacing multiple ones that previously had to be combined into the final configuration),  factories that are less reliant on outside parts and encouraging mass customization of products that would delight customers. 

Customers are already lining up, and see manufacturing-scale 3D printing as a game-changer:

“Jabil Circuit Inc. [itself a digital supply-chain innovator] plans to be an early adopter of HP’s device, printing end plastic parts for aerospace, auto and industrial applications that it currently makes using processes such as injection molding, John Dulchinos, vice president of digital manufacturing at the electronics-manufacturing service provider, said in an interview.

“‘We have use cases in each of these segments,’ Dulchinos said. ‘Parts that are in hundreds or thousands or tens of thousands of units — it’s cheaper to 3D print them than mold them.’”

Other HP partners in the venture include BMW, Nike, and and Johnson & Johnson. The article cites research by Wohlers Associates predicting that manufacturing using 3D printers could “eventually grab at least 5 percent of the worldwide manufacturing economy, and translate into $640 billion in annual sales.”

3D Systems is also making the transition to large-scale 3D printing.

As I’ve written before in regard to GE’s leadership in the field, toss in some nanotech on the side, and you’ve really got something.

 

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Distributed Manufacturing by 3D Printing Revolution for IoT Comes of Age!

Posted on 12th July 2016 in 3-D printing, circular company, circular economy, collaboration, Internet of Things, manufacturing, paradigm shift

Two major developments in the 3-D printing world, from Fictiv and (who woulda thunk it!) UPS, make me think the time has come for “distributing manufacturing” and getting away from the old massive, manufacturing mentality exemplified by Ford’s River Rouge plant.

OK, first a confession and a little history. Being short & named David, I’ve always had a fascination with David & Goliath, and you can bet who I’d root for. I also was deeply touched by two visionaries in my past:

  • Steve Clay-Young, who used to run the workshop at the old Boston Architectural Center & turned me on to a neat, nearly-forgotten bit of WWII history: either Popular Science or Popular Mechanix (can’t remember which), organized a network of hobbyists with metal lathes, who played a major role in the war effort. The magazine published plans for turning metal for munitions, and these guys each worked in their workshops to make them.
  • Eric Drexler, the nano-tech guru, spoke at the Eco-Tech conference in the ’90s about his vision of a bread-box-size gizmo on your kitchen counter that would churn out all sorts of customized products for you.

Now, it’s all taking place, and I suspect 3D printing will be a crucial element in the IoT-based transformation of the economy.

 

                                   Fictiv distributed manufacturing model

Fictiv is a startup founded to “democratize manufacturing,” which just went public with its new “distributed manufacturing” service using a nationwide network of 3D high quality printers and CNC machines:

 

“We route parts to machine with open capacity so you don’t wait 5 days for a part that takes 5 hours…. We aggregate orders so every customer receives the benefits of large purchasing power….”

Perhaps coolest, “Parts are produced as close to customers as possible to reduce inefficiencies in logistics and shipping lead-time”  so that (for an extra charge) they’re fabricated and delivered in 24 hours, and otherwise delivered in two days.  I suspect that, just as having sensors on their products that results in real-time feedback allowing GE to compress the design cycle, especially upgrades, that this proximity and quick turn-around will allow designers to radically alter the design process by “failing rapidly,” just the way early spread-sheet software allowed business managers to do “what-if” hypotheticals for the first time.

By bundling orders, they give startups the bargaining power of large companies.As co-founder Dave Evans, an experienced product design pro, says, distributed, local manufacturing can even the playing field for smaller companies, especially startups just designing their first products:

“When ordering from a large manufacturing company, parts need to navigate through their complex system and then be shipped from the machine warehouse direct to the customer, increasing lead times.

From an engineer’s perspective, when you’re in the prototyping and ideation stages, time is everything and even a 1-2 day loss from a 3PL (third-party logistics player) matters significantly.

What’s important to consider here is that in manufacturing, things can and will go wrong. So when remote manufacturers inevitably have to manage errors, there’s a lot of complexity to deal with …. This is very evident in overseas mass manufacturing, which is why companies put engineers as close to the source as possible. It’s amazing how few companies consider the same principles during the early prototyping stages of a product when time is everything.

The beauty in working with smaller, local manufacturers on the other hand, is that parts can be picked up as soon as they’re ready or delivered via same-day courier, saving you the 1-2 days of shipping. In addition, if things go wrong (they always do), smaller shops have more agility, fewer organizational layers, and in general can respond more quickly compared with their larger counterparts.”

              3D printing at The UPS Store

Equally important is the continuing stream of 3D services being offered by UPS. which recently announced a nationwide on-demand 3D printing network.  The network will combine 3D printers at more than 60 The UPS Stores® and Fast Radius’ On Demand Production Platform™ and 3D printing factory in Louisville, KY. My friends at SAP will marry its SAP’s extended supply chain solutions will be integrated with the UPS 3D network and — most important — its global logistics network “to simplify the industrial manufacturing process from digitization, certification, order-to-manufacturing and delivery.”

If I’m correct, the UPS network will concentrate on prototyping at this point, but it’s easy to see that it could soon have a dramatic impact on the replacement parts industry. Why should the manufacturer warehouse a large supply of spare parts, just because they might be needed, when they could instead simply transmit the part’s digital file to the nearest UPS 3D printer, generate the part, and use UPS to deliver it in a fraction of the time.

Combine that with the predictive maintenance possible with feedback from sensors on products, and you truly have a revolution in product design and maintenance as well as manufacturing. It would also foster the IoT-based circular company vision that I’ve been pushing, because supply chain, manufacturing, distribution, and maintenance would all be linked in a great circle.

Sweet!

 

 

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The IoT Will Reinvent Replacement Parts Industry

Posted on 12th August 2015 in 3-D printing, automotive, design, Internet of Things, maintenance, management, manufacturing, sensors

Of all the Internet of Things’ revolutionary impacts on industry, perhaps none will be as dramatic as on replacement parts, where it will team with 3-D printing to reduce service time, inventory and costs.

I came to that realization circuitously, upon noticing Warren Buffett’s blockbuster purchase of Precision Castparts, the major precision parts supplier to the aeronautics industry.  Having read last year about yet another breakthrough innovation by Elon Musk, i.e., the first totally 3-D printed rocket engines, I was curious to see what Precision was doing in that area.  Unless my search of their website was flawed, the answer is zip, and that suggests to me that Buffett, who famously once said he doesn’t invest in technology because he doesn’t understand it, may have just bought …. a rather large dinosaur.

I noticed that one of Precision’s biggest customers is GE, which not only is using 3-D jet fuel nozzles on its engines but also ran a high-profile contest to design a 3-D printed engine mount that was open to you, me and the kids trying out the new 3-D printer at our little town’s library (note to Mr. Buffett: might be good to schedule a sit-down with Jeff Immelt before one of your biggest customers takes things in-house). As I’ve written before, not only is GE a world leader in the IoT and 3-D printing, but also in my third magic bullet, nanotech: put all three together, and you’re really talking revolution!

OK, I know 3-D printing is sloow (in its current state), so it’s unlikely to replace traditional assembly lines at places such as Precision Castparts for large volumes of parts, but that doesn’t mean it won’t rapidly replace them in the replacement parts area.  I talked to a friend several years ago whose biz consists of being a broker between power plants that need replacement parts yesterday and others with an excess on hand, and couldn’t help thinking his days were numbered, because it was predicated on obsolete technology — and thinking.

Think of how the combined strengths of the IoT and 3-D printing can help a wide range of industries get replacement parts when and where they need them, and at potentially lower cost:

  • sensors in IoT-enabled devices will give advance notice of issues such as metal fatigue, so that repairs can be done sooner (“predictive maintenance“), with less disruption to normal routine, cheaper and reducing the chance of catastrophic failure.
  • because data can be shared on a real-time by not only your entire workforce, but also your supply chain, you can automate ordering of replacement parts.
  • perhaps most important, instead of a supplier having to maintain a huge inventory of replacement parts on the possibility they may be needed, they can instead be produced only when needed, or at least with a limited inventory (such as replacing a part in inventory as one is ordered). This may lead to “re-shoring” of jobs, because you will no longer have to deal with a supplier on the other side of the globe: it might be in the next town, and the part could be delivered as soon as printed, saving both delay and money.
  • your company may have your own printer, and you will simply pay the OEM for the digital file to print a part in-house, rather than having to deal with shipping, etc.

And, as I mentioned in the  earlier post about GE’s leadership in this area, there are other benefits as well:

  • “We’ll no longer do subtractive processes, where a rough item is progressively refined until it is usable.  Instead, products will be built atom-by-atom, in additive processes where they will emerge exactly in the form they’re sold.
  • “Products will increasingly be customized to the customer’s exact specifications. The products will be further fine-tuned based on a constant flow of data from the field about how customers actually use them.”

Sooo, Mr. Buffett, it’s time that you come to terms with 21-st century technology or Berkshire Hathaway’s financial slide may continue.

 

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GE & IBM make it official: IoT is here & now & you ignore it at your own risk!

Posted on 20th April 2015 in 3-D printing, cities, data, design, health, Internet of Things, m-health, M2M, management, manufacturing, mobile, open data, strategy

Pardon my absence while doing the annual IRS dance.

While I was preoccupied, GE and IBM put the last nail in the coffin of those who are waiting to launch IoT initiatives and revise their strategy until the Internet of Things is more ….. (supply your favorite dismissive wishy-washy adjective here).

It’s official: the IoT is here, substantive, and profitable.

Deal with it.

To wit:

The two blue-chips’ moves were decisive and unambiguous. If you aren’t following suit, you’re in trouble.

The companies accompanied these bold strategic moves with targeted ones that illustrate how they plan to transform their companies and services based on the IoT and related technologies such as 3-D printing and Big Data:

  • GE, which has become a leader in 3-D printing, announced its first FAA-approved 3-D jet engine part, housing a jet’s compressor inlet temperature sensor. Sensors and 3-D printing: a killer combination.
  • IBM, commercializing its gee-whiz Watson big data processing system, launched Watson Health in conjunction with Apple and Johnson & Johnson, calling it “our moonshot” in health care, hoping to transform the industry.  Chair Ginny Rometty said that:

“The Watson Health Cloud platform will ‘enable secure access to individualized insights and a more complete picture of the many factors that can affect people’s health,’ IBM says each person generates one million gigabytes of health-related data across his or her lifetime, the equivalent of more than 300 million books.”

There can no longer be any doubt that the Internet of Things is a here-and-now reality. What is your company doing to catch up to the leaders and share in the benefits?

 

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Is GE the future of manufacturing? IoT + nanotech + 3D-printing

Posted on 5th December 2014 in 3-D printing, collaboration, design, energy, environmental, Internet of Things, M2M, maintenance, management, manufacturing, open data, strategy

The specific impetus for this post was an article in The Boston Globe about heart stents that fit perfectly because they’re 3-D printed individuallly for each patient.

GE jet engine 3-D-printed fuel nozzle

That prompted me to think of how manufacturing may change when three of my favorite technologies — nanotech, 3-D printing and the Internet of Things — are fully mature and synergies begin (as I’m sure they will) to emerge between the three.

I’m convinced we’ll see an unprecedented combination of:

  • waste elimination: we’ll no longer do subtractive processes, where a rough item is progressively refined until it is usable.  Instead, products will be built atom-by-atom, in additive processes where they will emerge exactly in the form they’re sold.
  • as with the stents, products will increasingly be customized to the customer’s exact specifications.
  • the products will be further fine-tuned based on a constant flow of data from the field about how customers actually use them.

Guess what?  The same company is in on the cutting edge of all three: General Electric (no, I’m not on their payroll, despite all my fawning attention to them!):

  • Their Industrial Internet IoT initiative is resulting in dramatic changes to their products, with built-in sensors that relay data constantly to GE and the customer about the product’s current status, allowing predictive maintenance practices that cuts repair costs, optimizing the device’s performance for more economical operations, and even allowing GE to switch from selling products to leasing them, with the lease price determined dynamically using factors such as how many hours the products are actually used.  Not only that, but they practice what they preach, with 10,000 sensors on the assembly line at their Durathon battery plant in Schenectady, plus sensors in the batteries themselves, allowing managers to roam the plant with an iPad to get instant readings on the assembly line’s real-time operation, to fine-tune the processes, and to be able to spot defective batteries while they are still in production, so that 100% of the batteries shipped will work.
    They’re also able to push products out the door more rapidly and updating them quicker based on the huge volumes of data they gather from sensors built into the products: “… G.E. is adopting practices like releasing stripped-down products quickly, monitoring usage and rapidly changing designs depending on how things are used by customers. These approaches follow the ‘lean start-up’ style at many software-intensive Internet companies. “’We’re getting these offerings done in three, six, nine months,’ he [William Ruh] said. ‘It used to take three years.’”
  • They’ve made a major commitment to 3-D printing, with 100,000 3-D printed parts scheduled to be built into their precision LEAP jet engines — a big deal, since there’s not a great deal of fault tolerance in something that may plunge to the earth if it malfunctions! As Bloomberg reported, “The finished product is stronger and lighter than those made on the assembly line and can withstand the extreme temperatures (up to 2,400F) inside an engine.”  They’re making major investments to boost the 3-D printers’ capacity and speed.  Oh, and did I mention their precedent-setting contest to crowd-source the invention of a 3-D printed engine mount?
  • They’re also partnering with New York State on perhaps the most visionary technology of all, nanotech, which manipulates materials on the molecular level. GE will focus on cheap silicon carbide wafers, which beat silicon chips in terms of efficiency and power, leading to smaller and lighter devices.

GE is the only member of the original Dow-Jones Index (in 1884) that still exists. As I’ve said before, I’m astounded that they not only get it about IoT technology, but also the new management practices such as sharing data that will be required to fully capitalize on it.

Thomas A. Edison is alive and well!

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My O’Reilly blog post about how the IoT will transform manufacturing

Posted on 29th April 2014 in 3-D printing, Internet of Things, M2M, manufacturing

Woopiedoo! I have a post in today’s O’Reilly SOLID blog (which is, among other things, promoting their SOLID conference in SF next month) about how the Internet of Things will transform manufacturing.

In it, I emphasized the manufacturing variation on the two transformative aspects of the IoT that I think will characterize its effect on every aspect of our lives and economy:

  1. for the first time, we will have real-time information on the current state of all sorts of things
  2. we will also be able to share that information, again, on a real-time basis, with everyone who could benefit from that information.

We’re already starting to see signs of that transformation, with GE’s Durathon battery factory (with 10,000 sensors on the assembly line plus others designed into the batteries themselves), SAP’s Future Factory, and Siemens’ Electronic Works factory.  As the price, size and energy demands of sensors continues to plummet, the trend will accelerate.

As a result, manufacturing will no longer be isolated from real-time activities in the rest of the enterprise:

  • “Designing sensors into products, rather than adding them on retroactively, will allow companies to identify defective products immediately, rather than waiting for post-production testing.
  • The built-in sensors will also allow companies to create new revenue streams. They will be able to sell customers real-time data on product operations that will allow the customers to optimize their use, and they may also choose, instead of selling the products, to lease them, with the price determined dynamically based on how much the product is actually used — take, for instance, jet turbines that are now priced on the basis of how many hours they actually operate.
  • The product design cycle will accelerate. Companies will be able to monitor a product’s actual usage in the field, then implement more rapid upgrades.
  • ‘Just-in-time’ supply chains will become even more efficient as real-time production data triggers resupply orders, just as distribution systems will become more closely integrated on the other end of the production cycle.”

The SOLID conference focuses on the convergence of hardware and software. It’s about time the two are fully integrated, and the results will be incredible!

 

 

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First survey of C-level execs’ view of the IoT

Posted on 30th October 2013 in 3-D printing, design, Internet of Things, M2M, management, manufacturing, marketing

For a big project I’m working on, I’ve fruitlessly combed the Web for surveys of C-level executives’ view of the Internet of Things — until now!

ARM has just released results of a worldwide June survey, “The Internet of Things Business Index: a quiet revolution gathers pace,” that included many C-level executives, which the Economist‘s Intelligence Unit did for ARM about respondents’ attitudes toward the IoT.

I’d strongly advise you to read the entire report for a reality check on the current state of the IoT (provided, of course, that the sample population really reflects corporate attitudes as a whole — in my mind, that’s a big if, because most companies just haven’t been disclosing much information about IoT initiatives. Of course that might be because they view IoT initiatives as a real strategic advantage!).

I was happily surprised, given the low level of business media coverage of the IoT until recent months, to see how many of those surveyed knew about the IoT and were actively involved in planning for corporate initiatives, although most of those initiatives were only in the early research stages and most companies weren’t convinced the IoT would be of major near-term benefit.

The report concluded that companies are taking the IoT seriously, although without a lot of public notice:

“The Internet of Things (IoT) is an idea whose time has finally come. Falling technology costs, developments in complementary fields like mobile and cloud, together with support from governments have all contributed to the dawning of an IoT ‘quiet revolution’. Now, after more than a decade of slow progress, the business community is beginning to look seriously at the IoT—to the extent that a mere 6% of business leaders believe that the idea of IoT is simply hype…”

Here are the major findings:

  • “over three-quarters of companies are either actively exploring or using the IoT. The vast majority of business leaders believe that it will have a meaningful impact on how their companies conduct business, yet there is some divergence about the wider effect it will have”
  • “optimism about the IoT is not yet matched by investment.” 96% expect to use the IoT in some way within 3 years, but they aren’t spending much on it: only 30% have increased their IoT spending by double-digits since 2012.
  • 61% think “companies that are slow to integrate the IoT into their business will fall behind the competition.” Consider yourself forewarned!
  • only 24% felt that the IoT would be “very relevant, used by the majority of the business” within the next 3 years.
  • “A lack of IoT skills and knowledge among employees and management is viewed as the biggest obstacle to using the IoT more extensively. To address these gaps, organisations are training staff and recruiting IoT talent, raising the potential for IoT talent wars. Others are hiring consultants and third-party experts, seeking to build knowledge and identify successful IoT business models.” (sounds like a lot of opportunity for our ilk!)
  • Here’s one that particularly resonated with me because of my relentless emphasis on collaboration as one of the “Essential Truths” of the IoT: “Companies must learn to co-operate with players across industries, including competitors…. businesses must be willing to adopt a different mindset. Successful IoT rollouts require interconnected networks of products and services, but few senior executives currently expect their business to become more co-operative with competitors as a result of the IoT. ” Oops: too bad for you — it ain’t just a technological shift, but an attitudinal one as well!
  • It’s going to lead to a data explosion. While companies think they’re up to this challenge, “….prior experience of storing and analysing large amounts of “big data” may lead them to underestimate the additional talent and skills needed to spot new uses and revenue steams emerging from it.” It will also increase needs for security and privacy. 

The Economist chose the ARM report as the setting to announce a new IoT Business Index, which will be updated to track progress toward actualizing the IoT. In the benchmark edition of the index, most businesses are in the “research” stage (at  point 4 on a scale of 1 to 10). They are more likely to use the IoT at this point for internal operations and processes instead of external products or services. As I’d expected, European companies are in the lead, and, among industries, manufacturing is the leading one. Hmm: wonder if that means a growing number are installing sensors on the assembly line?

The survey included 779 senior business leaders, among whom almost half (49%), were C-level executives or board members. The sample included:

  • 29% from Europe, 29% from North America, 30% from Asia-Pacific, and  12% from Latin America, the Middle East and Africa.
  • 19 industries. About 10% each from financial services, manufacturing, healthcare, pharmaceuticals and biotechnology, IT and technology, energy and natural resources, and construction and real estate.
  • The sample is evenly split between large firms, with an annual revenue of more than US$500m, and small and mid-sized firms.

All in all, I think this is an important reality check in terms of commercialization of the IoT. It seems that it’s increasingly on the corporate radar, but that hasn’t translated into a lot of concrete action. It will be interesting to track annual updates of The Economist‘s IoT Business Index to see if analysis turns into action.

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It’s Official: Tom Friedman Anoints the IoT; Plus Jobs Issue Is Raised!

Posted on 16th September 2013 in 3-D printing, Internet of Things, M2M, maintenance, manufacturing, services

OK, the Internet of Things is officially a Big Thing: Tom “World is Flat” Friedman wrote about it in the Sunday NY Times.

Friedman, searching for evidence of American “exceptionalism” in a bleak landscape of Capitol Hill paralysis, etc. zeroed in on GE’s “Industrial Internet” initiatives as a ray of hope. As he wrote,

“I wanted to see what new technologies, and therefore business models — and therefore jobs — it might be spawning that public policy, and education policy, might enhance. I have no idea whether or how G.E. will profit from any of these breakthroughs, but I saw the outlines there of three radically new business trends that the United States should want to dominate.”

One of those themes was how 3-D printing could streamline the design and production process.

The second, which I wrote about earlier, was the concept of crowdsourcing design, in particular the contest GE held to design a new jet turbine mount (more about that later!!!).

Finally, Friedman zeroed in on the IoT, specifically widespread use of sensors:

“Lastly, we are on the cusp of what G.E. calls ‘the Industrial Internet’ or the ‘Internet of Things’ — meaning that every major part of a G.E. jet engine, locomotive or turbine is now equipped with online sensors that constantly measure and broadcast every aspect of performance. Computers capture all this big data and use it to improve everything from the flight path to energy efficiency.”

He gave several examples, such as wind turbines and hospital beds, where data from sensors can help to optimize efficiency and cut operating costs. He pointed out that the data allows GE to create new services “… that offer not just to manage an airline’s or railroad’s engines, but how fast all its planes or trains go, how flight and train schedules are coordinated and even how its equipment is parked to get optimal performance and energy efficiency (aside to marketing managers: what kinds of services would the IoT allow you to introduce, perhaps replacing actual sales of products with leases based on use? Think about it!).

Friedman concludes, “Watch this space, even if Washington doesn’t: When everything and everyone becomes connected, and complexity is free and innovation is both dirt-cheap and can come from anywhere, the world of work changes.”

Indeed! Nice to have someone with Friedman’s clout recognizing the IoT is a paradigm shift!

MEANWHILE: Make certain to read the comments following the column. They are primarily negative, and zero in on one thing: the IoT’s threat to jobs. In particular, the critics focused on the GE engine mount design contest.  One was particularly pointed:

“According to CNNMoney, General Electric CEO Jeffrey Immelt pocketed $25.8 million in total compensation in 2012. That’s about $20,000 every hour and a half. How come 8 geniuses cost only 90 minutes of CEO time?”

You’ve gotta agree, $20,000 ($7,000 to the winner) is a pretty paltry sum considering what GE gets in return, and given readers’ suspicions that companies may let go their salaried designers and instead exploit freelancers (I’ve thought the same about some of the incentives offered by Innocentive member companies for some of the crowdsourcing projects that they’ve offered), you can bet that there will be more criticisms in the future if this becomes a common practice.

The IoT will undoubtably result in loss of some jobs — disruptive technologies do that — although optimists say they will create jobs as well. But if companies don’t want to reap a lot of criticism for their IoT initiatives, they’d better put some thought into the job creation aspect as well!

 

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GE Crowdsourcing Design For 3-D Printing Project

Posted on 1st August 2013 in 3-D printing, Essential Truths, Internet of Things, manufacturing, strategy, transportation

OK, I admit to losing all sense of objectivity on this one! After all, it hits all my sweet spots:

  • Internet of Things (AKA General Electric’s “Internet of Things”)
  • 3-D printing
  • crowdsourcing/collaboration.

As I wrote earlier, about GE’s collaboration with Electric Imp and Quirky, this exemplar of Industrial Age might (what could be more powerful than a GE locomotive???) really seems to get it that the Internet of Things is as much about new attitudes of collaboration and sharing data as it is about Internet technology.

GE jet engine mount

So it’s no surprise that Industry Week reports on a new GE initiative, soliciting crowdsourced designs for a new jet engine bracket that will be produced through 3-D printing.

As Christine Furstoss, technical director of Manufacturing and Material Technologies at GE Global Research, explains:

“‘For any industry to be successful, you really need to develop communities or ecosystems of partners and thought leaders…

‘No sustainable, established industry technology exists without multiple players, multiple styles of thought, multiple ways of growing … We feel like one of the best ways to stimulate that, to find the newest and best ideas, is to start with open collaboration.'”

Bravo!

Contrast that attitude with what is still all too prevalent, as summarized by Paul Horn, former senior vp of research at IBM:

“Horn remembers a time before open innovation — a competitive, suspicious era when innovative and great, transformative ideas were only allowed to grow in a tightly sealed vacuum.

‘When we built the Almaden Laboratory at IBM in the early 1980s, we put it south of Silicon Valley on purpose,’ he recalls. ‘In those days, our biggest fear was the leaking of intellectual property out into the valley.'”

I suspect that one of the biggest obstacles to full realization of the IoT’s promise will be the difficulty of leaving that old zero-sum game, my-gain-is-your-loss mentality behind!

I wasn’t aware that this latest competition, to design a 3-D printed bracket strong enough to support a jet engine on a commercial plane, is part of a 2-year crowdsourcing initiative, with approximately $20 million in prizes for products, designs and processes, especially in 3-D printing:

“‘We’re trying to find thought leaders in this area — people who may know through a technique they’ve devised or a piece of software that they’ve found or just their own experiences what is the best way to design with additive for real industrial parts,’ Furstoss explains. ‘We’re really at the birth of industrial additive technology. This is a way for us to build support for that community of makers.'”

Furstoss says the crowdsourcing competitions are no knock on GE’s own 50,000 engineers: “‘We have a platform in place that can put a student in his dorm on the same plane as our engineers,’ she says. ‘We’re making sure that people who may have ideas, may have skills, may have things to offer have an opportunity to bring them forward, no matter who they are.'”

It’s that kind of openness to not only new technologies, but also new management practices, that will give GE a huge head start over competitors that have yet to come to grips with the new reality: the Internet of Things!

 

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#IoT breakthrough! 3-D printing tiny batteries to allow “smart dust”

Posted on 1st July 2013 in 3-D printing, energy, Internet of Things, M2M

Last Friday my wife and I were driving through the wilds of Utah (aside: wow, is the West different from The Hub of the Universe!) when we chanced upon SciFri, which was doing a great segment about cool government-funded energy research (no, not the Solindra picking winners-type stuff, but real basic research that can lead to quantum leaps in performance).

One of the speakers was Prof. Jennifer Lewis, who has the all-time greatest academic title:  Hansjörg Wyss Professor of Biologically Inspired Engineering at the Harvard School of Engineering and Applied Sciences! Go biomimicry (just a little reminder, BTW, that nature has already solved every problem that we, as an advanced, information-based economy, face. Think not? The answer to your problem lies just outside your window: we’re just too divorced from nature to be able to see it!)!

OK, got that out of my system…..

Now for the big news: Prof. Lewis’ team and their associates at the University of Illinois have invented the Holy Grail for Internet of Things sensors: lithium-ion batteries the size of a grain of sand, created through 3-D printing (as you may remember, I blogged recently about the role 3-D printing could play in fully-realizing the IoT’s potential. Little did I think it would be this soon, and this direct a role)!

This is a game-changer when it comes to sensors: their size has been getting smaller and smaller, but the big obstacle to realizing Kristofer Pister’s vision of “smart dust” sensors so tiny and self-powered that they could be strewn about was that the batteries were still relatively big and clunky. Lewis’ breakthrough changes all of that.

lithium-ion batteries produced by 3-D printing

The batteries are built by printing precisely interlaced stacks of tiny battery electrodes, each less than the diameter of a human hair.

Here’s the process:

“In this case, the inks also had to function as electrochemically active materials to create working anodes and cathodes, and they had to harden into layers that are as narrow as those produced by thin-film manufacturing methods. To accomplish these goals, the researchers created an ink for the anode with nanoparticles of one lithium metal oxide compound, and an ink for the cathode from nanoparticles of another. The printer deposited the inks onto the teeth of two gold combs, creating a tightly interlaced stack of anodes and cathodes. Then the researchers packaged the electrodes into a tiny container and filled it with an electrolyte solution to complete the battery.”

The research was funded by the National Science Foundation and the DOE Energy Frontier Research Center on Light-Material Interactions in Energy Conversion.

This is so exciting. Now to commercialize the technology and to turn our attention to the real obstacles to the Internet of Things: privacy and security problems!

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