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3D print guide


Lines on the Side of Print

Lines on the Side of Print

The sides of your 3D printed part are composed of hundreds of individual layers. If things are working properly, these layers will appear to be a single, smooth surface. However, if something goes wrong with just one of these layers, it is usually clearly visible from the outside of the print. These improper layers may appear to look like lines or ridges on the sides of your part. Many times the defects will appear to be cyclical, meaning that the lines appear in a repeating pattern (i.e. once every 15 layers). The section below will look at several common causes for these issues.

Common Solutions

Inconsistent extrusion

The most common cause for this issue is poor filament quality. If the filament does not have very tight tolerances, then you will notice this variation on the side walls of your print. For example, if your filament diameter varied by just 5% over the length of the spool, the width of the plastic extruded from the nozzle could change by as much as 0. 05mm. This extra extrusion will create a layer that is wider than all the others, which will end up looking like a line on the side of the print. To create a perfectly smooth side wall, your printer needs to be able to produce a very consistent extrusion which requires high-quality plastic. For other possible causes of variation, please read the Inconsistent Extrusion section.

Temperature variation

Most 3D printers use a PID controller to regulate the temperature of the extruder. If this PID controller is not tuned properly, the temperature of the extruder may fluctuate over time. Due to the nature of how PID controllers work, this fluctuation is frequently cyclical, meaning that the temperature will vary with a sine wave pattern. As the temperature gets hotter, the plastic may flow differently than when it is cooler. This will cause the layers of the print to extrude differently, creating visible ridges on the sides of your print. A properly tuned printer should be able to maintain the extruder temperature within +/-2 degrees. During your print, you can use Simplify3D’s machine control panel to monitor the temperature of your extruder. If it is varying by more than 2 degrees, you may need to recalibrate your PID controller. Please consult your printer manufacturer for exact instructions on how to do this.

Mechanical issues

If you know that inconsistent extrusion and temperature variation are not to blame, then there may be a mechanical issue that is causing lines and ridges on the sides of your print. For example, if the print bed wobbles or vibrates while printing, this can cause the nozzle position to vary. This means that some layers may be slightly thicker than others. These thicker layers will produce ridges on the sides of your print. Another common issue is a Z-axis threaded rod that is not being positioned properly. For example, due to backlash issues or poor motor controller micro-stepping settings. Even a small change in the bed position can have a major impact on the quality of each layer that is printed.

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Not Extruding at Start of Print

Not Extruding at Start of Print

This issue is a very common one for new 3D printer owners, but thankfully, it is also very easy to resolve! If your extruder is not extruding plastic at the beginning of your print, there are four possible causes. We will walk through each one below and explain what settings can be used to solve the problem.

Common Solutions

Extruder was not primed before beginning the print

Most extruders have a bad habit of leaking plastic when they are sitting idle at a high temperature. The hot plastic inside the nozzle tends to ooze out of the tip, which creates a void inside the nozzle where the plastic has drained out. This idle oozing can occur at the beginning of a print when you are first preheating your extruder, and also at the end of the print while the extruder is slowly cooling. If your extruder has lost some plastic due to oozing, the next time you try to extrude, it is likely that it will take a few seconds before plastic starts to come out of the nozzle again. If you are trying to start a print after you nozzle has been oozing, you may notice the same delayed extrusion. To solve this issue, make sure that you prime your extruder right before beginning a print so that the nozzle is full of plastic and ready to extrude. A common way to do this in Simplify3D is by including something called a skirt. The skirt will draw a circle around your part, and in the process, it will prime the extruder with plastic. If you need extra priming, you can increase the number of skirt outlines on the Additions tab in Simplify3D. Some users may also prefer to manually extrude filament from their printer using the Jog Controls in Simplify3D’s Machine Control Panel prior to beginning the print.

Nozzle starts too close to the bed

If the nozzle is too close to the build table surface, there will not be enough room for plastic to come out of the extruder. The hole in the top of the nozzle is essentially blocked so that no plastic can escape. An easy way to recognize this issue is if the print does not extrude plastic for the first layer or two, but begins to extrude normally around the 3rd or 4th layers as the bed continues to lower along the Z-axis. To solve this problem, you can use the very handy G-Code offsets which can be found on the G-Code tab of Simplify3D’s process settings. This allows you to make very fine adjustments to the Z-axis position without needing to change the hardware. For example, if you enter a value of 0.05mm for the Z-axis G-Code offset, this will move the nozzle 0.05mm further away from the print bed. Keep increasing this value by small increments until there is enough room between the nozzle and the build platform for the plastic to escape.

The filament has stripped against the drive gear

Most 3D printers use a small gear to push the filament back and forth. The teeth on this gear bite into the filament and allow it to accurately control the position of the filament. However, if you notice lots of plastic shavings or it looks like there is a section missing from your filament, then it’s possible that the drive gear has removed too much plastic. Once this happens, the drive gear won’t have anything left to grab onto when it tries to move the filament back and forth. Please see the Grinding Filament section for instructions on how to fix this issue.

The extruder is clogged

If none of the above suggestions are able to resolve the issue, then it is likely that your extruder is clogged. This can happen if foreign debris is trapped inside the nozzle, when hot plastic sits inside the extruder too long, or if the thermal cooling for the extruder is not sufficient and the filament begins to soften outside of the desired melt zone. Fixing a clogged extruder may require disassembling the extruder, so please contact your printer manufacturer before you proceed. We have had great success using the “E” string on a guitar to unclog extruders by feeding it into the nozzle tip, however, your manufacturer should also be able to provide recommendations.

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The Complete Guide to 3D Printing [Part 2]

3D printing is used in a variety of industries, both for rapid prototyping and short-term production.

A key application of 3D printing in various industries is the rapid prototyping of new parts during R&D. No other technology has the capability to instantly produce plastic or metal parts - even in non-factory conditions.

3D printers can be used in-house by companies, while some businesses prefer to order 3D printed prototypes through service bureaus.

Medical

3D printing can be used to make medical components such as titanium implants and surgical guides (SLM), 3D printed prostheses (SLS, FDM) and even 3D bioprinted human tissues. Components for medical equipment and technology - X-ray machines, MRI, etc. - can also be made by 3D printing.

SLA and SLS technologies are also widely used in the dental industry for model making, prostheses and restorations.

Aerospace industry

The aerospace industry has become a major consumer of 3D printing technology because it can produce very light parts with an excellent strength-to-weight ratio. Examples include things as simple as cab bulkheads (SLS) and down to revolutionary engine components (SLM) such as the 3D printed fuel injector tip designed and manufactured by GE.

Cars

Automotive companies regularly use 3D printers to make one-off parts and repairs, as well as rapid prototypes. Common 3D printed automotive parts include brackets, dashboard components, and antennas (FDM).

More extreme examples include vehicles with large 3D printed metal structural components, such as early models from automotive startup Divergent.

Jewelry and art

3D printing technologies such as SLA are widely used (as an indirect fabrication process) in the production and repair of jewelry, while almost all types of 3D printers can be used to create art and sculpture.

Construction

Advances in additive manufacturing with high quality workmanship have expanded the scope of applications in construction and architecture. Concrete 3D printing, which is a bit like FDM but with very wide nozzle extruders, plays an important role in this industry, but more common 3D printing technologies such as SLM can be used for products such as bridge structures.

3D printing file formats:

3D printing parts can be designed with standard CAD software, but 3D printers can only read certain file formats. There are four main file formats for 3D printing.

STL: The most common file format for 3D printers, STL contains part geometry information in the form of tessellated triangles. It does not contain information such as color, material, or texture. The file size is proportional to the detail, which can be a problem.

OBJ: Less common than STL, the OBJ file format encodes the geometry of a 3D model and can include curves and free-form surfaces in addition to tessellation. It can also contain color, material, and texture information, making it useful for full color processes.

3MF: Invented by Microsoft, 3MF is an XML-based format with small file sizes and a good level of error prevention. It has not yet been widely adopted, but is supported by companies such as Stratasys, 3D Systems, Siemens, HP, and GE.

AMF: The successor to the STL format, AMF is much more compact and allows you to tessellate both curved and flat triangles, making it much easier to encode parts of various shapes. Since its inception, the format has been slowly adopted.

3D printing settings and specifications:

3D printing uses specific terminology that may not be clear to beginners. These terms refer to printer settings and/or specifications that can affect how 3D printed parts turn out.

Infill

When making 3D printed parts, it may be necessary to specify an infill percentage, which refers to the internal density of the part. A low infill percentage will result in a mostly hollow part with minimal material holding the mold together; a high infill percentage will result in a stronger, denser, and heavier part.

Layer Height

Layer height, sometimes referred to as z-resolution, is the distance between one 2D part layer and the next. A smaller layer height means finer resolution (and higher possible level of detail) along the z-axis, i.e. top down. A low layer height is an indication of a high quality printer, but users can set a higher layer height for faster, more economical printing.

Print speed

The printer's print speed, measured in millimeters per second, indicates the speed at which the machine can process the source material. Like the layer height, this value can either be a measure of the printer's maximum speed or be user-defined: slower print speeds usually result in more accurate prints.

Print temperature

When applied to processes such as FDM, print temperature usually refers to the temperature of the hot end, the part of the print head that heats the thermoplastic filament. Some FDM printers are also equipped with a heated print bed, the temperature of which is specified by the manufacturer. In both cases, the temperature is usually controlled by the user.

Resolution

In 3D printing, resolution almost always refers to the smallest possible movement along the X and Y axes (width and depth) of either the laser beam (SLA, SLM, etc.) or the printhead (FDM). This value is more difficult to measure than the height of the layer, and it is not always proportional to it.

Shells

Like wall thickness in injection molding, shell (or shell thickness) refers to the outer wall thickness of the 3D printed part. When 3D printing, users usually have to choose the number of shells: one shell = outer walls as thick as a 3D printer nozzle; 2 shells = twice the thickness, etc.

Color 3D printing:

Since 3D printing is primarily used as a prototyping tool, single color prints are sufficient for most applications. However, there are several options for color 3D printing, including high-end material inkjet printers, multi-extruder FDM printers, and post-processing options.

Inkjet Printing Technologies

Major 3D printing companies such as Stratasys, 3D Systems and Mimaki have developed 3D inkjet printers for printing materials and binders that can print 3D models in full color as well as 2D inkjet printers. However, these machines are expensive and the parts do not always have excellent mechanical properties.

Multiextrusion

Several FDM 3D printers are equipped with two (or more) printheads, allowing you to simultaneously print on two spools of filament - different colors or even different materials - within the same print job. It's simple and affordable, but usually limited to two colors.

Filament replacement

Single extruder FDM 3D printer can produce multi-color prints. To do this, you need to pause printing at certain points and replace the spool of thread with a thread of a different color. This is a very slow method of applying color and does not allow precise control over where each color goes.

Adding color after printing

Many 3D printed parts can be dyed, tinted or painted after printing. While this adds another step to the process, it often strikes the best balance between quality and economy.

Post-Processing 3D Printed Parts:

Many 3D printed parts require at least some level of post-processing after leaving the print bed. This may include important processes such as the removal of supports, or additional cosmetic processes such as painting. Some processes apply to all or most 3D printing technologies, and some are specific to a particular technology.

Support Removal

3D printing technologies such as FDM and SLA require the installation of support structures (vertical struts between the printed layer and the part itself) to keep the printed object from breaking during the manufacturing process.

These supports must be removed when the part is finished. Some printers, such as dual-extrusion FDM machines, can print dissolvable support structures, allowing the support structures to be easily detached from the part using liquid chemicals. Insoluble supports must be manually cut from the part, leaving a mark that may need to be sanded down.

Washing and removing the powder

Some 3D printing technologies (such as SLA) leave sticky marks on parts, while others (SLM, SLS) may leave powder marks. In these cases, the parts must be washed - manually or with a special machine - or the powder removed with compressed air.

Heat treatment

Many of the key 3D printing technologies print parts from materials that are not yet in their final chemical state after leaving the printing mold. Such details are sometimes called "green".

Many 3D printed metal parts require heat treatment after printing to increase layer fusing and remove contaminants. And bonded inkjet 3D printers, for example, produce parts that need to be stripped and sintered after printing to remove resin bond layers from inside metal parts.

Some 3D printed resin parts require post-curing after printing to increase their hardness and make them usable.

Surface Treatment

3D printed parts can be subjected to a wide range of surface treatments, from textural treatments such as sanding and smoothing, to visual treatments such as painting and toning. Some technologies, such as FDM, can create a rather rough surface that requires sanding, while others, such as SLA, produce a much smoother surface.

Combination of 3D printing with other technologies:

3D printing does not have to be used as a separate process. Rather than being seen as a competitor to CNC machining and injection molding, it can actually complement these and other manufacturing processes.

Combination examples include:

  • 3D print the main body of the part and then CNC mill the thin parts to tighter tolerances;
  • 3D printable master pattern for investment casting or vacuum casting;
  • 3D print the part and then injection mold it using injection molding.

There are hybrid manufacturing systems that combine 3D printing with other technologies. For example, Mazak's INTEGREX i-400 AM and DMG MORI's Lasertec DED can perform both 3D printing and CNC milling.

Will 3D printing replace other manufacturing processes?

Analysts have long speculated about whether 3D printing could replace other manufacturing processes, including:

  • Processing;
  • Molding;
  • Casting.

However, despite the desire of AM equipment manufacturers to position 3D printing as an end-to-end manufacturing technology, in practice, 3D printing is still limited to some specific manufacturing operations, especially low-volume production of specific materials.

In some areas, 3D printing has certainly overtaken other processes. For example, rapid prototyping with inexpensive plastics like ABS now dominates 3D printing, as ABS is cheaper to print than machined. 3D printing also seems to have established itself as the ideal tool for making objects such as patient-specific titanium medical implants: the speed and geometric flexibility of 3D printing is hard to beat in these specific situations.

In addition, 3D printing is an ideal tool for making objects such as patient-specific titanium medical implants.

Despite this, processes such as CNC machining currently remain the best for producing high quality parts and prototypes from engineering materials such as POM, PEI, PPS and PEEK, with surface finishes far superior to 3D printing. . In addition, processes such as injection molding are still infinitely faster for mass production of simple plastic parts.

In addition, although additive manufacturing is one of the most significant technological advances in manufacturing, which allows it to take a stronger position in manufacturing in general, more established processes such as CNC and injection molding are also being improved to produce higher quality parts. .

3D printing will continue to take an increasing share of manufacturing jobs, but it will not completely replace other technologies.

What did 3D printing look like 10 years ago?

A decade ago, the nascent 3D printing industry was gearing up for what it believed would be a 3D printing revolution: a 3D printer in every home, allowing families to print new items they might need, such as a spare part for a refrigerator, a new toy for kids, or even components to build a second 3D printer.

In 2012-2014, FDM 3D printer manufacturers such as MakerBot actively promoted their 3D printers in the consumer market, trying to convince ordinary people that a 3D printer can improve their home life and work. However, it was clear that these companies were trying to exploit the novelty factor of 3D printing and that their products had no practical application; a 2012 MakerBot press release seems to prove it: Make an entire chess set at the touch of a button. Friends, classmates, colleagues and family members will see what you are doing and say "Wow!".

Just a few years later, this so-called 3D printing revolution clearly failed, and many 3D printer manufacturers began to rethink their goals, moving from consumer to professional and industrial markets, where there were more concrete (and profitable) applications of additive technology.

In addition, those who were already working in the professional and industrial fields - companies such as 3D Systems and Stratasys - began to try to destroy the idea of ​​​​3D printing as a prototyping technology, positioning it as a viable mass production tool (which, obviously, , could be more profitable for the 3D printing industry, as manufacturers would have to fill entire factories with 3D printers, buy 3D printer management software, and hire 3D printing consultants).

What will 3D printing look like in 10 years?

3D printing companies have abandoned the prospect of putting a 3D printer in every home. However, in 10 years, they can expect some form of additive manufacturing to appear in more factories.

Although there is less talk about 3D printing today than in 2012, the technology continues to gain momentum in the professional and industrial world.

According to a recent report, market research firm 3DPBM Research expects the value of additive metal manufacturing to rise from $1.6 billion in 2020 to $30 billion by 2030, and this is largely due to the repositioning of AM as a manufacturing tool and the development of more high-performance engineering materials. (That said, 3D printing will remain a valuable prototyping tool in many industries, and prototyping applications will benefit just as much from technological advances.)

However, not only metal AM is being developed. Technologies such as HP's Multi Jet Fusion have opened up new possibilities for plastic printing, and innovators such as Carbon have developed new high-speed processes in the photopolymerization category. Niche areas such as 3D bioprinting and micro 3D printing are also regularly opening up new opportunities, and composite 3D printing (such as continuous carbon fiber 3D printing) is also on the rise: IDTechEX predicts that by 2030, the market size of composite 3D printing will be $1.7 billion

In short, 3D printing will gradually become a serious competitor to other manufacturing processes in many disciplines.

How to outsource 3D printing services?

Investments in 3D printing hardware and software are not suitable for all businesses, so many successful companies outsource their 3D printing needs to third parties, such as online 3D printing service bureaus (for one-time projects) or prototyping partners and production, such as 3ERP (for one-time projects or repeat orders).

When outsourcing 3D printing services, it is important to consider whether your business needs design and manufacturing services or just manufacturing services. (Keep in mind that a poorly executed 3D model may fail for 3D printing).

In general, though, ordering 3D printed parts from a third party is easier than ever. Many manufacturers can start 3D printing with just a digital 3D model, although more important projects may require a technical drawing to communicate additional information such as materials, colors, and tolerances. Some 3D printing service providers (including 3ERP) will offer advice on suitable 3D printing technologies and materials for your project.

Explore our full range of 3D printing services, including available technologies and materials, or request a quote for your 3D printing project.

The Complete Guide to Stereolithographic (SLA) 3D Printing

Stereolithographic (SLA) 3D printing is gaining immense popularity due to its ability to produce highly accurate, isotropic and waterproof prototypes and models with fine details and smooth surfaces from a variety of modern materials.

This comprehensive guide explains how SLA printing technologies work, why thousands of professionals use them today, and how this 3D printing technology can be useful in your work.

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The development of 3D printing technology continues to influence how companies approach prototyping and manufacturing. This technology is becoming more accessible, and equipment and materials are developing in accordance with the possibilities and requirements of the market. That's why today designers, engineers and others are integrating 3D printing into workflows at all stages of development.

3D printing is helping professionals across industries reduce recruitment costs, accelerate iteration, streamline manufacturing processes, and even discover entirely new business models.

Stereolithographic 3D printing technology has evolved significantly. In the past, resin 3D printers were monolithic and costly, requiring skilled technicians and costly service contracts to operate. Today's small desktop printers are highly flexible and produce industrial-quality products at a much lower cost.

Stereolithography is a type of additive manufacturing. It is also known as photopolymerization in the bath or 3D printing using polymer resin. Devices that use this technology have a common principle of operation: under the influence of a light source (laser or projector), a liquid polymer turns into a solid plastic. The main differences are in the location of the main components such as the light source, work platform and resin tank.

See how stereolithography 3D printing is done.

Stereolithographic 3D printers use light-sensitive curable materials called "polymers". When stereolithographic polymers are exposed to specific wavelengths of light, short molecular chains join together causing the monomers and oligomers to polymerize into either rigid or flexible patterns.

Graphical representation of the main mechanisms of stereolithographic 3D printing.

Models printed on SLA printers have the highest resolution and accuracy, the finest detail, and the smoothest surface of any 3D printing technology, but the main advantage of this method is its versatility.

Materials manufacturers have developed innovative formulas for stereolithographic polymers with a wide range of optical, mechanical and thermal properties similar to standard, engineering and industrial thermoplastic resins.

Comparison of 3D stereolithography with two other common plastic modeling technologies: Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS).

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Learn how to go from design to 3D printing with a Form 3 3D printer. Watch this 5-minute video to learn the fundamentals of using a Form 3 printer, from software and materials to processes printing and post-processing.

Use any CAD software or 3D scan data to design the model and export it to a 3D print file format (STL or OBJ). All printers based on SLA technology work with software that allows you to set print parameters and separate the digital model into layers. After the settings are complete, the model preparation software sends instructions to the printer via a wireless or cable connection.

More advanced users can design directly for SLA technology or, for example, print models with voids to save materials.

After a quick check of the settings, the printing process begins. The printer may run unattended until printing is complete. In printers with a cartridge system, material is replenished automatically.

Formlabs' online Dashboard allows you to remotely manage printers, resins, and employee access.

After printing is complete, models should be rinsed with isopropyl alcohol to remove resin residue from their surface. After the washed models have dried, some materials require final polymerization, a process that ensures the best possible strength and stability of the parts. Finally, remove the support structures from the models and sand down the remaining traces of the supports for a clean finish. Models produced with SLA technology can be machined, primed, painted or assembled depending on the intended use.

The final polymerization is particularly important for functional polymer resins used in engineering, dentistry and jewellery.

Engineers, designers, fabricators and others choose stereolithography 3D printing because it provides excellent detail, smooth surfaces, superior model fidelity, and features such as isotropy and water resistance. In addition, it allows you to work with various materials.

Because 3D printing builds models layer by layer, the strength of finished parts can vary depending on the orientation of the part relative to the printing process: the X, Y, and Z axes will have different properties.

Extrusion-based 3D printing processes such as deposition filament modeling (FDM) are anisotropic due to a special approach to creating different layers during the manufacturing process. This anisotropy limits the application of FDM technology or requires additional changes in the design of the model to compensate for it.

Check out our detailed guide comparing FDM vs. SLA 3D printers to see how they differ in terms of print quality, materials, application, workflow, speed, cost, and more.

Stereolithographic 3D printers, on the other hand, allow the production of highly isotropic models. Achieving detail isotropy relies on a number of factors that can be tightly controlled by integrating the chemical composition of materials with the printing process. During printing, the components of the polymers form covalent bonds, but when creating subsequent layers, the model remains in an "immature" state of partial reaction.

When immature, the resin retains polymerizable groups that can form bonds between layers, giving the model isotropic and waterproof properties after final curing. At the molecular level, there are no differences between the X, Y, and Z planes. This results in models with predictable mechanical characteristics critical for applications such as jigs and fixtures and finished parts, as well as functional prototyping.

SLA printed parts are highly isotropic compared to FDM parts.

Due to its isotropic nature, stereolithographic printed models, such as this jig for Pankl Racing Systems, can withstand directional loads during the manufacturing process.

SLA printed objects are continuous, whether they are solid or have internal channels. Watertightness is important when it is necessary to control and predict the impact of air or liquid flows. Engineers and designers are using the water resistance of stereolithography printers for air and fluid flow applications in the automotive industry, biomedical research, and to test the design of parts in consumer products such as kitchen appliances.

OXO relies on the water resistance of stereolithographic printed models to create durable working prototypes of air and fluid products such as coffee makers.

Stereolithographic 3D printing is used to produce precise, reproducible components in a variety of industries, including dentistry and manufacturing. In order to produce accurate models during the printing process, many factors must be strictly controlled.

The quality of stereolithographic 3D printing is somewhere between standard and precision machined. SLA has the highest tolerance compared to other commercial 3D printing technologies. Learn more about tolerances, accuracy and precision in 3D printing.

The heated resin tank combined with the closed working environment provide virtually the same conditions for every model. The higher accuracy also depends on the lower printing temperature compared to thermoplastic-based technologies in which the raw material is melted. Because stereolithography uses light instead of heat, it prints at close to room temperature and models are not subject to thermal expansion and contraction.

Dental example (comparing a scanned component to an original CAD model) demonstrating the ability to maintain tight tolerances for an entire stereolithographic model.

LFS stereolithography 3D printing involves an optic in a Light Processing Unit (LPU) that moves along the x-axis. parabolic mirrors so that it is always perpendicular to the plane of the platform, so it always moves in a straight line, ensuring maximum precision and accuracy. This allows consistency to be achieved as the size of the equipment increases, for example, when working with a large-sized Formlabs Form 3L stereolithography printer. The LPU also uses a spatial filter, which forms a clear laser spot.

The characteristics of the individual materials also play an important role in ensuring the reliability and reproducibility of print results.

Formlabs Rigid Resin has a high green modulus, or modulus of elasticity, prior to final polymerization, allowing very thin models to be printed with high precision and reliability.

Stereolithography printers are considered the best 3D printers due to the smooth surface of the models produced, the appearance of which is comparable to parts produced by traditional methods such as machining, injection molding and extrusion.

This surface quality is ideal when a flawless finish is required and also helps to reduce post-processing time because these models are easy to sand, polish and paint. For example, large companies like Gillette use stereolithography 3D printing to create finished products such as razor handles in their Razor Maker platform.

Large companies like Gillette use stereolithography 3D printing to create finished products such as razor handles in their Razor Maker platform.

The z-layer height is often used to determine the resolution of a 3D printer. On Formlabs stereolithographic 3D printers, it can be adjusted from 25 microns to 300 microns to trade off speed and print quality.

FDM and SLS printers typically print Z-axis layers between 100 and 300 microns wide. At the same time, a part printed with 100 micron layers on an FDM or SLS printer is very different from a part printed with 100 micron layers on an SLA printer. Models printed on a stereolithographic printer have a smoother surface immediately after printing, because their outer walls are straight, and each new printed layer interacts with the previous one, smoothing out the effect of the stairs. When printed on an FDM printer, layers are often visible in models, and the surface of models printed on an SLS printer has a grainy structure due to sintered powder.

In addition, the stereolithography printer can print fine details: the Form 3 laser spot size is 85 microns, while industrial SLS printers have a laser spot size of 350 microns, and FDM-based devices use nozzles with a diameter of 250– 800 microns.

Models printed on FDM printers often show layer lines and may have inaccuracies around complex features. Models printed on stereolithography printers have sharp edges, a smooth surface, and almost imperceptible layer lines.

The advantage of SLA polymers lies in a wide range of formulations offering a variety of characteristics: they can be soft or hard, contain additives such as glass and ceramics, or have special mechanical properties such as high bending temperature under load or impact resistance. Materials can be designed for a particular industry, such as dentures, or have properties close to those of final materials to create prototypes that can be tested and run under stress.

Ceramic Resin can be 3D printed with a stone-like texture and then fired to create a ceramic product.

In some cases, it is this combination of versatility and functionality that is leading businesses to use polymer-based 3D printing in-house. After solving existing problems through the use of a certain functional polymer, other applications are usually quickly discovered. In this case, the printer becomes a tool for discovering the various properties of various polymers.

For example, hundreds of engineers in the Design and Prototyping group at the Advanced Manufacturing Equipment Research Center (AMRC) at the University of Sheffield have access to 12 stereolithographic 3D printers and various construction materials that they use in numerous research projects for these partner companies. like Boeing, Rolls-Royce, BAE Systems and Airbus. They printed High Temp Resin washers, brackets, and a mounting system for a sensor that must operate in high temperature conditions, and used Durable Resin to create complex spring components for a material handling robot as part of a composite manufacturing automation system.

AMRC engineers have access to 12 stereolithographic 3D printers and various construction materials, allowing them to create custom-designed parts for a variety of research projects, such as brackets for a stacking robot (above) and mounts for an environmental sensor. high temperature (below).

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Stereolithographic 3D printing makes it easier for businesses across industries to innovate. Such industries include engineering, manufacturing, dentistry, healthcare, education, entertainment, jewelry, and audiology.

Rapid prototyping with 3D printing enables engineers and developers to turn ideas into working proofs of concept, transform concepts into high-quality prototypes that look and work like end products, and take products through testing phases to launch into mass production.

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By creating the necessary prototypes and 3D printing special tools, molds and production aids, manufacturing companies can automate production and optimize workflows at a much lower cost and in much faster time than traditional manufacturing. Thus, production costs are reduced and defects are prevented, quality is improved, assembly is accelerated and labor productivity is increased.

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Digital Dentistry reduces the risks and uncertainties associated with human error, enabling consistent quality and precision at every step of the workflow, and improving patient care. 3D printers can produce a range of high quality custom products at low cost, providing exceptional fit and reproducible results.

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3D printers are multifunctional tools for creating immersive learning and research environments. They stimulate creativity and introduce students to professional-level technology, enabling the implementation of the STEAM method in the fields of science, technology, art and design.

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Affordable, professional-grade desktop 3D printers help clinicians produce medical devices that meet individual needs and improve patient outcomes. At the same time, the organization significantly reduces time and money costs: from laboratories to operating rooms.

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High resolution printed physical models are widely used in digital sculpting, 3D character modeling and prop making. 3D-printed models have been featured in animated films, video game characters, theatrical costumes, and even special effects for blockbuster films.

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Professional jewelers use the power of CAD and 3D printing to rapidly prototype, customize jewelry to customer specifications and produce large batches of blanks for casting. Digital tools allow you to create dense, highly detailed models without the tedious, error-prone production of stencils.

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Hearing professionals and labs use digital workflows and 3D printing to simplify the production of high-quality custom and hearing aids, as well as to mass-produce behind-the-ear hearing aids, hearing protectors, custom earmoulds, and headphones .

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Many companies are starting to use 3D printing technology through service bureaus and laboratories. Outsourcing can be a great solution when the need for 3D printing is infrequent or you need to do one-off jobs using materials that have unique properties or produce special models. Service bureaus can also provide advice on various materials and offer additional services such as design or improved finishes.

The main disadvantages of outsourcing are the high cost and duration of production. Often, outsourcing becomes a step on the way to in-house production as needs grow. One of the main advantages of 3D printing is its speed compared to traditional production methods. But it is noticeably reduced when the delivery of the model produced by the involved organization takes several days or even weeks. As demand and production capacity increase, the costs of outsourcing are rising rapidly.

With the increasing availability of industrial quality 3D printing today, more companies are opting to bring 3D printing into their factory right away, vertically integrating it into existing workshops or labs, or providing printers to engineers, designers and other professionals who benefit from digital transformation. projects into physical models or are engaged in the production of products in small batches.

Compact desktop stereolithography 3D printers are an excellent solution for rapid model production. Depending on the number of parts needed and the volume of prints, the investment in a compact 3D printer can pay for itself in just a few months. In addition, compact appliances allow you to purchase just the amount of equipment you need to run your business and scale your production by adding more units as demand grows. Using multiple 3D printers also allows you to print models from different materials at the same time. And when the need arises for the production of large parts or the use of non-standard materials, service bureaus can come to the rescue.

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High production speed is an important reason to buy a desktop 3D printer. When working with a print bureau, there are delays related to the speed of production, communication and delivery. A desktop 3D printer like the Form 3 delivers models in hours, allowing designers and engineers to print multiple parts a day. This contributes to faster iterations and significant time savings in product development, as well as rapid testing of mechanisms and assemblies, avoiding costly tool changes.

Purchasing a desktop 3D printer saves a lot of money by eliminating bureau services and traditional processing methods, as their cost rises sharply with increasing demand and production volumes.

For example, the production engineer and others at Pankl Racing Systems used stereolithographic 3D printing technology to produce products on a tight schedule. This allowed them to independently manufacture custom-designed jigs and other small-sized components for the production line. While stereolithography was initially viewed with skepticism, this technology proved to be an ideal solution to replace the machining of a number of tools. In one of the cases, it made it possible to reduce the manufacturing time of conductors by $51-137

By 3D printing custom-designed jigs, Pankl Racing Systems has significantly reduced both order preparation time and production costs.

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