A 3D Printer uses a digital object to create a physical item. The digital model is sent to print preparation software that slices it into layers representing horizontal cross-sections of the part.
The slicer solidifies the modeled parts by melting resin or sintering layer by layer. The parts are then removed and processed as needed for the application.
Rapid Prototyping
A 3D printer is able to produce high-fidelity prototypes, which closely match the final products. This allows designers to perform reliability tests and other engineering tasks. The process can also reduce the time it takes to produce prototypes, compared to traditional manufacturing techniques.
The prototypes are a great way to get feedback from customers. This helps improve the final product and refine the design. For example, 3D printed prototypes can be used to test the effect of a new color on consumer perception. If the response is positive then the company can proceed with production.
A 3D-printer can be used to fabricate components, unlike other prototyping techniques that require expensive tools and molds. This allows R&D to iterate more quickly on designs, resulting in a faster design cycle and a quicker time to market for the final product.
There are several 3D printing techniques available for rapid prototypes, each with their own strengths. For instance, material jetting (such as FDM) produces parts with a high finish and form but is relatively brittle. Binder jetting is a method that uses two printjets: one for depositing build materials and the other for dissolvable support materials. It produces stronger, more accurate, but slower, parts.
SLS and DMLS can produce parts that are extremely strong and lightweight. These processes are expensive, and it can take weeks to finish a single component. Electron beam melting is a fast, cost-effective process that only works with certain metals like titanium and chromium cobalt alloys.
MJF, as well as PolyJet based on Photopolymer Resins, provide excellent surface finishes with fine feature resolution. This machine can also produce elastomeric components that are flexible and stretchy.
3D Technix can also be used to replace manual prototyping techniques, such as sanding and spray painting. This allows companies to save money by avoiding a costly production and make iterative adjustments more quickly. The overall development cycle can be significantly reduced by replacing months of waiting with days or even weeks.
In-House Production
In-house printing is a great option for manufacturing companies looking to take the next steps. For one, it allows for rapid prototyping to improve efficiency. It can also save on shipping costs by replacing heavy traditional parts with lighter 3D printed models.
Another benefit of in-house production is that it provides control over intellectual property, mitigating risks from sharing a design with competitors. It can also reduce the time it takes to bring new products to market, by eliminating the requirement to wait for traditional processes such as machining, molding, and casting. A 3D printer can also be used to create manufacturing fixtures and jigs. This includes polymer nests that hold components being machined or molded, as well as custom fixtures and tooling for quality assurance testing.
As the capabilities of 3D printers continue to expand, many schools now offer CAD and product development courses that include experience using the technology. There are also now over a dozen degrees specializing in additive design. The ability to print a model or prototype in less than an hour is a huge advantage for student projects and for startups that need quick, inexpensive tools to test their designs.
While it may still be too expensive for most individuals to print their own homes, the technology is gaining traction in other applications, including medical uses. Physicians can now create models of internal organs and structures using CT scans to prepare for surgery. 3D printers are also used to create prosthetics, artificial teeth, and hearing aids. Some are using them to make gunshot wound models to help forensic investigators.
The rise of smart factories and the on-demand manufacturing model supports the idea that 3D-printing can be a part of high-volume production. Whether it’s used to augment a traditional manufacturing process or in its place, it can reduce production time and costs by using digital inventories and on-demand printing. It can also improve resilience, create a more flexible supply chain and reduce lead times. It can even be used to replace dedicated production systems with flexible manufacturing system that supports both high-volume as well as low-volume product.
Expansive Materials
To create parts, 3D printing uses a variety of materials including metals, plastics and other types. Many of these materials need to be heated up or sintered to reach their final shape. They also need to cool down, and this results in their thermal expansion or contraction. This effect is a necessary part of the additive manufacturing process, and it helps make printed parts stronger.
A 3D Printer creates 3D forms by depositing a polymer plastic, or filament, on a print bed layer by layer. It can work with any type of computer-aided design (CAD) software to produce the required geometry. The CAD files are converted into a 3D-ready file format, typically an STL or OBJ. This file can then be loaded into a 3D-printer and used to create the object.
Using a 3D printer, it’s possible to build complex geometries that couldn’t be produced with traditional manufacturing techniques. This opens the door for a wide variety of applications in engineering, architecture and other fields.
Some of the most popular 3D printers are made with biodegradable materials like polylactic acid, which is derived by renewable resources such as corn starch or cane sugar. This gives the technology an eco-friendly edge over traditional manufacturing, reducing environmental harm.
Other 3D printing methods include stereolithography (SLA), digital light processing (DLP), selective laser sintering (SLS) and electron beam melting (EBM). SLS uses a high-powered laser to fuse fine plastic, metal, ceramic or glass powder particles together layer by layer. This process is very precise and accurate, and is used to manufacture medical implants and aircraft components.
Another option is material jetting, which uses high-pressure jets of polymer fluids to build layers of molten thermoplastic. It’s less precise but more economical than SLS. It can be used in conjunction with other 3D-printing processes to create a variety of colors and textures.
The quality of 3D prints depends on the type and density of infill, as well as temperature control. In addition, the printing surface should be free of moisture to prevent warping. Moisture can transform from water into steam, disrupting the flow of molten filament and weakening the resulting print.
Time-Saving
The printing time is an important factor in 3D printing. Depending on the size of the part and its settings, it can take several days to print. You can reduce the print time by making some adjustments to your hardware and software.
First, consider the material you’re using. Plastic 3D printers are typically a lot faster than metal ones, because they use much less power. The majority of the printing materials used by 3D printers come from renewable resources such as corn starch and sugarcane. This means that the resulting products are eco-friendly and far more sustainable than most products made through traditional methods.
3D printing allows you to print multiple layers simultaneously, as it is an additive process. This is great for prototyping, as it allows you to make iterations of a product quickly and easily. The parts can be produced locally, saving on shipping costs.
3D printing also saves time by eliminating the need for destructive testing on prototypes. This is a common step in the development of mechanical parts, and it involves doing thermal, stress, and cyclic testing until the component breaks. These tests can be run overnight if you 3D print your prototype. This saves you the cost of hiring someone else to do them.
A 3D printer offers many design possibilities, which are not possible with other manufacturing methods. For example, it can create structures with overhangs and complex lattices, which would be costly or impossible to create in a single piece with traditional manufacturing processes. 3D printing is also used to create bespoke medical devices like hearing aids and artificial teeth that are tailored to each patient. It can also be used to make replicas of internal structures from CT scans, which are useful for surgical planning. A variety of 3D printing machines make it possible to print decorative items and jewelry.
