3D printing has become a common way to manufacture everything from plastic trinkets to advanced aerospace components. The category of 3D printing covers a wide range of technologies, techniques, and materials.
This pczippo blog will cover topics all about 3D printing including: 3D printing history, How Does A 3D Printer Work, the pros and cons of 3D printing, and some general optimization advice to help you print high-quality parts.
What Is 3D Printing?
There are several different types of 3D printing processes in use today. 3D printing first appeared in the early 1980s to replace hand-crafted models and prototypes carved from wood or glued together from scraps of card or plastic.
3D printing is a logical extension of fast prototyping (the development of models and prototypes using automated processes). As a result, both time and money are saved. Engineering, industry, business, and even personal use have all benefited from 3D printing.
3D printing gets done through the use of additive manufacturing, which is the process of joining material under computer control to create a three-dimensional item. Layers of material, including liquid resin to powdered grains, are fused together. A computerized 3D model or CAD file can be used to print a wide range of shapes, even very complicated ones.
A subtractive manufacturing, which carves away at an object, is the exact opposite of additive manufacturing. In other words, 3D printers create three-dimensional models one layer at a time, from the bottom up.
Who Invented The 3D Printer
According to the widely acknowledged history of 3D printing, Charles Hull is the inventor. In 1986, he developed and patented the stereolithography 3D printing technology. Charles Hull also co-founded DTM Inc, later renamed 3D Systems, which is still a world-leading manufacturer of 3D printing machines at present. It must be pointed out that Hideo Kodama first published a study in 1980 concerning the use of photopolymers to swiftly create plastic parts but was unable to obtain a patent.
3D Systems created the SLA-1 in 1987. It was the first 3D printer, and it was built using his unique stereolithography method. To make a final product, an ultraviolet laser was utilized to solidify the photopolymer. The SLA-1 can be seen in the image below:
How Does 3D Printing Work?
Everything begins with a 3D model. You can either build one from zero or download one from a 3D library.
3D Software
Tinkercad is a great place for newbies to start. It is free and runs in your browser; there is no need to install it on your PC. Tinkercad features introductory training and an option to export your model as a printed format, such as.STL or.OBJ.
Now that you have a printable file, the next step is to prepare it for your 3D printer. This is called slicing.
Slicing: From file to 3D Printer
Slicing is the process of dividing a 3D model into hundreds or thousands of layers using slicing software. When your file has been sliced, it is ready to be processed and sent to your 3D printer. The file can be sent to your printer via USB, SD, or Wi-Fi. Your sliced file is now ready for layer-by-layer 3D printing.
What Are the Types of 3D Printing
The overwhelming majority of 3D printers work by layering together the materials. The distinction is often in the raw material and how the machine fuses each layer to generate the end result. There are three types of 3D printers:
Stereolithography (SLA)
It is the process of converting a liquid photopolymer into a solid item. It traces a high-powered laser in the shape of the part’s 2D cross-sectional picture. The plastic layer on the bed plate undergoes polymerization by this light. The build plate is then moved slightly, a new coat of photopolymer is applied, and the laser solidifies it to the preceding layer. The following graphic displays a Stereolithography (SLA) printer:
Selective Laser Sintering (SLS)
The process of selective laser sintering begins with the coating of a thin layer of powder to the build plate. A laser then lines out the part’s cross-section and melts the plastic or metal powder, allowing it to solidify into a solid shape. The process is then repeated by applying a new layer of powder over the prior one.
Fused Deposition Modeling (FDM)
Plastic for FDM machines is delivered on a spool of filament. This filament is forced through a chamber heated to the point of melting the material. The plastic is then sent into a nozzle, where it is deposited one layer at a time to form a solid object.
Material Used in 3D Printing
ABS (Acrylonitrile Butadiene Styrene)
Plastic that is easy to shape and difficult to break. The same stuff that the LEGO bricks are composed of.
Filaments made of carbon fiber
Carbon fiber is utilized to make products that must be both robust and lightweight.
Filaments that conduct electricity
These printable materials are still in the testing stage, but they can be used to create electric circuits without the usage of wires. This is a material that can be used in wearable technologies.
Filaments that are malleable
Flexible filaments yield prints that are both pliable and durable. These materials can be used to print on a variety of items ranging from wristwatches to phone covers.
Filament made of metal
Metal filaments are created by combining finely ground metals with polymer glue. To achieve the true look and feel of a metal object, they can be made of steel, brass, bronze, or copper.
Filament of wood
These filaments are made of finely ground wood powder and polymer glue. These are obviously used to print wooden-looking things and might appear lighter or darker depending on the printer’s temperature.
What are the Best Practices for High-Quality 3D Printing?
Your ability to manufacture high-quality 3D printed items is heavily reliant on adhering to 3D printing DFM standards. It is important to:
Limit Overhangs: These overhangs should be kept to a minimum because most 3D printing objects do not print properly with excessive overhangs. Overhanging components requires support structures, which must be post-processed, adding steps and compromising surface uniformity.
Layer Height Must Be Reduced: The layer height determines the size of each layer in the print. The better the resolution of the part, the lower the layer height.
Reduce Printing Speed: Slowing down the printing process causes the print to take longer but generally results in higher quality pieces.
Choose Appropriate Materials: Some materials generate higher quality products with superior surface finishes than others. As a result, the right material can make a big difference.
Matching Technology to Application: Printing technologies have significant effects on part quality. When compared to SLA or SLS, FDM, for example, generates comparatively low-quality products.
What are the Positives and Negative aspects of 3D Printing?
Because of its numerous advantages, 3D printing is widely employed in a variety of industries. However, some issues have stopped 3D printing from becoming a dominating manufacturing method thus far. The following are some advantages and disadvantages:
Positives Of 3D Printer
- Rapid Product Development: 3D printing facilitates rapid product development by allowing engineers to make adjustments quickly on prototypes.
- Less powerful devices can be purchased at a very low price. These machines, however, create parts with little industrial utility.
- Ease of Use: 3D printers are now relatively accessible and do not require much skills to use. The pieces are translated into printable layers using slicing software, and the machines are set up for maximum performance by default.
Negatives Of 3D Printer
- Material Restrictions: 3D printing has limited industrial functionality. This is due to the fact that printers can only use particular materials. Metal alternatives are particularly restricted.
- Low Production Volume: Although 3D printers can iterate quickly during R&D, technologies lose their advantage when it comes to large-scale production.
- Established technologies such as CNC machining and injection molding can create big volumes considerably more quickly.
What Is the Price of a 3D Printer?
The price of a 3D printer varies considerably depending on the technology and materials used. The following are some examples of both low- and high-quality 3D printers:
| 3D Printer | Technology | Cost | Unique Features |
| Creality Ender 3 Pro | FDM | $240 | Low-cost |
| Ultimaker S5 | FDM | $6,950 | High-quality functional prints; Can print with infused composite fibers; Dual Extrusion |
| Creality LD-002H | SLA | $179 | Low cost; Higher quality than similarly priced FDM printers; Resolution even better than some higher-end FDM printers |
| Form 3L | SLA | $10,999 | Can print large-high-quality parts; Very high part resolution (25 microns) |
| Sintratec Kit | SLS | $5,999 | Low-cost entry to SLS; High resolution (100 Micron); Can print functional parts |
| ProX SLS 6100 | SLS | $100,000 | Automated material handling; High production volume; High resolution (80 microns) |
Wrap- up
In wrapping up our exploration of 3D printing, it’s fascinating to see how this technology has truly revolutionized the way we bring ideas to life. Picture this: a process that takes a digital blueprint and transforms it into a physical object layer by layer. The magic happens as the 3D printer meticulously adds material, creating a tangible representation of what was once just a virtual concept.
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