Introduction
3D printing, or additive manufacturing, has become, over the years, a reliable manufacturing technique used in all kinds of sectors. But do you really know what is 3D printing, how it works and all its possible applications?
Basics of 3D printing
3D printing is a manufacturing technique, more and more used today to make proofs of concept, prototypes or end-products. Companies are implementing 3D printing at different stages of their manufacturing processes and rethinking their business strategy with this competitive advantage.
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Engineers, designers, and even hobbyists are elaborating innovative applications of this cutting-edge technology. 3D printing is a technique which builds objects layer by layer from a 3D file. The process is literally transforming a digital version of an object, into a physical version.
History of 3D printing
There is a real history of 3D printing: additive manufacturing is not a new technique. But do you know what was the first technology ever developed? Stereolithography, or SLA! The first attempts have been made by a French team of engineers composed by Alain Le Méhauté, Olivier de Witte and Jean-Claude André. Because of a lack of a business perspective, the project has been abandoned.
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Since 2000, the evolutions of additive manufacturing are even faster, and new applications are found every year: medical 3D printing, 3D printed cars, mechanical applications of 3D printing. This technology opens new opportunities in every sector. We will see more in detail the applications of 3D printing later in this article.
How does 3D printing work?
There is not one unique way to 3D print. Indeed, when thinking about 3D printing, a lot of people are still thinking about the FDM process. But 3D printing is much more than that. There are actually several possibilities, and technologies to create parts additively. The choice of your 3D printing technology and the material will be determined by your project. What properties do you need? What resistance? Here is how the main 3D printing technologies work.
Plastic 3D printing
or SLS: This 3D printing technique creates objects by sintering the powder inside the printer, using a laser. During this layer by layer process, the powder bed is preheated and a laser sinters the powder according to the 3D model to create the solid object.
or FDM: This 3D printing method is well-known by hobbyists, but also in education. FDM 3D printers are using one or two print heads for the deposition of melted 3D printing material. The material is melted and extruded through a nozzle, to create the desired object each layer at a time. FDM is mostly known for being a plastic 3D printing technique, but it is now possible to use it to print metal materials for example.
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Resin 3D printing
: The DLS technology developed by Carbon works by projecting a continuous sequence of UV images, generated by a digital light projector, through an oxygen-permeable, UV-transparent window below a liquid resin bath. The dead zone created above the window maintains a liquid interface below the part. Above the dead zone, the curing part is drawn out of the resin bath.
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or SLA: Stereolithography the first 3D printing technique ever created. This resin additive manufacturing process us using photochemical processes. It uses liquid photopolymers that can be cured. The build plate moves down in small increments and the liquid polymer is exposed to light where the UV laser draws a cross-section layer by layer. The process repeats until the object is printed.
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Metal 3D printing
, or DMLS: These 3D printers create parts additively thanks to a laser, sintering fine metal powder particles to fuse them together. The process is quite similar to the Selective Laser Sintering process for plastic. The difference is the sintering temperature, much higher for metal printing techniques. Indeed, polyamide needs to be sintered at a temperature of 160°C to 200°C, whereas metal melts at a temperature around between 1510°C and 1600°C meaning that a higher wattage laser is needed to reach that temperature.
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: This additive manufacturing method also creates metal parts additively. Binder Jetting is a binding agent. This liquid binding agent is deposited on the powder, according to the 3D model to create. The powder is lightly cured for solidification between each layer. When the printing process is complete, the build box is removed from the printer and placed into an oven for curing. After this, the parts are extracted from the build box and the remaining powder is removed thanks to brushes and air blowers.
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Color 3D printing
: This technology is creating multicolor parts! Just like other processes, Colorjet technology prints out the object layer by layer. A rolling batch leaves a uniform layer of the sandstone-like powder and then, two printing heads pass over this batch, coloring and adhering to the object at the same time.
How to select the right 3D printing technology?
All 3D printing processes have their own advantages and limitations. All industries and all projects have different requirements and the nature of your project will help you determine which process and which material will be perfectly adapted to your 3D printing idea. Choosing the right 3D printing process and material will participate in the success of your 3D printing experience. The mechanical properties of your object will depend on the mechanical properties of the material you chose to 3D print.
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Do you need a flexible or rubber-like material? A heat resistant material? Do you need to find the cheapest material for your prototypes, or do you need to get the most detailed parts to create your end product? The possibilities are endless, but once you’ve found the perfect process for you, be sure to check the design guidelines of the materials and process, to make the most of the additive manufacturing process and get all the interesting properties of the 3D printing material.
What are the materials used in 3D printing?
Speaking of materials, do you know what materials are used in 3D printing? From strong plastics to light metals, additive manufacturing is now able to create your parts using a wide variety of materials. As we just saw with 3D printing technologies, the most used materials are plastics (with materials such as Nylon PA12, PEBA, Alumide, etc.), resins (with materials such as VeroClear, VeroWhite, Elastomeric Polyurethane, etc.) and metals (with materials such as Aluminum, Titanium, Stainless Steel, Brass, Bronze, Silver, etc.). But you will have to check the mechanical properties, advantages and design guidelines of these materials to make your final choice and get the best 3D printed parts for your project.
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Now more and more materials can be 3D printable, even the most improbable ones. It is now possible to 3D print concrete or even human tissues. Additive manufacturing technology is evolving and improving quite quickly, researchers keep on pushing the boundaries of this amazing technology to develop new incredible applications, showing year after year that everything is 3D printable.
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Advantages of 3D printing
The advantages of 3D printing are numerous, and more importantly, they are different for each sector or application! While implementing this technology in your business, you’ll have to correctly identify your opportunities, to make the most of additive manufacturing and all its advantages for you. Let’s see what are the main benefits of 3D printing.
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If you want to know how much your 3D printing project will cost, you can get an instant quote on our website by uploading your 3D file. The price of your part will depend on different factors such as the choice of technology, material, the volume of your part, the amount of material needed, etc.
3D printing applications
3D printing can be used by all kinds of industries, and for really different applications. Here is an overview of what 3D printing can do for you:
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Fashion and 3D printing are opening new possibilities. Indeed, designers are quite used to additive manufacturing, they use it to create artistic pieces for fashion shows. But this technology tends to be more used to manufacture traditional clothes, but also shoes. What are the advantages of this manufacturing technique for fashion? Mass-customization, complete freedom of design, and access to materials with great mechanical properties!
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What are the differences between 3D printing and traditional manufacturing?
Additive manufacturing is now a real alternative to traditional manufacturing techniques. Using 3D printers, CNC machines, injection molding or casting are all reliable manufacturing methods, with different advantages. 3D printing presents a lot of advantages and opens new possibilities. But what are the differences between 3D printing and traditional manufacturing? Injection molding vs 3D printing, metal casting vs 3D printing: Why is 3D printing a real alternative to these manufacturing techniques? While starting a project, you will have to identify the needs of your project to select the perfect manufacturing technique. As we saw a bit earlier, additive manufacturing presents numerous advantages, compared to other technologies.
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Last but not least, as it is an additive technique, 3D printing is allowing to avoid material waste. Indeed, if injection molding was first seen as a manufacturing technique producing low scrap, compared to processes like CNC machining, it appears that the winner in this category is the 3D printing technology!
How to get started with 3D printing?
To get started with 3D printing, you will have to first identify your 3D printing opportunities. Is additive manufacturing a great asset for your tooling process? Is it a chance for you to boost your Kickstarter campaign by developing the perfect proof of concept or prototyping to attract backers? Additive manufacturing can also be a great asset for your production, or to create custom-made objects.
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There is no doubt, all businesses can improve their strategy by using additive manufacturing and make the most of this incredible competitive advantage. Don’t wait for your competitors to take a step ahead of you. If you need some help to identify your opportunities, contact our 3D printing experts from Sculpteo Studio.
Get your 3D file!
Once your project is clearly identified, you will have to create your 3D model and get an STL file. STL is the most common file format to 3D print, but there are some other file formats you can use. An STL file stores information about your 3D model. The format represents the raw surface of a model with small triangles. The more complex and detailed the structure is, the more triangles will be used to represent the model.
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For this, you will have to choose a 3D modeling software adapted to your project. For example, if you need an engineering mechanical software, you will use programs such as Solid Edge, or Fusion 360, if you need architecture 3D software, you will use ArchiCAD, or Revit. Free CAD software can also be the perfect solution to develop your 3D design and get your STL file. Here is another solution if you don’t want to start a design process, you can buy a 3D model on a database, or on a software library.
How to design for 3D printing?
These 3D programs can be advanced and difficult to use. But even if you know how to use a 3D modeling software it doesn’t mean that you are able to create a 3D model.
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You will have to be careful with your wall thicknesses, your face orientations, and you will have to avoid crossed volumes so the 3D printer understands correctly what it has to print. You will also have to be careful with non-manifold models: Open objects with edges that are not totally connected or objects with added faces are part of the most common errors while using 3D printing!
How to 3D print your model?
Once your model is ready, you can 3D print it! You can print it with your own 3D printers. If you have a 3D machine, it is certainly a desktop FDM 3D printer, but have you ever tried industrial 3D printing?
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If you don’t want to invest in an industrial 3D printer but access professional quality, you can send your file on a 3D printing service such as Sculpteo, you will just have to choose among +75 possibilities of materials and finishing options, and you will get a free instant quote. Industrial Additive Manufacturing is for anyone who’s production requirements are strength, good quality, and great mechanical properties.
What is the future of the 3D printing industry?
With our annual study about the industry of additive manufacturing, The State of 3D Printing, we see the evolution of the uses of this technology. Businesses are confident in their use of technology. Businesses are investing more and more money each year to implement this additive technology at different levels of their company. From R&D to production, and tooling, 3D printing now plays a significant role in a manufacturing and business context.
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