The use of advanced 3D printing technology enhanced with component placement and electrical interconnect deposition can provide electronic prototypes that now can be rapidly fabricated in comparable time frames as traditional 2D bread-boarded prototypes; however, these 3D prototypes include the advantage of being embedded within more appropriate shapes in order to authentically prototype products earlier in the development cycle. The fabrication freedom offered by 3D printing techniques, such as stereolithography and fused deposition modeling have recently been explored in the context of 3D electronics integration—referred to as 3D structural electronics or 3D printed electronics. Enhanced 3D printing may eventually be employed to manufacture end-use parts and thus offer unit-level customization with local manufacturing; however, until the materials and dimensional accuracies improve (an eventuality), 3D printing technologies can be employed to reduce development times by providing advanced geometrically appropriate electronic prototypes. This paper describes the development process used to design a novelty six-sided gaming die. The die includes a microprocessor and accelerometer, which together detect motion and upon halting, identify the top surface through gravity and illuminate light-emitting diodes for a striking effect. By applying 3D printing of structural electronics to expedite prototyping, the development cycle was reduced from weeks to hours.
In terms of current users, 3D printing of PCBs today is generally done in research labs in enterprises and universities, defense industries, and among bleeding-edge, experimental electronics designers. Many of these users are now designing boards for riskier project ideas than they otherwise could, simply because an in-house DIY prototyping machine saves them serious time and money.
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For now, quicker turnaround and cheaper production are the two biggest benefits of 3D printers to PCB designers. They can turn a multi-week, $500 process involving a third-party prototype maker, often in Asia, into hours. Designers say that by eliminating third parties, they cut off an avenue to IP theft and reduce the risk of miscommunication. And with relatively tiny initial investment, 3D printers allow engineers to prototype more unproven ideas, a benefit of enormous value to IoT invention.
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