Should you get a 3D printer, how it works, and how useful it is?

3D printers are more than just a pastime. The technique has a lot of applications in the fabrication and industrial world. Furthermore, with the rising perception that 3D printers are now much more accessible to acquire, you should not miss out on this emerging trend. Learn More About 3D Printers

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What is 3D Printing?

3D printing or additive manufacturing (AM) technologies create three-dimensional parts from computer-aided design (CAD) models by successively adding material layer by layer until physical part is created.

3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital file.

The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced cross-section of the object.

3D printing is the opposite of subtractive manufacturing which is cutting out / hollowing out a piece of metal or plastic with for instance a milling machine. Learn More About 3D Printers

3D printing enables you to produce complex shapes using less material than traditional manufacturing methods.

While 3D printing technologies have been around since the 1980s, recent advances in machinery, materials, and software have made 3D printing accessible to a wider range of businesses, enabling more and more companies to use tools previously limited to a few high-tech industries.

Today, professional, low-cost desktop and benchtop 3D printers accelerate innovation and support businesses in various industries including engineering, manufacturing, dentistry, healthcare, education, entertainment, jewelry, and audiology.

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How Does 3D Printing Work?

All 3D printing procedures begin with a CAD model, which is then transferred to software for preparation. The 3D printer may build the part layer by layer by solidifying resin or sintering powder, depending on the technology. After that, the pieces are taken from the printer and post-processed for the intended use.

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1. Design

Three-dimensional models, or mathematical representations of any three-dimensional surface built using computer-aided design (CAD) software or developed from 3D scan data, are used to make parts in 3D printers. After that, the design is saved as an STL or OBJ file that can be read by print preparation software.

3D printers come with software that lets you choose print parameters and split the digital model into layers that reflect the part's horizontal cross-sections. Orientation, support structures (if needed), layer height, and material are all adjustable printing options. The program transmits the instructions to the printer through a wireless or cable connection after the setup is complete.

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2. 3D Print

Some 3D printers utilize a laser to cure liquid resin into solid plastic, while others employ high temperatures to fuse microscopic particles of polymer powder. The majority of 3D printers can operate unattended until the print is finished, and contemporary systems automatically replace the material needed for the pieces from cartridges.

An online Dashboard for Formlabs 3D printers lets you manage printers, materials, and teams from anywhere.

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3. Post-Process

The printed parts may need to be rinsed in isopropyl alcohol (IPA) to remove any uncured resin from their surface, post-cured to stabilize mechanical properties, manual work to remove support structures, or cleaning with compressed air or a media blaster to remove excess powder, depending on the technology and the material. With the use of accessories, some of these procedures may be automated.

3D printed components can be utilized immediately or after machining, priming, painting, fastening, or joining to get the desired finish. Positives for investment casting jewelry and dental equipment, as well as molds for unique items, are frequently created using 3D printing as an intermediary stage alongside traditional manufacturing processes.

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Types of 3D Printers

The three most established types of 3D printers for plastics parts are stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM). Formlabs offers two professional 3D printing technologies, SLA and SLS, bringing these powerful and accessible industrial fabrication tools into the creative hands of professionals around the world.

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Stereolithography (SLA)

Stereolithography, the world's first 3D printing technology, was developed in the 1980s and remains one of the most popular among professionals. In a process called photopolymerization, SLA 3D printers use a laser to cure liquid resin into hardened plastic.

SLA resin 3D printers have grown in popularity as a result of their ability to produce high-accuracy, isotropic, and watertight prototypes and parts in a variety of advanced materials with fine features and a smooth surface finish. Standard, engineering, and industrial thermoplastics all have optical, mechanical, and thermal properties that SLA resin formulations match.

Resin 3D printing a great option for highly detailed prototypes requiring tight tolerances and smooth surfaces, such as molds, patterns, and functional parts. SLA 3D printers are widely used in a range of industries from engineering and product design to manufacturing, dentistry, jewelry, model making, and education.

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Stereolithography is ideal for:

Rapid prototyping

Functional prototyping

Concept modeling

Short-run production

Dental applications

Jewelry prototyping and casting

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Selective Laser Sintering (SLS)

SLS 3D printers sinter tiny particles of polymer powder into a solid structure using a high-power laser. The component is supported by the unfused powder during printing, eliminating the requirement for specific support structures. SLS is hence well suited to complicated geometries such as internal features, undercuts, thin walls, and negative features. SLS-printed products offer outstanding mechanical properties, with strength comparable to injection-molded parts.

The most common material for selective laser sintering is nylon, a popular engineering thermoplastic with excellent mechanical properties. Nylon is lightweight, strong, and flexible, as well as stable against impact, chemicals, heat, UV light, water, and dirt.

SLS is a popular choice among engineers for functional prototype and a cost-effective alternative to injection molding for limited-run or bridge production because to its combination of cheap cost per component, high productivity, and well-established materials.

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Selective laser sintering is ideal for:

Functional prototyping

End-use parts

Short-run, bridge, or custom manufacturing

Learn More About SLS 3D Printers

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Fused Deposition Modeling (FDM)

Fused deposition modeling (FDM), often known as fused filament fabrication (FFF), is the most popular 3D printing method among consumers. FDM 3D printers function by extruding thermoplastic filaments such as ABS (Acrylonitrile Butadiene Styrene) and PLA (Polylactic Acid) via a heated nozzle, melting the material, and layering it on a build platform. Each layer is placed one by one till the portion is finished.

FDM 3D printers are ideal for simple proof-of-concept models as well as rapid and low-cost prototyping of simple parts that would otherwise be machined. However, when compared to SLA or SLS, FDM has the lowest resolution and precision, making it unsuitable for printing complicated patterns or objects with intricate elements. Chemical and mechanical polishing methods can produce higher-quality finishes. Industrial FDM 3D printers employ soluble supports to address some of these challenges and can print a larger choice of technical thermoplastics, but they come at a high cost.

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Fused deposition modeling is ideal for:

Basic proof-of-concept models

Simple prototyping

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Learn More About FlashForge Adventurer 3 Lite FDM 3D Printer

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What can you make with a 3D printer

Almost everything you desire, from vases to GoPro mounts to phone covers, as long as you don't hate plastic. A 3D printer might be the manufacturing tool you need, whether you're a tinker interested in prototype or a tabletop-gaming fan looking to increase your tiny collection.

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3D Printer Care & Maintenance

A 3D printer may be a difficult machine to work with. Basic maintenance may go a long way toward preventing malfunctions and print defects. If your printer's print bed does not automatically level, check it on a regular basis and adjust it as needed.

Some printers have print beds constructed of materials that hold prints really well—perhaps a little too well, based on our research. Adjusting print temperatures and a few other parameters can assist, but they aren't always sufficient. Many printers now have detachable, flexible print beds; if yours does, carefully bend the bed to release your model. If you push too hard, the finish of the bed will be damaged. If the print is still stuck, return the bed to its printing temperature and see if the model will come off more easily. Then, carefully unstick the print's edges with a scraper before cutting your way to the middle. If you're still having trouble, take the print bed and place it in the freezer for an hour. This should help you eliminate the print by shrinking it somewhat.

On the print bed, plastic scraps might accumulate over time. Most stubborn filth can be removed with a towel and warm water; hard grime can be removed with rubbing alcohol that contains at least 90% isopropyl alcohol.

Finally, follow the manufacturer's instructions for heating and cooling the printer to avoid jams.

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Accuracy and Precision in 3D Printing: What You Need to Know

When it comes to 3D printing accuracy and precision, there are a number of elements to consider, but it's also crucial to determine your individual requirements.

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For example, a precise-but-inaccurate 3D printer may be the best choice for some applications. A low-cost fused deposition modeling (FDM) machine will produce less accurate parts, but for an educator teaching students about 3D printing for the first time, it may not be important for the model to exactly match a student’s CAD design.

Knowing that the printer will consistently perform as advertised and generate the quality that the user expects, within the tolerances that the user is accustomed to, might be critical to a positive experience.

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3D Printing Resolution

There are three dimensions to consider in 3D printing and additive manufacturing: two planar 2D dimensions (X and Y) plus the Z dimension, which makes it 3D printing. Because the planar and Z dimensions are often controlled by completely distinct methods, their resolutions will differ and must be considered individually. As a result, there's a lot of misunderstanding about what "3D printing resolution" implies and what print quality to expect.

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High Resolution 3D Printing - Compare Different 3D Printing Processes

What determines the resolution of a 3D printer? There is no simple solution. Because 3D printers make components in three dimensions, you'll need to think about at least two numbers: the XY plane's minimum feature size and the Z-axis resolution (layer thickness or layer height). Even though it has nothing to do with print quality or surface polish, the Z-axis resolution is easy to evaluate and hence often reported. The more significant XY resolution (minimum feature size) is determined by microscopic imaging and so is not often included on spec sheets.

In practice, this means selecting a 3D printer that excels in both areas (in all 3 dimensions).

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Learn More About Creality CR 10 Smart 3D Printers

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What factors should you consider while selecting a 3D printer?

No matter what price range you’re considering, we think the best 3D printers offer the following features:

High-quality prints: Without too much tweaking, the printer should put out smooth-looking models with layers that are 0.1 mm or thinner and barely visible.

Easy-to-use hardware: Even a complete beginner should be able to put the printer together, load filament, start a print, and remove a finished model from the print bed. The bed should also level itself or be simple to level manually (a sloping print bed can cause printing errors).

Ample connectivity options: Ideally, you should be able to start a print over Wi-Fi or transfer the file over a USB cable. Loading files onto an SD card that you plug into the printer is also okay. A design that requires you to keep a computer tethered to the printer at all times via USB is a serious flaw but not necessarily a dealbreaker.

Intuitive software: Beginners should be able to jump right into using a printer’s software, including making adjustments to models before printing. The software should come preloaded with print settings but provide options for more experienced users to fine-tune. It’s a big plus if a printer is compatible with Ultimaker Cura, which has become somewhat of an industry standard and a favorite of ours.

Large-enough print volume: It would be nice to have the ability to print objects as large as you want, but the reality is that most models found in libraries like Thingiverse are designed for small 3D-printer beds, with workarounds for combining several printed pieces to create a larger object. As a result, beginners need only a print bed large enough to print models about the size of a small tissue box.

Heated bed: Heated beds prevent prints from warping, help models stick to the print bed, and allow you to print using a wider range of materials. (ABS, one of the two most common types of plastic used for 3D printing, and other materials shrink as they cool. Without a heated bed, you are limited to PLA, the other main type of plastic.)

Compatibility with any brand of filament: Some companies embed chips in the spools of plastic that feed into their 3D printers, requiring you to buy refills directly from the printer manufacturer. Proprietary filament is generally more expensive, and if the company that makes it goes out of business, you won’t be able to use the printer.

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Suited to everyday life: The machine should look at home sitting on a desk. Ideally, it isn’t too big or heavy, and it’s relatively quiet so you can’t hear it from every corner of the house. Although some printers are marginally faster than others, large prints can take days; even small prints take hours. A quiet printer is much easier to live with. Printers should also be able to print in polylactic acid, or PLA, plastic. While melting any type of plastic releases volatile organic compounds and other particulates into the air, the CDC considers PLA to be safer (PDF). PLA also has a sweet, inoffensive smell—still, it’s best for both children and adults to use a 3D printer in a well-ventilated room.

Enclosed printing chamber: Enclosing the print space keeps prints at a consistent temperature to prevent warping and other printing imperfections. It’s an especially good idea to have an enclosed chamber if you are printing with acrylonitrile butadiene styrene, or ABS—one of the two most popular printing materials—which is more prone to warping because it shrinks when it cools. Although enclosed printing chambers are nice to have, they’re not essential, and they’re actually fairly rare among inexpensive 3D printers.