3D print metal insert

The simple post-processing techniques presented in this guide are an excellent way for professionals to create low-cost silicone molds, threaded inserts for enclosures, vacuum formed parts, and more.

Threaded brass inserts can be a great way to add longevity to 3D printed enclosures that need to accept screws.

In this “how to” we will show you some of the best practices associated with installing threaded brass inserts into your 3D printed enclosures.

Working time will vary depending on your model and how many inserts you plan to install. The process shown took us about 10 minutes from start to finish.

SUPPLIES

Soldering Iron

Threaded brass inserts with matching machine screws

Washers

Pliers

Vise

Heat resistant gloves

Eye protection

Respiratory mask

Need some of these products? We've curated an Amazon wish list for you.

STEP 1: OBTAIN YOUR MODEL

If you are designing your model to meet a specific need, remember to design the holes in your model slightly smaller than the inserts you plan to install. This will account for any plastic that melts when installing inserts. If you are adding inserts to a downloaded model, purchase your inserts with the hole diameter in mind.

For our model, we chose this “Light Switch Box” designed by Thingiverse user qbasan.

Manufacturers of threaded brass inserts specify the hole size needed for the insert.

Step 2: Prepare & Print

When installing inserts, changing a few print settings in MakerBot Print can be a big help.

Increase the number of shells in your print. This will leave more plastic around inserts.

Once you have selected your settings you can print your object. We chose to print our model on the MakerBot Replicator+.

STEP 3: ROUGHING

Supplies Used: Needlenose pliers

Once your model has been printed and removed from the build plate, remove any rafts or support material.

Supplies Used: Soldering Iron

Allow your soldering iron to heat for 3-5 minutes before installing inserts. This will ensure that you have to use the least amount of force to install inserts.

The 2021 Guide to 3D Printing Materials

Learn about polymers, composites, and metals all available for 3D Printing!

Supplies Used: Soldering Iron

Before installing your inserts, it’s also important that your model be secure. If your model moves during installation of an insert, you could damage the void or even the model itself.

We used a multi-axis vice that allowed us to work on the model from a few different angles.

Secure the model

Adjust the angle of the model

Supplies Used: (continued use through Step 9) Multi-axis vice, soldering iron, threaded brass inserts, and pliers

Because PLA has a relatively low heat deflection temperature and can deform at moderate temperatures, it is important to install inserts gradually.

A: Grasp your insert with pliers
B: Position insert over hole

C: Press the insert half way into your print holding the soldering iron vertically
D: Move on to the next insert

Push lightly, your soldering iron should do most of the work for you

As brass transfers temperature relatively quickly, your inserts should be cool within a minute or so.

STEP 8: COMPLETELY INSTALL INSERTS

Once you’ve allowed your model to cool for a minute or so, install the inserts until they are flush with the top of your model.

When completing the installation of inserts be sure to avoid:

Installing too quickly

Pushing down on your inserts with too much force

Caution:

Never attempt to hold inserts in place with your hand when installing. Always use pliers.

Supplies Used:

Screws & washers

Screwdriver

Multi-axis vice

Thread in your screws using a screwdriver or drill.

Insert washers and screws

Insert additional hardware

Caution: Be sure not to over tighten. This can force the insert free from the surrounding plastic.

If you over tighten your screws, you may need to melt out your inserts and reinstall.

Here is our final part. After installing inserts, screws, and washers, we added the final switches to this electrical enclosure.

Visit one of our other applications pages for tips on how to take your print even further.

We recommend that you visit our pages on:

Vacuum Forming
Silicone Molding
Painting

Last but not least, remember to share your work with us on Thingiverse and social media @MakerBot.

We can’t wait to see what you make!

Light Switch Box
Qbasan
11/12/2014
https://www.thingiverse/thing:541876

Powered by MakerBot Learning.

How metal 3D printers work. Overview of SLM and DMLS technologies. additive manufacturing. 3D metal printing.

Hello everyone, Friends! 3DTool is with you!

BLT metal 3D printer catalog

Selective laser melting ( SLM ) and direct metal laser sintering ( DMLS ) are two additive manufacturing processes that belong to the family of 3D printing using the powder layer method. The two technologies have much in common: they both use a laser to selectively melt (or melt) metal powder particles, bonding them together and creating a pattern layer by layer. In addition, the materials used in both processes are metals in granular form.

The differences between SLM and DMLS come down to the basics of the particle bonding process: SLM uses metal powders with a single melting point and completely melts the particles, while in DMLS the powder consists of materials with variable melting points. nine0014

Specifically:
SLM produces single metal parts while DMLS produces metal alloy parts.
Both SLM and DMLS technologies are used in industry to create final engineering products. In this article, we will use the term "metal 3D printing" to summarize the 2 technologies. We will also describe the main mechanisms of the manufacturing process that are necessary for engineers to understand the advantages and disadvantages of these technologies. nine0002 There are other manufacturing processes for producing dense metal parts, such as electron beam melting (EBM) and ultrasonic additive manufacturing (UAM). Their availability and distribution is rather limited, so they will not be presented in this article.

How does metal 3D printing work? The basic manufacturing process for SLM and DMLS is very similar.

1. The printing chamber is first filled with an inert gas (such as argon) to minimize the oxidation of the metal powder. It then heats up to the optimum operating temperature. nine0002 2. A layer of powder is spread over the platform, a powerful laser makes passes along a predetermined path in the program, fusing the metal particles together and creating the next layer.
3. When the sintering process is completed, the platform moves down 1 layer. Next, another thin layer of metal powder is applied. The process is repeated until the entire model is printed.

When the printing process is completed, the metal powder already has strong bonds in the structure. Unlike the SLS process, parts are attached to the platform via support structures. The support in metal 3D printing is created from the same material as the base part. This condition is necessary to reduce deformations that may occur due to high processing temperatures. nine0002 When the 3D printer's chamber cools down to room temperature, excess powder is removed manually, such as with a brush. The parts are then typically heat treated while they are still attached to the platform. This is done to relieve any residual stresses. They can then be further processed. The removal of the part from the platform occurs by means of sawing.

In SLM and DMLS, almost all process parameters are set by the manufacturer. The layer height used in metal 3D printing varies from 20 to 50 microns and depends on the properties of the metal powder (fluidity, particle size distribution, shape, etc.). nine0002 The basic size of the print area on metal 3D printers is 200 x 150 x 150 mm, but there are also larger sizes of the working area. Printing accuracy is from 50 - 100 microns. As of 2020, metal 3D printers start at $150,000. For example, our company offers 3D metal printers from BLT.
metal 3D printers can be used for small batch production, but the 3D printing capabilities of such systems are more like those of mass production on FDM or SLA machines. nine0002 The metal powder in SLM and DMLS is recyclable: typically less than 5% is consumed. After each impression, the unused powder is collected and sieved, and then topped up with fresh material to the level required for the next production.
Waste in metal printing, are supports (support structures, without which it will not be possible to achieve a successful result). With too much support on the manufactured parts, the cost of the entire production will increase accordingly. nine0002

3D metal printing on BLT 3D printers

SLM and DMLS metal parts have almost isotropic mechanical and thermal properties. They are hard and have very little internal porosity (less than 0.2% in 3D printed condition and virtually non-existent after processing).
Metal printed parts have higher strength and hardness and are often more flexible than traditionally made parts. However, such metal becomes “tired” faster. nine0014

Support structures are always required when printing with metal, due to the very high processing temperatures. They are usually built using a lattice pattern.

Supports in metal 3D printing perform 3 functions:

• They form the basis for creating the first layer of the part.
• They secure the part to the platform and prevent it from deforming.
• They act as a heat sink, removing heat from the model. nine0014

Parts are often oriented at an angle. However, this will increase the amount of support required, the printing time, and ultimately the overall cost.
Deformation can also be minimized with laser sintering templates. This strategy prevents the accumulation of residual stresses in any particular direction and adds a characteristic surface texture to the part.

Since the cost of metal printing is very high, software simulations are often used to predict how a part will behave during processing. These topology optimization algorithms are otherwise used not only to increase mechanical performance and create lightweight parts, but also to minimize the need for supports and the likelihood of part distortion. nine0014

An example of printing on a BLT 3D printer

Unlike polymer powder melt processes such as SLS, large hollow sections are not typically used in metal printing as the support would be very difficult to remove, if at all possible.
For internal channels larger than Ø 8 mm, it is recommended to use diamond or teardrop cross-sections instead of round ones, as they do not require support. More detailed recommendations on the design of SLM and DMLS can be found in other articles on this topic. nine0014

As an alternative to hollow sections, parts can be made with sheath and cores, which in turn are machined using different laser power and pass speeds, resulting in different material properties. The use of sheath and cores is very useful when making parts with a large solid section, as it greatly reduces printing time and reduces the chance of warping.

The use of a lattice structure is a common strategy in metal 3D printing to reduce part weight. Topology optimization algorithms can also help design organic lightweight shapes. nine0014

SLM and DMLS technologies can produce parts from a wide range of metals and metal alloys, including aluminum, stainless steel, titanium, cobalt, chromium and inconel. These materials meet the needs of most industrial applications, from aerospace to medical applications. Precious metals such as gold, platinum, palladium and silver can also be processed, but their use is of a minor nature and is mainly limited to jewelry making. nine0014

The cost of metal powder is very high. For example, a kilogram of 316 stainless steel powder costs approximately $350-$450. For this reason, minimizing part volume and the need for supports is key to maintaining optimal manufacturing cost.
The main advantage of metal 3D printing is its compatibility with high-strength materials such as nickel or cobalt-chromium superalloys, which are very difficult to machine with traditional methods. Significant cost and time savings can be achieved by using metal 3D printing to create a near-clean shape part. Subsequently, such a part can be processed to a very high surface quality. nine0002

Various post methods. treatments are used to improve the mechanical properties, accuracy and appearance of metal printed products.
Mandatory post-processing steps include the removal of loose powder and support structures, while heat treatment (heat annealing) is typically used to relieve residual stresses and improve the mechanical properties of the part.

CNC machining can be used for critical features (such as holes or threads). Sandblasting, plating, polishing, and micro-machining can improve the surface quality and fatigue strength of a metal printed part. nine0014

Pros:

1. Metal 3D printing can be used to make complex custom parts, with geometries that traditional manufacturing methods cannot provide.
2. Metal 3D printed parts can be optimized to increase their performance with minimal weight.
3. Metal 3D printed parts have excellent physical properties, metal 3D printers can print a wide range of metals and alloys. Includes difficult-to-machine materials and metal superalloys. nine0014

Cons:

1. Manufacturing costs associated with metal 3D printing are high. The cost of consumables is from $ 500 per 1 kg.
2. The size of the working area in metal 3D printers is limited.

• Metal 3D printing is most suitable for complex, one-piece parts that are difficult or very expensive to manufacture using traditional methods, such as CNC.
• Reducing the need for building supports, will significantly reduce the cost of printing with metal. nine0002 • 3D printed metal parts have excellent mechanical properties and can be made from a wide range of engineering materials, including superalloys.

And that's all we have! We hope the article was useful to you.

Catalog of 3D printers for metal BLT

You can purchase metal 3d printers, as well as any other 3d printers and CNC machines, by contacting us:

• By email: [email protected]

• By phone: 8(800)775-86-69

• Or on our website: http://3dtool.ru

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3D printer threads and thread inserts for plastic

At Formlabs we design various functional parts for printing on our stereolithography (SLA) 3D printers such as the Form 3. These parts include prototypes used for our own R&D , clamps and fasteners to be used on our production lines, models for design verification before casting the final product in the appropriate material, such as nylon. nine0014

Regardless of the application, we often need to connect 3D printed components with screws and threaded fasteners. As the catalog of versatile and reliable engineering polymers grows, the differences between "imitation" prototypes and functional prototypes diminish.

This article is a guide to threading and threading 3D parts with a 3D printer. There are many ways to connect multiple 3D printed parts together, but if you need the ability to repeatedly connect and disconnect components and secure mechanical fastening, there is no real substitute for metal screws. nine0014

Do you like to see everything with your own eyes? Watch a video about 3D printing threaded connections and threaded inserts for 3D plastic parts.

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Download our white paper on stereolithography to find out how SLA printing works, why thousands of people use it today, and how this 3D printing technology can be useful in your work.

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Let's take a look at some of the threading options for 3D parts we've put together based on years of Formlabs experience and your suggestions. We've ranked these options, starting with the one we think is the best, with the pros and cons of each option for different use cases. nine0014

Experience Formlabs print quality firsthand. We will send a free 3D printing sample directly to your office.

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Benefits: Strongly connects 3D printed parts without the use of glue. The metal threads are durable and reusable.

Disadvantages: Inserts may loosen with increasing temperature.

3D print a sleeve blank with a depth and diameter that matches the insert specifications. Rinse with isopropyl alcohol (IPA) and allow to dry without final polymerization. Insert the insert into the sleeve with a screwdriver and use the screw to secure it completely into the plastic. Then finish curing the part to reduce the creep effect and fix the insert in the plastic even better. Performing this step last reduces the chance that the insert will break the sleeve when screwed in. nine0014

Benefits: Connects 3D printed parts very securely. The metal threads are durable and reusable.

Cons: Requires glue (don't try to use a soldering iron!).

Threaded inserts with heat setting are designed for installation in thermoplastics using a soldering iron with a soldering tip. They can be used in acrylic models and Fused Deposition Models (FDM), but cannot be used with in SLA photopolymer parts, which bend but do not melt when heated.

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.

However, the notches and ridges on the heat set inserts make them a very effective thread fastener if you bond them with a two part epoxy or cyanoacrylate adhesive. Determine the bushing size by the largest diameter of the insert and apply some adhesive before installation. For best results, the part must be completely dry and cured. nine0014

Benefits: Nuts are easy to match to any required screw size.

Drawbacks: Side nut slots can eliminate the need for glue, but may make it harder to support the model during printing.

The addition of a hexagon socket on the nut press-fit end creates a reusable strong metal-to-metal connection. To increase the twisting force, you can choose a square nut. This nut can also be plastic or have blocking elements. If necessary, a drop of cyanoacrylate glue will help hold the nut in place, but if the design includes a side socket, there is no need for glue. Use a 0.1 mm offset around the press-in nut and clearance around the screw itself. nine0014

Benefits: Prototyping uses the same metal parts as mass-produced injection molded parts. Sleeve blanks made from Tough (and Durable) polymer are unlikely to crack if you follow the screw manufacturer's sleeve design guidelines.

Disadvantages: The screws will hold tight, but the threads will not be as resistant to repeated use as metal threads. Standard resins can be used, but the bushing is more likely to crack. nine0014

Follow manufacturer's recommendations for core sizes and print with high impact engineering resins (such as our Tough Resin and Durable Resin). Before using the screws, complete the final curing. If you are prototyping an injection molded part that will use tapping or tapping screws in its final assembly, this is a good option for testing.

Benefits: No need to buy special plastic screws. nine0014

Disadvantages: The screws will hold tight, but the threads will not be as resistant to repeated use as metal threads.

We have tested screws in our Tough Resin product and found that their use is identical to that of threading screws designed for plastics. The size of the hole diameter of the threaded bushing must be in the range between the main (threaded) diameter of the screw and the inner diameter. The screw shown is a #8 screw in a 0.16" diameter hole. nine0014

Benefits: Can be used for prototyping large and custom threaded designs.

Disadvantages: Not a durable or reusable fastening solution, especially for smaller thread sizes.

3D printed threads from standard resins are better than Tough Resins because they are much harder. 3D printed threads remain relatively brittle, depending on the size of the thread, and are not recommended if the fastening system is to be used continuously and repeatedly. nine0014

Thread sizes ¼-20 or larger are generally functional without the need for post-processing. For smaller screws, the threads must be modified to provide better fastening. For example, printing a round thread profile (on a screw and a nut) and using a 0.1mm offset results in a better thread fit and improved wear characteristics. For all screw sizes, it is best to orient the parts so that the supporting structures do not touch the threads.

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