3D Printing:

There's a good chance you're interested in learning more about 3D printing if you're reading this. So, what is 3D printing and why is it so interesting? Simply put, 3D printing is the additive-manufacturing technique of creating a three-dimensional object from a digital model.  In the case of FDM (Fused Deposition Modelling), this process begins with a 3D printer pushing molten material from a print head, which is then programmed to move across 3 axis, extruding subsequent layers of material to create the desired object. With a printer that fits on your desktop, you can create objects at home using 3D printing, which has grown so widespread in recent history. Over 3.4 million consumer 3D printers have been sold globally as of 2017. The technological advancements driving this additive manufacturing revolution have been nothing short of astonishing!

In this article, we’ll look at a brief history of 3D printing, the process of manufacturing an object using FDM technology, and the advantages and benefits of using 3D printing in lieu of traditional manufacturing practices in different industries.

A Brief History.

3D printers have been around a lot longer than you’d think. The concept of 3D printing has existed since the 1940’s, and in the 1960’s a group of Japanese scientists created a technique called stereolithography which used lasers to solidify a small layer of liquid plastic into a desired shape. Many of the Resin 3D printers on the market use this same technology, although much has improved over the many years since its conception.

Although 3D printing has been around for more than 50 years, its full potential didn't emerge until the early 2000s. A group of scientists at the University of Utah created software in 2002 that allowed people to print objects from digital models. The first professional desktop printers went on sale shortly after that. Since then, the technology has advanced and is now capable of creating a variety of valuable goods. Let's examine everything you should know about this fascinating technology and all of its tremendous potential.

The Printing Process.

The 3D printing process begins with modelling. A 3D model can be made using a variety of techniques, with computer-aided design being the most popular (CAD). Users utilizing CAD software can enter an object's dimensions to produce a digital model that can be printed. Other common techniques involve the use of a 3D scanner to scan an existing object, and a more traditional mesh-based computer modeling which allows users to shape and sculpt a 3D object – much like you what you would do if you were creating a vase from clay. Many alternative techniques, such SLA, FDM, or selective laser sintering, can be used to directly print models that were produced using CAD (SLS).

Once a model has been generated, it must be translated into code, known as .gcode. This is accomplished by utilizing a slicer program, which converts a 3D model into the gcode format required by 3D printers. Gcode, a language specific to 3D printers and CNC (Computer Numerical Control) machines, instructs the printer how and where to deposit material at each location on the build surface in order to create the object.

Plastics and metal powders are the two most prevalent types of materials utilized in 3D printing. The most widely utilized material is plastic since it is less expensive and more convenient to use than metal powders. Metal powders are utilized to make complicated structures that plastic filaments cannot produce. They are also utilized to make load-bearing components like screws and nuts that need to be strong and long-lasting. Stainless steel and aluminum are frequently utilized as powdered metals in 3D printing. When necessary, they can also be utilized to produce titanium components and other specialty metals.

The Benefits to 3D Printing.

There are several advantages to 3D printing that conventional production methods cannot provide. These include the capacity to produce intricate shapes that cannot be produced using conventional techniques. Traditional manufacturing methods, for instance, would not be able to create a hollow tooth, but a 3D printer may manufacture an object with internal cavities or hollow areas without this restriction.

Because 3D printing doesn't require special equipment or tooling, it may be completed considerably more quickly than traditional manufacturing processes. Fewer product revisions and shorter production times are possible with rapid prototyping using 3D printing. Additionally, this accelerated pace makes it simple and quick to generate small product batches. Due to the significant cost of developing specialized machinery and tooling for each batch, it is more difficult to manufacture small quantities of products using traditional production methods. Additionally, utilizing 3D printing to manufacture plastic parts can be up to 80% less expensive than using conventional manufacturing techniques.

Beyond creating components, 3D printing has other applications. It can also be applied to the production of completed goods. Some businesses produce copies of their items using 3D printers on demand, doing away with the need for massive stocks and pricey shipping operations. Prototypes for new products or improvements to existing ones can also be made using 3D printing.

Custom prosthetics can also be made via 3D printing. A few hospitals and clinics regularly create new prosthesis for patients using 3D printers. These 3D printed prosthetics are more comfortable, lighter, and can be more easily adjusted to the patient's demands than conventional prosthetics.

Manufacturers in the aerospace sector utilize 3D printers to create airplane parts. In addition to being utilized to build new aircraft, these components are also used to modify and repair older ones. Additionally, it is used to test novel ideas and create prototypes for new aircraft components. Manufacturers in the automotive industry are employing 3D printers to produce prototypes of new car designs and test various configurations before moving into mass production. Manufacturing of consumer goods, medical devices, and architecture, engineering, and construction (AEC) products are made more cost effective and readily available than ever before with the use of 3D printing technology.

3D printing has been around for quite a while and can be used in a variety of beneficial ways to help make production and manufacturing more convenient than ever before. As 3D printing becomes more accessible and the technology advances, the potential advantages over traditional manufacturing methods will become more obvious. In just a short time, since the early 2000’s, the 3D printing revolution has taken over the market, and one day, may allow for even more efficient production than ever before.

If you're interested in learning more about how we use 3D printing in our design and prototyping process, head over to our project blog.