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What Is 3D Printing? Streamline Prototyping and Production

January 28, 2022

3D printing

“Please don’t touch”.

You’ll find these words boldly written at art galleries, museums, or exhibitions. These signs are meant to prevent you from touching artworks, installations, exhibits, and paintings to prevent corrosion or stains from dirt particles, knocks, or perspiration.

But this is changing. Visitors can now view and touch replicas on display without causing damage, thanks to 3D printing software.

History of 3D printing

3D printing isn’t as new as you may think. The history of 3D printing dates back to 1945 when American writer William Fitzgerald Jenkins, under the pen name of Murray Leinster, described the process of feeding magnetronic plastics into moving arms in his story “Things Pass By”. However, the first practical application didn’t take place until the 1960s.

The birth of the liquid metal recorder

The Teletype Corporation invented inkjet technology in the 1960s, which could print up to 120 characters per second using a drop of material from a nozzle. This technology paved the way for today’s consumer desktop printing software.

In 1971, Teletype started creating objects with melted wax, based on Johannes F. Gottwald’s patent. Gottwald’s idea was to create a solid object using liquid metal that would solidify into a shape based on the inkjet’s movement at each layer. This initiative gave birth to the liquid metal recorder, which became the foundation of rapid prototyping and enabled printing to move beyond ink.

The first rapid prototyping patent application

Dr. Hideo Kodama of the Nagoya Municipal Industrial Research Institute in Japan was the first to file a patent application for rapid prototyping technology in 1980. Single-beam laser curing was the foundation of his rapid prototyping system, and the process involved building objects in slices of layers and hardening the photopolymer material with ultraviolet (UV) light exposure. However, Dr. Kodama never commercialized this printing process because he failed to file the patent specification within a year of application.

Stereolithography and stereolithographic apparatus machine

Jean Claude André from the French National Center for Scientific Research (CNRS), Alain le Méhauté from the Research Center for the General Electric Company (CGE), and Oliver de Witte from Cilas filed a patent for the stereolithography process in 1984. They believed the new technology would revolutionize manufacturing but found it difficult to secure funding for pursuing research. They soon abandoned the patent and gave up the project.

Charles Hull invented stereolithography and released the first commercial 3D printer, the stereolithographic apparatus machine (SLA-1), in 1987. Hull’s journey in 3D printing began by looking for a new way to use UV technology. He was researching ways to place thin plastic layers on each other to create tabletop and furniture coatings. During his research, he came across stereolithography, a process for making physical objects based on 3D models using digital data.

Stereolithography uses UV laser beams to turn acrylic-based photopolymer into a plastic 3D model. This technology opened new horizons for inventors to prototype and test without a huge upfront investment.

After filing the patents in 1986, Hull founded 3D Systems Corporation and released SLA-1 with new features, such as standard triangle language (STL) file format and digital slicing. This event marks the birth of 3D printing.

Selective laser sintering technology

Carl Deckard at the University of Texas invented selective laser sintering (SLS) technology, an alternative to 3D printing. The SLS technology creates a 3D model by sintering nylon or polyamide-based powdered material with a laser.

He developed this technology while researching how to enable machines to produce parts without any casting at the University of Texas, where he received guidance from Dr. Joe Beaman. Deckard received the patent in 1989 after applying in 1987. DTM Inc initially received the license for SLS but was later acquired by 3D Systems in 2001.

Fused deposition modeling technology

Scott Crump, along with his wife Lisa Crump, invented fused deposition modeling (FDM) technology in 1989. It all began when Scott, a mechanical engineer, experimented with candle wax and polyethylene to create a toy frog for his daughter. His idea was to automate the modeling process by attaching a glue gun to a robotic gantry system.

After patenting FDM technology in 1989, Scott and Lissa co-founded Stratasys and built the first operational FDM 3D printer in 1992. Scott also extensively worked on acrylonitrile butadiene styrene (ABS) plastic filaments that FDM machines use.

Evolution of 3D printing: from the 1990s to 2000s

1993: Zprinting is developed at the Massachusetts Institute of Technology (MIT)
1994: Solidscape releases the first wax 3D printer
1997: Electron beam melting (EBM) 3D printers are created
1998: Polyjet 3D printing technology is launched
1999: Synthetic scaffolds of a human bladder are bioprinted at the Wake Forest Institute for Regenerative Medicine
2000: The first multicolor and inkjet 3D printer is created
2002: A 3D printed miniature human kidney is created at the Wake Forest Institute for Regenerative Medicine
2004: Replicating rapid prototyper (RepRap) movement begins
2005: The first color high-definition (HD) 3D printer is launched by ZCorp
2008: The first 3D printed prosthetic is developed
2009: The BfB RapMan printer, the first affordable FDM 3D printer, is released
2009: The first 3D printed blood vessel is created
2011: The first 3D printed car is created
2012: The first prosthetic jaw is printed and implanted
2013: Obama mentions 3D printing during a State of the Union speech
2013: A working 3D printed gun STL file is created by Cody Wilson
2014: The first 3D object is printed in space
2017: The first use of 3D printing in construction

A great 3D printer is only as good as the software behind it. My team tested the best 3D printing tools for beginners and pros; check it out now!

Types of 3D printers and printing technologies

3D printing is an umbrella term for different additive manufacturing technologies and processes that build plastic or metal parts layer by layer. The 2015 ISO/AST 52900 standard classifies 3D printers and printing technologies into eight types.

1. Material extrusion

Material extrusion is a popular additive manufacturing process that creates 3D parts with a continuous filament of composite or thermoplastic material. During the process, a nozzle extrudes and deposits heated materials layer by layer onto a build platform that holds the 3D printed part. You can use material extrusion systems to extrude concrete, plastic, metal paste, chocolate, and bio-gels.

Material extrusion in 3D printing

  • 3D printing technology: FDM
  • Materials used: Polylactic acid (PLA), ABS, polycarbonate (PC), polyetherimide (PEI), polyetherimide (PEI), and other plastic filaments
  • Dimensional accuracy: ±0.5%
  • Common applications: Investment casting patterns, electrical housings, jigs, fixtures, electrical housings, and form and fit testings
  • Strengths: Low cost and availability of a wide range of materials

FDM printers

FDM, also known as fused filament fabrication (FFF), uses material extrusion and is one of the oldest additive printing technologies. Most home 3D desktop printers use FDM technology.

FDM printers consist of a control system and a platform extrusion nozzle. FDM 3D printing systems heat and deposit the thermoplastic filament in x- and y-coordinates to build an object in the z-direction. An object with parts overhanging more than a 45-degree angle may need additional support, as FDM 3D printers build the object from the bottom up.

FDM 3D printers are ideal for individuals and small businesses looking to quickly create cost-effective 3D objects. Industrial FDM printers ease the process of creating both prototypes and end-use parts.

Types of FDM/FFF 3D printers

There are four types of FDM/FFF 3D printers, based on the varying degree of the extruder and printing platform movement.

1. Cartesian printers are the most common type of FDM 3D printer. They use the Cartesian coordinate system to position three axes and direct the printhead. Cartesian printers use three or more motors to allow the printhead to work on the x-y axis and the printing bed to move on the z-axis. These FDM printers are user-friendly, easy to learn, and ideal for horizontal prints. But the axes’ weight results in low-quality printing during faster prints.

2. Delta printers speed up the printing process but don’t offer accurate results like Cartesian printers. These 3D printers have three motors that move the hot-end with latitudinal and longitudinal coordinates. Delta printers are lightweight, offer more central accuracy, and allow high-speed printing. They cannot print objects with larger horizontal surfaces and need more vertical space to function.

3. Polar printers use the Polar coordinate system instead of the Cartesian system. These printers use two motors: one helps the extruder move up and down, and the other enables the printing platform to move sideways and rotate. Polar printers are ideal for creating larger objects in less space. They are energy efficient but expensive. Moreover, you’ll have trouble finding parts and technical support.

4. CoreXY printers are similar to Cartesian printers, but have a specific belt design that facilitates the inter-dependency between x and y movements. These printers leverage a clever motion system to help the print surface lift and meet the extruder. Designers looking for better print quality choose CoreXY 3D printers because they have less torque, fewer vibrations, high accuracy, and lightweight parts. However, they are expensive and not energy efficient.

2. Vat polymerization

Vat polymerization, or resin 3D printing, uses UV light to cure vat photopolymer resin. 3D printers expose liquid polymers to UV light in this process. The heated photopolymer molecules bond together to create a solid form. Operators follow the same method for creating layers on top of one another.

Medical and manufacturing industries use vat polymerization to create detailed and accurate facial prosthetics, hearing aids, surgical learning tools, and low-volume injection molding.

Vat polymerization in 3D printing

  • 3D printing technologies: SLA, digital light processing (DLP), masked stereolithography (MSLA), programmable photopolymerization (P3), high-area rapid printing (HARP), lithography-based metal manufacturing (LMM), light enabled additive production (LEAP), projection micro stereolithography (PµSL), and digital composite manufacturing (DCM)
  • Materials used: Photopolymer resins
  • Dimensional accuracy: ±0.5%
  • Common applications: Dental applications, jewelry casting, and polymer prototypes
  • Strengths: Fine details and smooth finish

Types of vat polymerization printers

1. SLA printers rely on vat polymerization technology to create accurate, watertight, and isotropic prototypes from liquid photosensitive thermoset polymers. These printers use galvanometers on each x- and y-axis to aim UV laser beams across a resin vat. SLA printing is ideal for creating miniatures and objects with complex patterns. However, SLA printers are expensive and less environment-friendly.

2. DLP printers use the vat photopolymerization technique to cure resin and build an object layer by layer. The name comes from a digital micromirror device (DMD) that generates digital light and dark area patterns to create individual layers. Each layer contains square pixels and small rectangular blocks called voxels.

DLP printers offer faster print times, fine details, and a smooth finish. That’s why industries that manufacture dental applications, jewelry, and mold-type prototypes use DLP 3D printing technology.

3. MSLA printers work similarly to SLA printers, but use a large UV light source instead of a laser beam to trace each layer. A digital mask above the light source controls the illumination of different print regions. Modern MSLA printers use monochromatic LCD screens to minimize the screen degradation caused by the burn-in effect of the bright backlight. Industries with round-the-clock production needs prefer these printers because of the quick turnaround time.

Other popular vat polymerization 3D printing technologies are:

  • Programmable photopolymerization (P3)
  • High-area rapid printing (HARP)
  • Lithography-based metal manufacturing (LMM)
  • Light enabled additive production (LEAP)
  • Projection micro stereolithography (PµSL)
  • Digital composite manufacturing (DCM)

3. Powder bed fusion

Powder bed fusion (PBF) 3D printing technology uses polymer or metal powder to create an object layer by layer. In this technology, printers use a build platform to fusion powdered particles and additively manufacture objects. A PBF device spreads a layer of powdered material with a blade, fuses specific points with energy, and continues the same process until the entire object fabrication is complete.

PBF technology emerged in the 1990s when companies started experimenting with melting powder particles with a laser or heat source to create an object. PBF printers require little or no support structure, making them ideal for rapid prototyping, high-volume production runs, and visual prototyping.

PBF in 3D printing

  • 3D printing technologies: Selective laser sintering (SLS), selective laser melting (SLM), electron beam melting (EBM), direct metal laser sintering (DMLS), and multi jet fusion (MJF)
  • Materials used: Thermoplastic, metal, and ceramic powders
  • Dimensional accuracy: ±0.3%
  • Common applications: Complex ducting, functional part design, and low-run production
  • Strengths: Completely customizable and reduces post-processing time

Types of PBF printers

1. SLS printers use a high-power laser to sinter nylon or polyamide powder particles into solid objects based on 3D models. Once the fusion bed device spreads the powder inside the build chamber, the printer preheats the powder to a temperature below the melting point. Then the laser scans the 3D model, heats the powder, and fuses particles together to create a solid object. Engineers and manufacturers across industries are leverage SLS printers to build strong and functional structures.

2. SLM/DMLS printers, also known as direct metal laser melting (DMLM) printers, use metal additive manufacturing technology to selectively melt the powdered material and build an object layer by layer. While the powder bed supports the object during the printing process, you should add additional structures to support overhanging features. SLM printers are ideal for building complex shapes and multiple parts simultaneously. DMLS printers work similarly to SLS printers, but heat the powder to a molecular level fusing point instead of melting it.

3. EBM printers use a high-energy beam of electrons to melt powdered metal and create an object according to the specifications set by a CAD model. A magnetic field guides the electrons that create a form within a vacuum. These printers are capable of eliminating metal impurities and building high-strength parts. Aerospace, defense, petrochemical, and automotive industries use EBM printers to print components.

4. MJF printers rely on multiple inkjet heads to print 3D objects. These printers lay a material powder layer and deposit a fusing and detailing agent. Different head arrays carry out heating, recoating, and agent distribution processes. MJF printing renders 3D files as voxels or volume elements, which are 3D equivalents of two-dimensional (2D) printing pixels.

4. Material jetting

Material jetting (MJ) printing technology selectively deposits and cures material droplets on a build plate to create objects one layer at a time. The UV light cures hundreds of resin droplets once the printheads jet them. Using MJ technology, you can create objects of different colors and textures.

MJ printing usually uses standard resin material, but you can also use other castable and temperature-resistant materials. Industries with multi-material printing requirements leverage this technology to create objects at speed and high accuracy.

MJ in 3D printing

  • 3D printing technologies: Drop on demand (DOD), polyjet, nanoparticle jetting (NPJ)
  • Materials used: Photopolymer resin
  • Dimensional accuracy: ±0.1mm
  • Common applications: Low run injection molds, medical model, full-color product, and injection mold-like prototypes
  • Strengths: Multi-material printing and smooth surface finish

Types of MJ printers

1. DOD printers use two print jets to create a cross-sectional area of a component. While one print jet deposits the build material, the other evaporates the support material. Industries dealing with mold-making applications or lost-wax casting use DOD printers for high-quality large character printing.

2. Polyjet printers create exceptionally detailed objects by jetting curable liquid photopolymer layers onto a building surface. Once the printhead jets photopolymer droplets, a UV light immediately cures and solidifies the layer. After completing a layer, the printer moves down the build platform and starts working on the next layer. These printers can create complex geometrical parts using gel-like support material. Objet, Ltd. introduced the first MJ printer in 1999 and later sold it to Stratasys.

3. NPJ printers use Xjet’s proprietary powdered material suspension technology to build 3D parts. These printers simultaneously jet a metal nanoparticle liquid in suspension and support material on a heated bed to create 3D objects. You can remove the support material before sintering the produced parts. Medical, automotive, aerospace, and electrical industries use NPJ printers to make many small parts at once.

5. Binder jetting

Binder jetting is another additive manufacturing technology that uses a liquid bonding agent to bind powder bed regions and create 3D objects. In this process, an industrial printhead deposits the agent on a powdered particle layer and repeats the process until the object is complete. After creating an object, the printer uses compressed air to remove unbound powder from the powder bed. Commonly used powder particles include sand, metal, ceramics, and composites.

Binder jetting was developed at MIT in the early 1990s. After obtaining the exclusive license in 1996, ExOne launched the first commercial binder jet metal 3D printer in 1998 and the first sand 3D printer in 2002.

Binder jetting in 3D printing

  • 3D printing technologies: Sand binder jetting, metal binder jetting, and plastic binder jetting
  • Materials used: Sand, silica, polymer, ceramic-metal composites, and metal powder
  • Dimensional accuracy: ±0.2 mm (metal) and ±0.3 mm (sand)
  • Common applications: Sand casting, functional metal bodies, and full-color models
  • Strengths: Superior color reproduction, design flexibility, and faster print speeds

Types of binder jetting printers

1. Sand binder jetting printers use sandstone or gypsum to create 3D objects. After printing an object, you’ll need to remove molds and clean them to get rid of the loose sand. You can break the molds once they’re ready for casting. Sand binder jetting printers can produce large and complex geometries at a lower cost.

2. Metal binder jetting printers create 3D objects by joining metal powder particles with a polymer liquid binder. A printer first spreads a powder layer and then deposits binder droplets on the powder bed. The process repeats until an object is complete. During post-processing, these objects go through curing, sintering, infiltration, and polishing. Metal binder jetting printers are ideal for manufacturing complex geometries that traditional manufacturing can’t handle.

3. Plastic binder jetting printers work similarly to metal binder jetting printers, but use plastic powder instead of metal powder. These printers don’t require an object to go through sintering.

6. Directed energy deposition

Directed energy deposition (DED) is a metal additive manufacturing process that uses an energy source to melt material fed in wire or powder forms. The heat source melts the material as it leaves the nozzle and creates an object layer by layer. The energy is usually an electron beam, laser, or arc. Different industries use DED technology often to repair objects instead of creating them. Adopting DED is expensive and requires manufacturers to take objects through rigorous post-processing.

DED in 3D printing

  • 3D printing technologies: Laser engineered net shaping (LENS), electron beam additive manufacturing (EBAM), and cold spray additive manufacturing (CSAM)
  • Materials used: Metals, either in powder or wire form
  • Dimensional accuracy: ±0.1 mm
  • Common applications: High-end automotive components repair and functional prototypes
  • Strengths: Works in three dimensions and doesn’t need support structures

Types of DED printers

1. LENS printers use a high-power laser of up to 3 kilowatts (kW) to fuse powdered metals into fully dense 3D structures. The geometric information in the CAD model drives the printing process and builds an object layer by layer. You can leverage closed-loop process controls to ensure the mechanical integrity of completed objects. Aerospace and automotive industries use LENS printers to produce and repair high-end components.

2. EBAM printers use an electron beam to create 3D elements from powder or wire feedstock. The high melting capacity of electron beams eliminates residual stress and produces parts inside the controlled environment of a vacuum. Most commonly used metals in EBAM printing are cobalt, nickel, titanium, and copper.

3. CSAM printers, or cold spray printers, use metal molecules’ velocity to bond metal powders and create 3D objects. Different industries use CSAM printers for coating processes and layering metal in exact geometries at a higher speed. You may not produce superior print quality using CSAM technology.

Other popular DED 3D printing technologies are:

  • Direct metal deposition (DMD): A powder jet manufacturing technology used for building, repairing, and reconfiguring forging dies
  • Wire arc additive manufacturing (WAAM): A fusion manufacturing process that creates 3D objects by melting electrodes with electric arc
  • Rapid plasma deposition (RPD): An additive manufacturing technique for creating objects from metals and metal ores using titanium wire

7. Micro 3D printing

Micro 3D printing, or microscale additive manufacturing, is the technology behind tiny products and components that traditional manufacturing can’t produce. While most micro 3D printers produce parts with single-digit micron thickness, some can print objects measurable in nanometers (nm).

Microscale 3D printing

  • 3D printing technologies: Microstereolithography (µSLA), projection microstereolithography (PµSL), two-photon polymerization (TPP), lithography-based metal manufacturing (LMM)
  • Materials used: Ceramic, polymer, and metal
  • Dimensional accuracy: ± 30 µm
  • Common applications: Electromagnets, embedded electronics, medical implants, and sensors
  • Strengths: Ability to produce tiny yet strong elements

Types of micro 3D printing

1. Microstereolithography creates 3D objects by exposing special liquid resin or other photosensitive material to a UV laser. Microstereolithography belongs to the vat polymerization family. This technique builds an object layer by layer after creating a cross-section of an object with the laser.

2. Projection microstereolithography works similarly to microstereolithography printers, but uses light from a projector instead of a laser. Printers relying on this additive manufacturing technique create objects faster with rapid photopolymerization of liquid polymer.

3. TPP, also known as 2PP, uses a pulsed femtosecond laser to trace object patterns in a resin vat. TPP printers offer the highest accuracy but are expensive. The medical world frequently uses this technology for medical implants and tissue engineering.

4. LMM technology polymerizes light-sensitive resin to create objects. After printing, objects go through a sintering process for finishing.

8. Sheet lamination

Sheet lamination stacks, laminates, and bonds thin sheets layer by layer to create 3D objects. This 3D printing method uses materials such as paper, metal, and polymers. Objects created in this method require post-production finishing with computer numerical control (CNC) routers and laser cutters. Manufacturers use sheet lamination to produce non-functional prototypes and composite items.

Sheet lamination in 3D printing

  • 3D printing technologies: Laminated object manufacturing (LOM), ultrasonic consolidation (UC)
  • Materials used: Polymer, metal, and paper
  • Dimensional accuracy: ±0.1 mm
  • Common applications: Casting molds, non-functional prototypes, and casting molds
  • Strengths: Cost-efficient and faster production

Types of sheet lamination

1. LOM: Originally developed by Helisys Inc., the LOM rapid prototyping system bonds sheets together with glue. You can use a CNC router or laser to create an object from the bonded sheets. While this technique is affordable and offers a fast turnaround time, there’s more work to do on the post-production finishing front.

2. UC: Also known as ultrasonic additive manufacturing (UAM), UC technology uses ultrasonic vibrations to bond metal sheets and create objects. This 3D printing method can quickly bond different types of metal. However, you’ll still need a CNC router to make a 3D printed shape and add details to an object.

3D printing vs. additive manufacturing vs. CNC machining vs. injection molding

Additive manufacturing is the process of layering material to create an object. 3D printing is a form of additive manufacturing and creates objects layer by layer with a machine and CAD software. Additive manufacturing is common in industrial applications, while 3D printing is popular in consumer and recreational applications.

CNC machining is a subtractive manufacturing process that creates custom-designed parts by removing material layers from a stock piece. You can perform this process on various materials, including glass, foam, plastic, metal, and composites. Industries such as aerospace, healthcare, automotive, defense, and consumer electronics leverage CNC machining for replacement parts, direct parts, and rapid prototyping.

Injection molding is a manufacturing process that injects melted synthetic resins into molds to create objects. This manufacturing technology is ideal for the mass production of identical items. Commonly used materials include elastomers, glasses, metal, thermosetting polymers, and thermoplastic. Different industries use injection molding to produce large volumes of complex-shaped objects with less wall thickness.

How does 3D printing work?

Imagine building a custom cardboard box from scratch. You’d need a box cutter, packing tape, and cardboard. First, you’d create an outline and cut the cardboard. Next, you would affix the edges and make room for flaps.

If a 3D printer were to do the same job, it’d deposit layers of material to create the cardboard from the bottom up. These thin layers stick together to build a solid object. Here’s what the entire process looks like:

  • Find a 3D model: The first step is to find a suitable 3D model for printing an object. You can either create this from scratch or download it from a 3D library.
  • Create a printable file: During this step, you create and export a printable file of the 3D model using 3D modeling software.
  • Prepare for slicing: At this stage, you use slicing software to slice up a 3D model into layers and feed the file to the 3D printer.

Components of a 3D printer

Both fully assembled and do it yourself (DIY) 3D printing machines come with core components that make the printers simple and useful. Here’re the components you’ll encounter in a 3D printer.

  • X- and Y-axes: Correspond to the lateral movement
  • Z-axis: Corresponds to the vertical movement
  • Print bed: The flat surface on which a 3D printer builds an object
  • Controller: Handles logic functions and requirements of a 3D printer
  • Extruder: Pushes the filament into the nozzle for printing
  • Hot-end: Melts the plastic for depositing it onto the print
  • Nozzle: Melts the filament with heat
  • Heater block: Connects the heater cartridge and prevents heat fluctuations
  • Heater cartridge: Supplies the hot-end with heat
  • Thermistor: Reads the temperature of the hot-end
  • Motherboard: Ensures smooth functioning of the printer

3D printing materials

3D printing uses dozens of materials, each suited to specific use cases. The functionality and design of 3D objects depend on the features of these materials. Here’s a list of materials commonly used in 3D printing.

Material Features Applications
ABS - Tough and durable
- Heat and impact resistant
- Functional prototypes
PLA - Less resistant to heat
- Biodegradable and odorless
- Concept models
Polyethylene terephthalate glycol (PETG) - High transparency
- Chemical resistant
- Waterproof applications
- Snap-fit components
Nylon - Strong, durable, and lightweight
- Heat and impact resistant
- Functional prototypes
- Wear-resistant parts
Thermoplastic polyurethane (TPU) - Impact resistant
- Vibration dampening ability
- Flexible prototypes
- Medical devices
Polyvinyl alcohol (PVA) - Soluble material - Support material
High impact polystyrene (HIPS) - Soluble material
- Dissolves in chemical limonene
- Support material
Composites - Rigid and strong
- Limited compatibility with printers
- Functional prototypes
- Tooling and fixtures
Standard resin - High resolution
- Smooth finish
- Concept models
Clear resin - Optical transparency - Millifluidics
Draft resin - Faster material for 3D printing - Initial prototypes
- Rapid iterations
Tough and durable resin - Strong, functional, and dynamic
- Handles compression well
- Jigs and fixtures
- Wear and tear prototypes
Rigid resin - Thermally and chemically resistant
- Stays stable under pressure
- Electrical casings
- Automotive housings
High temp resin - High temperature resistance - Heat resistant mounts
- Molds and inserts
Flexible and elastic resin - Flexible
- Bending or compression resistance
- Consumer goods prototyping
- Medical devices and anatomical models
Medical and dental resin - Biocompatible - Dental and medical appliances
Jewelry resin - Easy to cast
- Strong shape retention
- Reusable molds
- Custom jewelry
Ceramic resin - Stone-like finish - Art and design pieces
Nylon 12 - Strong and durable
- Heat and impact resistant
- Functional prototyping
- Medical devices
Nylon 11 - Lower stiffness
- High elasticity
- End-use parts
- Medical devices
Nylon composites - Reinforced with glass, carbon fiber, or aluminum - Structural end-use parts
- Functional prototyping

3D printing benefits

Because 3D printing builds objects one layer at a time, it offers many benefits over traditional manufacturing techniques. Because of these advantages, industries opt for 3D printing to create functional products from different materials and deliver them faster.

Faster turnaround time

Modern 3D printers print complex designs from a CAD model in hours, enabling designers to have a prototype ready in no time. While post-processing takes time for larger volumes, you can reduce the design-to-production and lead times for low to mid-volume printing. This faster turnaround time provides engineers with more time to evaluate the design and features.

Low labor cost

Traditional manufacturing requires skilled operators and machinists, significantly increasing production costs. 3D printers automate the production process and eliminate these labor costs. Apart from post-processing, there’s no labor cost in 3D printing, making it the preferred choice across industries.

High quality

3D printers produce better designs and prototypes compared to traditional manufacturing. As 3D printing technologies create objects layer by layer, it’s easier to eliminate errors that occur in subtractive or injection methods.

Design freedom

Traditional manufacturing comes with several design restrictions that don’t apply to 3D printing. Most of the limitations revolve around optimally orienting a print to reduce support dependency and chances of print failure. Such limited restrictions make it easy for designers to work on complex geometries.

Waste minimization

With subtractive manufacturing methods, there is a high volume of waste material. The amount of waste is significantly less in additive manufacturing as it only uses the material needed to build an object. Furthermore, you can recycle and reuse raw materials to create other objects.

Design customization

3D printing systems build single parts one by one and are ideal for one-off production. Industries use this cost-effective single-run production ability to create custom implants, dental aids, prosthetics, sports gears, and fashion accessories.

3D printing challenges

  • Data storage requirements
  • Lack of training documentation
  • Limited post-processing know-how
  • Lack of 3D printing process knowledge
  • High equipment and manufacturing costs
  • Limited build-to-build accuracy during iterations

3D printing applications

Despite being developed in the 1980s, 3D printing didn’t surge in popularity until recently. Recent improvements in technologies have made 3D printing more accessible across industries. Here’s how these industries leverage 3D printing solutions to drive business innovation and growth.

Education

3D printing revolutionized classroom learning. For example, teachers can facilitate active learning with interactive maps or real-life structures. Students can create low-cost and high-quality prototypes from open hardware designs without expensive tools. Furthermore, they can duplicate museum items and collectibles to understand engineering and architectural principles.

Manufacturing

3D printing reduces labor costs and requires fewer materials, which is why manufacturers use it instead of traditional manufacturing to produce custom parts, one-off prototypes, and large product units. Furthermore, 3D printing enables manufacturers to reduce carbon footprint and establish a sustainable manufacturing process.

Healthcare

Recent advances in 3D printing technology have significantly contributed to healthcare. 3D printing application in medicine ranges from 3D-printed bioreactors to surgical planning models and prosthetics. 3D printing technology enables doctors and medical practitioners to understand complex cases and offer personalized treatment to patients. For example, patients needing prosthetics, orthopedic implants, or artificial organs can now use 3D printed ones instead of expensive alternatives.

Aerospace

The Aerospace and Defense (A&D) industry leverages 3D printing technology to create advanced composite and metal parts, spare parts, and maintenance, repair and operations (MRO). SLA and material jetting are two commonly used technologies used to create prototypes for aerodynamic testing. Other use cases include surrogates (placeholder parts), mounting brackets, high-detail visual prototypes, and jigs & fixtures.

Automotive

Automotive designers use 3D printing technologies to iterate designs, produce critical parts, and offer unparalleled customer service. Common use cases include production of assembly jigs, sensor mounts, brackets, grippers, welding hardware, functional prototypes, fit prototypes, and brazing fixtures.

3D printing software

Finding the right 3D printing software is key to faster rapid prototyping and product development. Let 3D printing software systems help you unify design, engineering, and manufacturing.

Finding the right 3D printing software is key to faster rapid prototyping and product development. Let 3D printing software systems help you unify design, engineering, and manufacturing.

To be included in this category, a software must:

  • Convert 3D models into easy-to-follow instructions for 3D printers
  • Repair and edit STL, 3MF, or OBJ files

*Below are the top five leading 3D printing software solutions from G2’s Winter 2022 Grid® Report. Some reviews may be edited for clarity.

1. Fusion 360

Fusion 360 is an integrated CAD, computer-aided manufacturing (CAM), computer-aided engineering (CAE), and printed circuit board (PCB) software that helps you design, engineer, and manufacture products from a single platform.

What users like:

“Fusion provides a real-time cloud space so I can work with my teammates on the same file. It saves different versions of each modification in case we need it later. Other positive aspects are the variety of file types the program supports, enabling us to open many files in the same environment. Also, there are many tutorials online that explain how to deal with the software.”

Fusion 360 Review, Farouk A.

What users dislike:

“Working with guidelines and vectors was sometimes difficult but in this sense, Rhinoceros had a way of solving lines very well. Fusion had problems in terms of cutting and joining them, but they have been solving it. These types of lines are essential when developing moderately complex structures.”

Fusion 360 Review, Federico C.

2. Onshape

Onshape is a software as a service (SaaS) product that lets you connect, collaborate, and build products on the cloud. This platform combines data analytics, CAD, business analytics, and real-time collaboration tools.

What users like:

“Onshape has a very intuitive built-in versioning and product lifecycle management (PLM), which means no file management and it eliminates uncontrolled copies. The ability to design co-dependent parts in a single view and various contexts is powerful, which you would use for state-specific features, such as closed or open state features.”

Onshape Review, Jairus M.

What users dislike:

“I'm still waiting for the photorealistic rendering capability to be added to Onshape. The software should come integrated with a rendering feature instead of a secondary app.”

Onshape Review, Will H.

3. Tinkercad

Tinkercad is a free and easy-to-use web app for creating 3D designs. Tinkercad is the first choice for many educators and has a community of 35 million users.

What users like:

“Tinkercad is a web-based software for 3D modeling that’s super easy to use and understand. You can create very complex 3D shapes by combining basic shapes.

I like the different shape generators that let you create complex geometries by just changing parameters. At first glance, it seems like it is software just for kids, but if you try it, you’ll find that it is a powerful software for 3D modeling.”

Tinkercad review, Damaris C.

What users dislike:

“If your models grow in complexity and you need more precision and more details, like precision measurement tools or 2D to 3D views, then you will probably need to migrate to a more advanced tool.”

Tinkercad review, Murilo A.

4. Solid Edge

Solid Edge is a portfolio of affordable and easy-to-use product development tools. It’s known for combining the simplicity of direct modeling and the flexibility of parametric design.

What users like:

“Solid Edge has one of the best user-interface in the design industry. You can use it for both 2D and 3D drawing and in the simulation segment. I like Solid Edge’s systematic design method, which is history-based. Solid Edge is good for converting 3D drawings to draft files. It also has a digital library of the engineered part. I like to compare to others because you can directly create threads on any surface without first creating a hole. Solid Edge has good sheet metal segments command under the surfacing tab. ”

Solid Edge Review, Amit P.

What users dislike:

“The motion simulation package has room for improvement, and the multibody dynamics seem quite sketchy to use. Also, we couldn't find any tutorials on the internet that correctly mention ways to use it properly. The sketch section was not that intuitive, and the overall modeling of bodies seemed to have a steep learning curve. Also, I feel it's time that CAD companies start adding node-based modeling to their tools. If Solid Edge does it, I'll be glad to shift completely to Solid Edge only.”

Solid Edge Review, Sanyog L.

5. SOLIDWORKS

SOLIDWORKS offers a suite of tools that help you design, engineer, and manufacture 3D products.

What users like:

“SOLIDWORKS gives you the ability to create 3D designs to a very high specification. It has several standard 3D tools and some surfacing options to create freeform parts. I also love the different rotational views. To go through your design tree is also super easy, so if you have problems and need to make corrections or edit the design intent, it's convenient.”

SOLIDWORKS Review, Jake W.

What users dislike:

“Correcting errors in the design is a little bit difficult and when creating a larger assembly, it consumes too much time. SOLIDWORKS needs to improve the 2D modeling to be more user-friendly.”

SOLIDWORKS Review, Ajoob S.

Scale rapid prototyping and create a resilient supply chain

From making proof-of-concept iterations to creating functional prototypes, 3D printing can handle it all – all while removing bottlenecks from traditional rapid prototyping. Furthermore, you can leverage 3D printing systems to decrease time to market, replace labor-intensive manufacturing, and transform how you manage inventories.

Learn more about the nuances of inventory management and develop a strategy for a competitive market.


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