All the Food that’s fit to Print: The extraordinary ascent of 3D Printing

The use of 3-D printing in AgTech

Prior to the current pandemic the most exciting example of what young people can do to wield the power of 3D printing occurred when two students at the University of Eindhoven, started a new venture, under the name Upprinting Food. Using food waste to fashion edible creations, they started with bread, and one of them mashed it with herbs and spices into a full flavor paste, where she printed it and then baked it to produce bright and attractive shaped snacks. 

As Covid-19 has evolved even more astonishing stories have emerged as students, from middle schools, high schools and universities have used 3D printers respond to the demand for personal protective equipment (PPE). Citizens, universities and industry have joined forces to design and create face masks in a united effort to protect frontline workers. The far-reaching implications of the 3D printing technology, which allow the design, sharing and replication of PPE has helped protect people and save lives. There is no doubt; the power of 3D printers is ready to change the world like never. 

3D printers is a transformative technology going mainstream. Originally created with industrial purposes in mind, the technology has already revolutionized several fields including aerospace, medical, dental, consumer goods, even national defense. The opportunity to create and replicate faster, on site and at lower costs has propelled the technology forward: What you can draw, you can create. From tiny working drills to full-sized operable boats there are myriad applications for 3D printers. 

3D printers are also making their way into people’s homes. Prices of consumer have dropped 80% in the last 10 years and the simplest one will set you back just $150. Originally seen as more of a novelty technology, now people can download designs and use CAD (computer-aided design) software to build some really cool products, such as this life-sized Lamborghini. If there is any doubt that 3D printing is a transformative technology, see how doctors can bioprint tissue and organs using an old laser jet printer.

What is it exactly?

3D printing technology was invented by Charles Hull in the early 1980’s. A form of additive manufacturing where layers of material are added one at a time, on top the last layer, such that photopolymers build up cross-sectional layers into a model. 3D printers evolved into two basic techniques, the original was Fused Deposition Modelling (FDM) and more recently Stereolithography, which uses a laser to shape and harden liquid resins. More recently new techniques that are faster are being experimented with, including chemically growing the object. There are now more than 10 different types of 3D printers incorporating all types of materials, including plastics, powdered metals, and even food. Even as the cost of the printers dropped their abilities have significantly improved. All of which has helped with the speed of adoption. 

While 3D printers have massive potential the challenge of meeting the needs of Covid-19 has also demonstrated the deficiencies that the technology has in its current iteration. It can take 2.5 hours to print a single protective mask, and the materials aren’t necessarily as robust or prepared for the rigors of hospitals and patient care as commercially available equipment. This points to the current challenge of 3D printing, but also where there is room for the next leap forwards in the technology. 

What’s happening now in ag

The early adopters of 3D printers included industries such as manufacturing and automotive. Now engineering, healthcare, consumer products, architecture, even jewelry, are all expected to invest billions more in 3D printing technology in the next decade. Agriculture doesn’t feature on the list in one recent market report, but the potential of 3D printers to contribute to food production and farming is enormous. 

Models and Prototypes

The application of 3D printers in the early 1980’s was presumed to be prototyping. A fast, low cost way to evaluate potential ideas, with could allow customization and reducing waste. Technotill was one of the first to created a patented to experiment with different R&D concepts. Typically, costing thousands of dollars and weeks to work through the different prototypes, they connected with Framework Animation and within a few days had their first prototype. It worked, and at a cost of a few hundred dollars it revolutionized thinking of how to innovate.

Tooling

One of the biggest opportunities to employ 3D printers in agriculture is the printing of tools. John Deere doesn’t use 3D printers to create end user products; they are incorporating them into their own production. Described as a “game changing technology” they are backing their words with actions. Fifteen years ago, John Deere had one 3D printer. Now they have over 40 working on the John Deere assembly line, printing tools for more efficient production, including printing moving parts cutting down on assembly time and costs. The opportunity for mass customization is a significant benefit of the 3D printer.

Scale modeling

Scale modeling is another application. This could be applied a couple of different ways. First, it would be useful for prototyping as mentioned before, testing the potential of a larger version of a machine or tool. Secondly, it could be used to design planters optimized based on field experience, in almost real time. From a crop standpoint, this could provide producers the opportunity for improved harvest and therefore profitability. When used as a scale model for building development, scaling can provide insight into locations for building structures and waterways, which could prevent disastrous outcomes otherwise. 

Functional & replacement parts

3D printing can generate significant value building functional or replacement parts. Farming machinery is expensive and often producers operate machinery long beyond a machine’s lifetime. This makes replacement parts sometimes hard to come by. 3D printing allows famers to build their own parts, either from an online source or from their own design.  

The benefit of the ability to create a part on demand, particularly in more rural or remote areas. When a machine is down, the field can’t be plowed, or the crop harvested. Ordering a part online may take several days for post-delivery, whereas 3D printing can often produce the part within a day’s time or less. When it’s harvest time, even a few hours can make a critical difference in profit and loss. HogSlat, a US-based company has the technology to print plastic prototype machine parts for pig farms.

Some companies and universities are even joining forces to re-create parts for animals, such as a certain rooster’s feet, which were both unfortunately lost due to sever frostbite. Dudley the duck was also a recipient of a much-needed prosthetic leg. Not only are these fun stories, but they are valuable lessons that could one day save valuable breeding stock for farmers and producers.

Urban farming/Indoor gardening

Farmshelf, a startup in New York, builds systems for indoor and urban farming. The company uses 3D printers to develop prototypes, then tested to determine practicality and functionality. Farmshelf attributes its ability to design and scale its product offering quickly and cost-effectively to the application of 3D printing technology. 

Hexagro is also using 3D printing to build its “living farm trees,” which are artistically designed vertical aeroponic gardens for indoor farming. Currently the company is using recycled plastics, but it is testing with biodegradable plastics for potential future use. Hexagro aims to bring its technology to urban companies and eventually individuals seeking to improve their personal wellness, something that has become of increasing concern to many of us in recent months. 

3Dponics offers downloadable instructions for printing hydroponic systems. They see opportunities n aquaculture, but also it can be the next phase of personal at-home aquaculture gardens. 

The potential of algae

Outside the typical spectrum of 3D printing opportunities in agriculture, seaweed can be used to create renewable and environmentally friendly materials for the creation of medical implant devices. Several components have proven useful, including alginate, which has been used to help in the regrowth of bones and teeth and a gelling substance, known as ulvan, which is used for its bioactive and cell carrier properties. 

Algae has also come into its own as a bioplastic to replace plastics made from fossil fuels. The production of algae plastics is carbon negative, an improvement over most fossil fuels.

Food and health

3D printing in the food and culinary industry will grow over the next few years since the technology applications are wide reaching and versatile. Chefs use pureed food to build artistically designed meals. The process uses the purest form of the product, no additives are necessary, which makes it simple, healthy and adaptable. 

3D food printing has become particularly appealing in hospitals where there is a need for soft food. Often visually unappealing, 3D printing allows for meals with this characteristic to be prepared in a much more appetizing manner. It also allows for very personalized food preparation including additional nutrients for patients requiring supplements or medications in their diet.

There’s a bit of a sustainability element to 3D printing food printing as well. Because the food is transformed, what it looked like originally doesn’t really matter. This has the potential to use food that producers throw out because it isn’t pretty enough for marketplace shelves, or from food cuttings. Low value cuts of meat, such as offal, can be printed to create new types of food, which is being done by the Meat and Livestock Australia. Potentially this opens up an entirely new value for what would otherwise be considered lesser meats and provide an alternative source of nutrition for those in need or the elderly, who may need a protein rich, more digestible food product.

Alternative food uses

Alternative meat steaks are ready now for printing to order. SavorEat is a startup redefining dining in Israel. The “meat” is printed and cooked layer by layer, so it is ready to be consumed as soon as the printing is done, and modifications can be made for well and medium well. Another company, Redefine Meat, can print up to 50 steaks an hour and hoping to be in European restaurants by 2021. On the dairy substitutes side, Perfect Day, uses 3D printing combined with gene sequencing to create a yeast fermentation product that looks and tastes like milk. 

Will 3D printing make fast food faster? Already experimenting with plant-based chicken nuggets, KFC has recently announced a development using 3D bioprinting technology to print chicken meat. Using both chicken cells and plant cells, the product will soon be available to thousands throughout Russia. With over 24,000 restaurants worldwide, this has the potential to become familiar food to millions should it be successful.

Who still needs it?

The biggest 3D printing companies are primarily in North America, Europe and Asia Pacific (APAC). As the industry grows, these regions are also showing growth, North America holds the largest share, but APAC is expected to grow the fastest. What is not seeing great growth is the rest of the world, which includes South America, Africa and the Middle East.

This is unfortunate, because Africa would clearly be on the list to benefit from the opportunities 3D printing allows. The challenge here is that the continent traditionally lags behind in technological adoption. The rural aspect would certainly benefit from the easier production of functional and replacement parts. As we’ve seen, there is potential to build larger and more complicated objects through 3D printing. It may come a time when 3D printing is the means for creating farm equipment in other regions. While 3D printing isn’t currently a massive market in Africa, there are a lot of eyes on the region just now, recognizing the opportunities therein, and the value this technology would bring is clear.  

At an industry level, there is still much room to grow and experiment with 3D printing in agriculture. As we have seen, only a handful of companies are incorporating it into their business models. Farmers and producers should also consider this technology and the potential it has for efficiencies and opportunities. 

Where does it go from here?

It is estimated that more than 140,000 industrial and over 2 million commercial 3D printers have been sold worldwide. In 2018, the 3D printing market was valued at $9.9 billion. The projection for 2024 is $34.8 billion, a more than three-fold increase. The rise of 3D printing is a result of several factors including increased opportunities in application, better customization, the development of industrial-grade materials and government investments in the technology. It’s a technology that is easily adoptable, reasonably low cost, and producers can see the value of it quickly, which is why companies like BMW are investing millions into it.

With growing applications for its use, 3D printing is going mainstream and many industries are embracing this technology. Within agriculture, while we are seeing some adoption, but the range of opportunities hasn’t been fully explored. With anticipated growth of sales, improvement in the technology and continued ease of adoption, farmers and producers would do well to learn more about this transformative technology and consider the benefits and value it could bring to their operations. 

Thanks to Alexa Potocki, for the research and writing, which made this article possible.