3D printer stage


A Step-By-Step Guide of 3D Printing

For many people, 3D printing seems to be a manufacturing technology that exists in the future world. 3D printing technology has been popularized and widely used today. 3D printing was born in the late 1980s. The world’s first 3D printer was born in 1986. However, due to its high price and immature technology, it was not popularized in the early days. After more than 30 years of development, 3D printing technology has become more skilled, accurate, and the price has been reduced.

At present, 3D printing technology is widely used in manufacturing, medical, education, design, and other industries. For example, Surgeons at the Albany Medical Center in the United States use 3D printing to produce organ models; archaeologists of the Italian Agency for Cultural Heritage Restoration (ISCR) applied the 3D printing technology to make copies of precious cultural relics. Now, it is no longer an unattainable dream for ordinary people to own a 3D printer. Makers around the world can use 3D printing technology to create all kinds of models. It can be said that whether for a company or an individual, 3D printing technology can easily realize their desire to print independently at anytime and anywhere.

Italian Cultural Heritage Restoration Agency (ISCR) used 3D printing to make cultural relics

 

How does 3D Printing Work?

3D printing is a new type of manufacturing and processing technology. Visually speaking, ordinary printers print graphics and text on 2D paper with ink, while 3D printers convert raw materials (such as metals, ceramics, plastics, etc.) into thin layers by heating, light, laser, etc. Then, like building a house, the layers are added up to form an entity in the space. Mainstream 3D printing technologies are FFF, SLA, SLM, etc. The FFF is the most common technology, which will be focused on in this article.

FFF (Fused Filament Fabrication) is a 3D printing technology using PLA, ABS and other thermoplastic filaments, which will be heated and extruded by an extrusion head, and then stacked layer by layer under the control of a computer to finally construct a shaped three-dimensional model. It is the most common and widely used 3D printing technology, with higher precision and lower cost.

The printing process of Raise3D’s 3D printer

Choose a Suitable 3D Printer

At present, there are various brands and printers on the market, you can choose the most suitable 3D printer according to your needs. It is a good choice for you to choose a Raise3D Pro2 Series printer that is easy to operate!

Raise3D Pro2 Series printer components

The easiest way to understand FFF printing technology is to learn the components of a 3D printer that applies the FFF technology. A 3D printer mainly contains components such as printing bed, extruder, moving parts, touch screen, etc.

Printing bed: The printing bed is the platform for printing models, and usually the print bed is heated to help layers adhere to each other firmly.

Extruder: The extruder is the core component of a 3D printer, which will melt and stretch the filaments to build the model.

Moving parts: The parts of the printer will move on three axes, which are X, Y, and Z-axis. The X-axis and Y-axis are responsible for forwarding and backward movements, and the Z-axis is responsible for vertical movements.

Touch screen: Users can operate the printer and complete various settings by clicking the built-in RaiseTouch on the LED touch screen.

 

How to 3D Print a Model?

Unlike traditional processes, 3D printing requires very few steps, allowing you to print more easily. Generally speaking, to print a model through 3D printing needs to go through the following four steps: modeling, slicing, printing, and post-processing.

Modeling

If you want to print a 3D object, you naturally need to obtain a digital model of the object. Modeling will turn the object you want to print into a digital model that can be printed on a 3D printer. You can create 3D models with 3D modeling software (such as CAD software). Of course, you can also download the model files other users create. The STL files are widely used in rapid prototyping, 3D printing, and computer-aided manufacturing (CAM). The ideaMaker Library of Raise3D will also provide you with a platform where you can share and obtain 3D modeling models and settings files.

3D Rabbit Model

Slicing

When you have a designed model, you can use specific slicing software such as ideaMaker to slice the model. The purpose of slicing is to allow the 3D printer to calculate the route and the amount of filament required when printing the model. Just like building a house, you need to calculate the steps to build and the amount of wood needed. ideaMaker will generate a GCode file, which is essentially a long list of instructions, and then the 3D printer will read the GCode instruction to build the model. ideaMaker is a powerful slicing software, which can create personalized configurations according to different printers, filaments, and models, it can also automatically create precise support structures. Therefore, ideaMaker will provide you with more possibilities for creativity.

Sliced Rabbit Model

Printing

After slicing is complete, you can upload the slice file to the printer, and calibrate the printer to prepare for printing. The extruders and the printing base need to be calibrated, to improve the accuracy of printing. During the printing process, you can observe the printing process through the transparent panel of a Raise3D Pro2 Series printer, or you can also monitor the printing progress remotely through our APP RaiseCloud in real-time. You will have a more intuitive and deeper understanding of the principles of 3D printing in this way. It will be a wonderful thing to observe the process of filaments accumulate layer by layer and monitor the printing progress!

Printing the model

RaiseCloud Mobile App.

Post-processing

Post-processing is the final stage of 3D printing. The post-processing of FFF 3D printing has the following steps (not all steps must be completed):

Removing support: After printing, you need to remove the support (if the model contains). Filament will remain on the surface of the model.

Sanding: You can use some sandpapers to make the model smoother.

Coloring: You can color the model according to your preference and add more details.

Polishing: You can use apply a specific coating or other processes to make the model surface smoother and brighter.

Welding / Assembling: When you print a multi-part model or a large model, you can divide it into multiple parts, and then assemble the parts to form a complete model.

Post Processing

Advantages and Development of 3D printing

Although it is a novel manufacturing technology, with its unique additive manufacturing method, 3D printing will surpass the traditional manufacturing process and become a new choice for future production.

Shortening the production cycle: 3D printing greatly shortens the product production cycle. By using a 3D printer, the company can more quickly produce the prototypes of the product and enable customers to make detailed and rapid feedback. The application of 3D printers in prototyping and small-scale production will continue to expand.

Manufacturing complex parts: 3D printing has powerful forming capabilities and will not be restricted by complex curved surfaces and precise structures so that 3D printing can produce very complex parts.

Unlimited design and manufacturing space: 3D printers can print everything as long as you create a 3D model on the computer. Different filaments can be combined to create more possibilities.

 

In the future, 3D printing will have higher precision and faster speed, and more multi-materials with excellent comprehensive performance will develop. Therefore, 3D printing will be applied in more sophisticated and high-end industries such as aviation, aerospace, military, etc. to create a new industry format.

Connect with Raise3D:

Have you had a great experience with Raise3D that you would like to share? Please contact us at inquiry@raise3d. com. We look forward to hearing from you.

For more information about Raise3D printers and services, browse our website, or schedule a demo with one of our 3D printing experts.

Metal 3D Printing Process in 3 Steps

Step 1: Print


Every 3D printed part starts in CAD, where you design your part. You then export to STL and upload into Eiger. Eiger is a cloud-based slicing and print management system that comes with every Markforged product. Eiger automatically configures your part based on the material and printer you’re using for the job.

When Eiger slices your part, it gets scaled up to account for shrinking and deformation in the downstream processes. Eiger then slices your part into discrete layers and identifies overhanging features, and builds supports and a raft underneath your part.

Eiger also monitors the metal part’s progress through each stage of the process. After preparing the print with printing software, it’s time to move to the metal 3D printer itself, the Metal X.

Before starting a print, the Metal X automatically maps and levels the print bed using a unique nozzle touch-off process to ensure the first layer prints properly. The print is built from two materials stored in the heated chamber located at the top of the printer. The first material is the metal and the second is a ceramic release. This filament material is metal powder safely suspended within a two-part plastic binder. The filament is heated and extruded onto the build plate where the part is built up layer by layer. The release material gets extruded as an interface between the part and its supports so that once your part comes out of the furnace, it's easy to remove.


Unlike other metal 3D printing systems, the Metal X process does not use loose metal powder, resulting in a safer and more cost-effective workflow.

The Markforged Metal X system is capable of printing in 17-4 PH Stainless Steel, h23, A2, and D2 Tool Steels, Copper, and Inconel 625, along with several other materials currently in development. You can easily switch between materials with a quick changeover.

Once your part is finished printing, the printer will notify you via email. At this point, you can go to the printer, remove the part from the build sheet, and clear the bed.

At this stage, the printed part is in green form. Next step, we'll be putting it into the wash for the debinding process.


Step 2: Wash


In the wash stage, Markforged’s Wash-1 removes the first stage of the binding material. The green part is taken from the printer and placed into the wash basket, which is then lowered into the solvent.

Wash times will vary during this stage, from a few hours to a few days, depending on the thickest region of your part. After washing is complete, you have a brown part. We then move to the sintering process.


Step 3: Sinter



Sintering transforms a brown part into a fully metal part. To do this, the temperature is ramped up slowly to burn away the trace amounts of remaining binding material. As the temperature ramps up closer to the melting point of the material, the metal particles fuse together to create a strong metal part.

The Markforged Sinter-2 is a furnace designed for mid-volume production runs and larger printed parts. The Sinter-2 and other Markforged sintering furnaces use a carbon-free retort to ensure part quality and alloy composition standards are met for finished pieces.

Each run takes about a day and can be monitored remotely using the Eiger software. Once a run is complete, the setter tray with finished metal pieces can be removed from the furnace. Once removed from the raft, these parts are ready for use.

In the furnace, the layer of printed release material between supports, rafts, and your printer part turns to powder. This allows the structure to be tacked to the raft to better control shrinking and accuracy throughout the process, but also an easy release after sintering.

At this stage, your part is fully sintered and ready to be used. It can be post machined, polished or otherwise processed as necessary for the final application, but in many uses the accuracy and strength of the part after this process means its ready for installation.

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Through this process, you can see how metal 3D printing provides a safe and cost-effective method of metal additive manufacturing. These processes are already driving innovation in lean manufacturing. Learn more about the best materials for metal 3D printing, and the history of 3D printing.

For Beginners: 3D Printing Steps - 3DPrinter

For Beginners: 3D Printing Steps

3D printing, also known as additive manufacturing, is a process by which solid objects can be created from digital files. This can be achieved using various 3D printing techniques . Most of these methods are associated with the creation of an object by sequential deposition of thin layers.

Below we will reveal the contents of the 9 steps0003 3D printing using the most common FDM (Fused Deposition Modeling) technology as an example, which involves the formation of objects by layer-by-layer laying of a molten polymer thread.

Stage 1: Creation of a digital model

The process of 3D printing of begins with the development of a virtual image of the future object in a 3D editor or CAD program (3D Studio Max, AutoCAD, Compass, SolidWorks " and etc.). A simple model can be created by any user who has the skills to work with a personal computer and standard application software packages.

It will take from several hours to several days to create a virtual image of the future object, depending on the complexity of the model.

Step 2: Export the 3D model to STL format

When the modeling is finished, the resulting file should be converted to STL format, which is recognized by most modern 3D printers. To do this, select "Save As" or "Import / Export" from the menu, depending on the program you are using.

Before exporting the file, you must specify the degree of detail of the model or the degree of its division into triangles. If you select the “Exact” option, the division will turn out to be dense, the finished file will take up quite a lot of space on the computer’s hard drive and will take longer to be processed by special software, but at the end the user will receive an object with a high-quality surface.

If you select the “Coarse” parameter, then the splitting will turn out to be less dense or completely loose, the finished file will take up less space on the hard disk and will be processed faster in a special program, but the quality of external surfaces will be much lower than with exact splitting.

Stage 3: G-code generation

The STL file with the future object is processed by a special slicer program, which translates it into a control G-code for 3D printer . If the model is not sliced, then the 3D printer will not recognize it. Some of the most popular slicing programs include Kisslacer, Skineforge, Slic3r, etc. special self-adhesive film and load a bobbin with polymer threads into a special compartment.

Step 5: Printing the 3D object

The most important elements of a 3D printer are the working platform and the print head. On the working platform, the finished object is formed. During operation, the platform moves up and down along the Z axis. The print head extrudes the melted polymer filament onto the working platform, layer by layer forming the finished object. The print head of the 3D printer moves horizontally and vertically (X, Y axes).

The 3D printing process itself is quite simple. The printhead extrudes the first layer of molten plastic into the working area, after which the platform descends down to the thickness of the layer and the formation of the next layer begins, which is superimposed on top of the previous one. After the completion of printing each layer, the platform goes down, this happens throughout the entire print cycle, until the finished object appears on the platform.

Step 6: Finishing the object

After printing is complete, most 3D models have numerous protrusions and overhangs that need to be carefully removed.

All about 3D printing. additive manufacturing. Basic concepts.

  • 1 Technology
  • 2 Terminology
  • 3 Fundamentals
  • 4 Print Technologies
  • 5 3D printers
  • 6 Application
  • 7 Domestic and hobby use
  • 8 Clothes
  • 9 3D bioprinting
  • 10 3D printing of implants and medical devices
  • 11 3D printing services
  • 12 Research into new applications
  • 13 Intellectual property
  • 14 Influence of 3D printing
  • 15 Space research
  • 16 Social change
  • 17 Firearms

Technology




Charles Hull - the father of modern 3D printing
3D printing is based on the concept of building an object in successive layers that display the contours of the model. In fact, 3D printing is the complete opposite of traditional mechanical production and processing methods such as milling or cutting, where the appearance of the product is formed by removing excess material (so-called "subtractive manufacturing").
3D printers are computer-controlled machines that build parts in an additive way. Although 3D printing technology appeared in the 80s of the last century, 3D printers were widely used commercially only in the early 2010s. The first viable 3D printer was created by Charles Hull, one of the founders of 3D Systems Corporation. At the beginning of the 21st century, there was a significant increase in sales, which led to a sharp drop in the cost of devices. According to the consulting firm Wohlers Associates, the global market for 3D printers and related services reached $2.2 billion in 2012, growing by 29%.% compared to 2011.
3D printing technologies are used for prototyping and distributed manufacturing in architecture, construction, industrial design, automotive, aerospace, military-industrial, engineering and medical industries, bioengineering (to create artificial fabrics), fashion and footwear, jewelry, in education, geographic information systems, food industry and many other areas. According to research, open source home 3D printers will allow you to win back the capital costs of your own purchase through the economy of household production of items.

Terminology




Additive manufacturing involves the construction of objects by adding the necessary material, and not by removing excess, as is the case with subtractive methods
The term "additive manufacturing" refers to the technology of creating objects by applying successive layers material. Models made using the additive method can be used at any stage of production - both for the production of prototypes (so-called rapid prototyping) and as finished products themselves (so-called rapid production).
In manufacturing, especially machining, the term "subtractive" implies more traditional methods and is a retronym coined in recent years to distinguish between traditional methods and new additive methods. Although traditional manufacturing has used essentially "additive" methods for centuries (such as riveting, welding, and screwing), they lack a 3D information technology component. Machining, on the other hand, (the production of parts of an exact shape), as a rule, is based on subtractive methods - filing, milling, drilling and grinding.
The term "stereolithography" was defined by Charles Hull in a 1984 patent as "a system for generating three-dimensional objects by layering".

Fundamentals


3D printed models

3D models are created by hand-held computer graphic design or 3D scanning. Hand modeling, or the preparation of geometric data for the creation of 3D computer graphics, is somewhat like sculpture. 3D scanning is the automatic collection and analysis of data from a real object, namely shape, color and other characteristics, with subsequent conversion into a digital three-dimensional model.
Both manual and automatic creation of 3D printed models can be difficult for the average user. In this regard, 3D printed marketplaces have become widespread in recent years. Some of the more popular examples include Shapeways, Thingiverse, and Threeding.
3D printing


The following digital models are used as drawings for 3D printed objects , powder, paper or sheet material, building a 3D model from a series of cross sections. These layers, corresponding to virtual cross-sections in the CAD model, are connected or fused together to create an object of a given shape. The main advantage of this method is the ability to create geometric shapes of almost unlimited complexity.
"Resolution" of the printer means the thickness of the applied layers (Z-axis) and the accuracy of positioning the print head in the horizontal plane (along the X and Y axes). Resolution is measured in DPI (dots per inch) or micrometers (the obsolete term is "micron"). Typical layer thicknesses are 100µm (250 DPI), although some devices like the Objet Connex and 3D Systems ProJet are capable of printing layers as thin as 16µm (1600 DPI). The resolution on the X and Y axes is similar to that of conventional 2D laser printers. A typical particle size is about 50-100µm (510 to 250 DPI) in diameter.

One of the methods for obtaining a digital model is 3D scanning. Pictured here is a MakerBot Digitizer
3D Scanner Building a model using modern technology can take hours to days, depending on the method used and the size and complexity of the model. Industrial additive systems can typically reduce the time to a few hours, but it all depends on the type of plant, as well as the size and number of models produced at the same time.
Traditional manufacturing methods such as injection molding can be cheaper for large-scale production of polymer products, but additive manufacturing has advantages for small-scale production, allowing for higher production rates and design flexibility, along with increased cost per unit produced. In addition, desktop 3D printers allow designers and developers to create concept models and prototypes without leaving the office.
Machining

FDM Type 3D Printers
Although the resolution of the printers is sufficient for most projects, printing slightly oversized objects and then subtractively machining them with high-precision tools allows you to create models of increased accuracy.
The LUMEX Avance-25 is an example of a device with a similar combined manufacturing and processing method. Some additive manufacturing methods allow for the use of multiple materials, as well as different colors, within a single production run. Many of the 3D printers use "supports" or "supports" during printing. Supports are needed to build model fragments that are not in contact with the underlying layers or the working platform. The supports themselves are not part of the given model, and upon completion of printing, they either break off (in the case of using the same material as for printing the model itself), or dissolve (usually in water or acetone - depending on the material used to create the supports). ).

Printing technologies


Since the late 1970s, several 3D printing methods have come into being. The first printers were large, expensive and very limited.

Complete skull with supports not yet removed

A wide variety of additive manufacturing methods are now available. The main differences are in the layering method and consumables used. Some methods rely on melting or softening materials to create layers: these include selective laser sintering (SLS), selective laser melting (SLM), direct metal laser sintering (DMLS), fusing deposition printing (FDM or FFF). Another trend has been the production of solid models by polymerization of liquid materials, known as stereolithography (SLA).
In the case of lamination of sheet materials (LOM), thin layers of material are cut to the required contour, and then joined into a single whole. Paper, polymers and metals can be used as LOM materials. Each of these methods has its own advantages and disadvantages, which is why some companies offer a choice of consumables for building a model - polymer or powder. LOM printers often use regular office paper to build durable prototypes. The key points when choosing the right device are the speed of printing, the price of a 3D printer, the cost of printed prototypes, as well as the cost and range of compatible consumables.

Printers that produce full-fledged metal models are quite expensive, but it is possible to use less expensive devices for the production of molds and subsequent casting of metal parts.
The main methods of additive manufacturing are presented in the table:


Method Technology Materials used
Extrusion Fused deposition modeling (FDM or FFF) Thermoplastics (such as polylactide (PLA), acrylonitrile butadiene styrene (ABS), etc. )
Wire Manufacture of arbitrary shapes by electron beam fusing (EBFȝ) Virtually all metal alloys
Powder Direct Metal Laser Sintering (DMLS) Virtually all metal alloys
Electron Beam Melting (EBM) Titanium alloys
Selective laser melting (SLM) Titanium alloys, cobalt-chromium alloys, stainless steel, aluminum
Selective heat sintering (SHS) Powder thermoplastics
Selective laser sintering (SLS) Thermoplastics, metal powders, ceramic powders
Inkjet 3D Inkjet(3DP) Gypsum, plastics, metal powders, sand mixtures
Lamination Lamination of objects (LOM) Paper, metal foil, plastic film
Polymerization Stereolithography (SLA) Photopolymers
Digital LED Projection (DLP) Photopolymers

Extrusion Printing

Fused Deposition Modeling (FDM/FFF) was developed by S. Scott Trump in the late 1980s and commercialized in the 1990s by Stratasys, a company of which Trump is one of the founders. Due to the expiration of the patent, there is a large community of open source 3D printer developers as well as commercial organizations using the technology. As a consequence, the cost of devices has decreased by two orders of magnitude since the invention of the technology.
3D printers range from simple do-it-yourself printers to plastic...
Fusion printing process involves the creation of layers by extrusion of a fast-curing material in the form of microdrops or thin jets. Typically, consumable material (such as thermoplastic) comes in the form of spools from which the material is fed into a printhead called an "extruder". The extruder heats the material to its melting temperature, followed by extrusion of the molten mass through a nozzle. The extruder itself is driven by stepper motors or servomotors to position the printhead in three planes. The movement of the extruder is controlled by a manufacturing software (CAM) linked to a microcontroller.
A variety of polymers are used as consumables, including acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polylactide (PLA), high pressure polyethylene (HDPE), polycarbonate-ABS blends, polyphenylene sulfone (PPSU), etc. Typically, polymer supplied in the form of a filler made of pure plastic. There are several projects in the 3D printing enthusiast community that aim to recycle used plastic into materials for 3D printing. The projects are based on the production of consumables using shredders and melters.

FDM/FFF technology has certain limitations on the complexity of the generated geometric shapes. For example, the creation of suspended structures (such as stalactites) is impossible by itself, due to the lack of necessary support. This limitation is compensated by the creation of temporary support structures that are removed after printing is completed.
Powder print

Selective sintering of powder materials is one of the additive manufacturing methods. Model layers are drawn (sintered) in a thin layer of powdered material, after which the work platform is lowered and a new layer of powder is applied. The process is repeated until a complete model is obtained. The unused material remains in the working chamber and serves to support the overhanging layers without requiring the creation of special supports.

The most common methods are based on laser sintering: selective laser sintering (SLS) for working with metals and polymers (e.g. polyamide (PA), glass fiber reinforced polyamide (PA-GF), glass fiber (GF), polyetheretherketone) (PEEK), polystyrene (PS), alumide, carbon fiber reinforced polyamide (Carbonmide), elastomers) and direct metal laser sintering (DMLS).
... to expensive industrial plants that work with metals
Selective Laser Sintering (SLS) was developed and patented by Carl Deckard and Joseph Beeman of the University of Texas at Austin in the mid-1080s under the auspices of the Defense Advanced Research Projects Agency (DARPA). A similar method was patented by R. F. Householder in 1979, but has not been commercialized.

Selective laser melting (SLM) is characterized by the fact that it does not sinter, but actually melts the powder at the points of contact with a powerful laser beam, allowing you to create high-density materials that are similar in terms of mechanical characteristics to products made by traditional methods.

Electron Beam Melting (EBM) is a similar method for the additive manufacturing of metal parts (eg titanium alloys) but using electron beams instead of lasers. EBM is based on melting metal powders layer by layer in a vacuum chamber. In contrast to sintering at temperatures below melting thresholds, models made by electron beam melting are characterized by solidity with a corresponding high strength.

Finally, there is the 3D inkjet printing method. In this case, a binder is applied to thin layers of powder (gypsum or plastic) in accordance with the contours of successive layers of the digital model. The process is repeated until the finished model is obtained. The technology provides a wide range of applications, including the creation of color models, suspended structures, the use of elastomers. The design of models can be strengthened by subsequent impregnation with wax or polymers.

Lamination


FDM 3D printers are the most popular among hobbyists and enthusiasts
Some printers use paper as a material for building models, thereby reducing the cost of printing. Such devices experienced the peak of popularity in the 1990s. The technology consists in cutting out the layers of the model from paper using a carbon dioxide laser with simultaneous lamination of the contours to form the finished product.

In 2005, Mcor Technologies Ltd developed a variant of the technology that uses plain office paper, a tungsten carbide blade instead of a laser, and selective adhesive application.

There are also device variants that laminate thin metal and plastic sheets.

Photopolymerization


3D printing allows you to create functional monolithic parts of complex geometric shapes, like this jet engine nozzle
Stereolithography technology was patented by Charles Hull in 1986. Photopolymerization is primarily used in stereolithography (SLA) to create solid objects from liquid materials. This method differs significantly from previous attempts, from the sculptural portraits of François Willem (1830-1905) to photopolymerization by the Matsubara method (1974).

The Digital Projection Method (DLP) uses liquid photopolymer resins that are cured by exposure to ultraviolet light emitted from digital projectors in a coated working chamber. After the material has hardened, the working platform is immersed to a depth equal to the thickness of one layer, and the liquid polymer is irradiated again. The procedure is repeated until the completion of the model building. An example of a rapid prototyping system using digital LED projectors is the EnvisionTEC Perfactory.

Inkjet printers (eg Objet PolyJet) spray thin layers (16-30µm) of photopolymer onto the build platform until a complete model is obtained. Each layer is irradiated with an ultraviolet beam until hardened. The result is a model ready for immediate use. The gel-like support material used to support the components of geometrically complex models is removed after the model has been handcrafted and washed. The technology allows the use of elastomers.

Ultra-precise detailing of models can be achieved using multiphoton polymerization. This method is reduced to drawing the contours of a three-dimensional object with a focused laser beam. Due to non-linear photoexcitation, the material solidifies only at the focusing points of the laser beam. This method makes it easy to achieve resolutions above 100 µm, as well as build complex structures with moving and interacting parts.

Another popular method is curing with LED projectors or "projection stereolithography".

Projection stereolithography

This method involves dividing a 3D digital model into horizontal layers, converting each layer into a 2D projection similar to photomasks. The 2D images are projected onto successive layers of photopolymer resin that harden according to the projected contours.

In some systems, the projectors are located at the bottom, helping to level the surface of the photopolymer material when the model moves vertically (in this case, the build platform with the applied layers moves up, rather than sinking into the material) and reduces the production cycle to minutes instead of hours.

The technology allows you to create models with layers of several materials with different curing rates.

Some commercial models, such as the Objet Connex, apply resin using small nozzles.

3D printers


Industrial plants

Industrial adoption of additive manufacturing is proceeding at a rapid pace. For example, US-Israeli joint venture Stratasys supplies $2,000 to $500,000 additive manufacturing machines, while General Electric uses high-end machines to produce gas turbine parts.
Home appliances


LOM takes papier-mâché to the next level The development of 3D printers for home use is being pursued by a growing number of companies and enthusiasts. Most of the work is done by amateurs for their own and public needs, with help from the academic community and hackers.

The oldest and longest running project in the desktop 3D printer category is RepRap. The RepRap project aims to create free and open source (FOSH) 3D printers provided under the GNU General Public License. RepRap devices are capable of printing custom-designed plastic components that can be used to build clones of the original device. Individual RepRap devices have been successfully applied to the production of printed circuit boards and metal parts.

Due to the open access to drawings of RepRap printers, many of the projects adopt the technical solutions of analogues, thus creating a semblance of an ecosystem consisting mostly of freely modifiable devices. The wide availability of open source designs only encourages variations. On the other hand, there is a significant variation in the level of quality and complexity of both the designs themselves and the devices manufactured on their basis. The rapid development of open source 3D printers is leading to a rise in popularity and the emergence of public and commercial portals (such as Thingiverse or Cubify) offering a variety of printable 3D designs. In addition, the development of technology contributes to the sustainable development of local economies through the possibility of using locally available materials for the production of printers.
Stereolithographic 3D printers are often used in dental prosthetics

The cost of 3D printers has been declining at a significant rate since around 2010: devices that cost $20,000 at the time are now $1,000 or less. Many companies and individual developers are already offering budget RepRap kits under $500. The Fab@Home open source project has led to the development of general purpose printers capable of printing anything that can be squeezed through a nozzle, from chocolate to silicone putty and chemicals.
Printers based on this design have been available as kits since 2012 for around $2,000. Some 3D printers, including the mUVe 3D and Lumifold, are designed to be as affordable as possible from the outset, with the Peachy Printer being priced around $100. .
Publicly funded Kickstarter-funded professional printers often perform well: Rapide 3D printers are quiet and fumes-free at $1499. 3D Doodler's '3D Printing Pen' Raised $2.3M in Kickstarter donations, with a selling price of $99 for the device itself. True, it is difficult to call the 3D Doodler a full-fledged 3D printer.

3D Systems Cube is a popular consumer 3D printer

As prices fall, 3D printers are becoming more attractive for consumer production. In addition, home use of 3D printing technologies can reduce the environmental footprint of industry by reducing the volume of consumables and the energy and fuel costs of transporting materials and goods.

Parallel to the creation of home 3D-printing devices, the development of devices for processing household waste into printed materials, the so-called. Recyclebot. For example, the commercial model Filastrucer was designed to recycle plastic waste (shampoo bottles, milk containers) into inexpensive consumables for RepRap printers. Such methods of household disposal are not only practical, but also have a positive impact on the ecological situation.

The development and customization of RepRap 3D printers has created a new category of semi-professional printers for small businesses. Manufacturers such as Solidoodle, RoBo and RepRapPro offer kits for under $1,000. The accuracy of these devices is between industrial and consumer printers. Recently, high-performance printers using a delta-shaped coordinate system, or the so-called "delta robots", are gaining popularity. Some companies offer software to support printers made by other companies.

Application



Using LED projectors helps reduce the cost of stereolithography printers. In the illustration DLP printer Nova

Three-dimensional printing allows you to equalize the cost of producing one part and mass production, which poses a threat to economies of scale. The impact of 3D printing may be similar to the introduction of manufacture. In the 1450s, no one could predict the consequences of the printing press, in the 1750s, no one took the steam engine seriously, and transistors 19The 50s seemed like a curious innovation. But the technology continues to evolve and is likely to have an impact on every scientific and industrial branch with which it comes into contact.

The earliest application of additive manufacturing can be considered rapid prototyping, aimed at reducing the development time of new parts and devices compared to earlier subtractive methods (too slow and expensive). The improvement of additive manufacturing technologies leads to their spread in various fields of science and industry. The production of parts previously only available through machining is now possible through additive methods, and at a better price.
Applications include breadboarding, prototyping, molding, architecture, education, mapping, healthcare, retail, etc.
Industrial applications:
Rapid prototyping: Industrial 3D printers have been used for rapid prototyping and research since the early 1980s . As a rule, these are quite large installations using powder metals, sand mixtures, plastics and paper. Such devices are often used by universities and commercial companies.

Advances in rapid prototyping have led to the creation of materials suitable for the production of final products, which in turn has contributed to the development of 3D production of finished products as an alternative to traditional methods. One of the advantages of fast production is the relatively low cost of manufacturing small batches.

Rapid production: Rapid production remains a fairly new technique whose possibilities have not yet been fully explored. Nevertheless, many experts tend to consider rapid production a new level of technology. Some of the most promising areas for rapid prototyping to adapt to rapid manufacturing are selective laser sintering (SLS) and direct metal sintering (DMLS).
Bulk customization: Some companies offer services for customizing objects using simplified software and then creating unique custom 3D models. One of the most popular areas was the manufacture of cell phone cases. In particular, Nokia has made publicly available the designs of its phone cases for user customization and 3D printing.
Mass production: The current low print speed of 3D printers limits their use in mass production. To combat this shortcoming, some FDM devices are equipped with multiple extruders, allowing you to print different colors, different polymers, and even create several models at the same time. In general, this approach increases productivity without requiring the use of multiple printers - a single microcontroller is enough to operate multiple printheads.

Devices with multiple extruders allow the creation of several identical objects from only one digital model, but at the same time allow the use of different materials and colors. The print speed increases in proportion to the number of print heads. In addition, certain energy savings are achieved through the use of a common working chamber, which often requires heating. Together, these two points reduce the cost of the process.

Many printers are equipped with dual printheads, however this configuration is only used for printing single models in different colors and materials.

Consumer and hobby use


Today, consumer 3D printing mainly attracts the attention of enthusiasts and hobbyists, while practical use is rather limited. However, 3D printers have already been used to print working mechanical clocks, woodworking gears, jewelry, and more. Home 3D printing websites often offer designs for hooks, doorknobs, massage tools, and more.

3D printing is also being used in hobby veterinary medicine and zoology – in 2013, a 3D printed prosthesis allowed a duckling to stand up, and hermit crabs love stylish 3D printed shells. 3D printers are widely used for the domestic production of jewelry - necklaces, rings, handbags, etc.

The Fab@Home open project aims to develop general purpose home printers. The devices have been tested in research environments using the latest 3D printing technologies for the production of chemical compounds. The printer can print any material suitable for extrusion from a syringe in the form of a liquid or paste. The development is aimed at the possibility of home production of medicines and household chemicals in remote areas of residence.

Student project OpenReflex resulted in a design for an analog SLR camera suitable for 3D printing.

Clothing


3D printing is gaining ground in the fashion world as couturiers use printers to experiment with swimwear, shoes and dresses. Commercial applications include rapid prototyping and 3D printing of professional athletic shoes - the Vapor Laser Talon for soccer players and New Balance for track and field athletes.

3D bioprinting



Titanium medical implants made with EBM technology

3D printing is currently being researched by biotech companies and academic institutions. The research is aimed at exploring the possibility of using inkjet/drip 3D printing in tissue engineering to create artificial organs. The technology is based on the application of layers of living cells on a gel substrate or sugar matrix, with a gradual layer-by-layer build-up to create three-dimensional structures, including vascular systems. The first 3D tissue printing production system based on NovoGen bioprinting technology was introduced in 2009year. A number of terms are used to describe this research area: organ printing, bioprinting, computer tissue engineering, etc.

One of the pioneers of 3D printing, research company Organovo, conducts laboratory research and develops the production of functional 3D human tissue samples for use in medical and therapeutic research. For bioprinting, the company uses a NovoGen MMX 3D printer. Organovo believes that bioprinting will speed up the testing of new medicines before clinical trials, saving time and money invested in drug development. In the long term, Organovo hopes to adapt bioprinting technology for graft and surgical applications.

3D printing of implants and medical devices


3D printing is used to create implants and devices used in medicine. Successful surgeries include examples such as titanium pelvic and jaw implants and plastic tracheal splints. The most widespread use of 3D printing is expected in the production of hearing aids and dentistry. In March 2014, Swansea surgeons used 3D printing to reconstruct the face of a motorcyclist who was seriously injured in a road accident.

3D printing services


Some companies offer online 3D printing services available to individuals and industrial companies. The customer is required to upload a 3D design to the site, after which the model is printed using industrial installations. The finished product is either delivered to the customer or subject to pickup.

Exploring new applications



3D printing makes it possible to create fully functional metal products, including weapons.
Future applications of 3D printing may include the creation of open source scientific equipment for use in open laboratories and other scientific applications - fossil reconstruction in paleontology, the creation of duplicates of priceless archaeological artifacts, the reconstruction of bones and body parts for forensic examination, the reconstruction of heavily damaged evidence collected from crime scenes. The technology is also being considered for application in construction.

In 2005, academic journals began to publish materials on the possibility of using 3D printing technologies in art. In 2007, the Wall Street Journal and Time magazine included 3D design in their list of the 100 most significant achievements of the year. The Victoria and Albert Museum at the London Design Festival in 2011 presented an exhibition by Murray Moss entitled "Industrial Revolution 2.0: how the material world materializes again", dedicated to 3D printing technologies.

In 2012, a University of Glasgow pilot project showed that 3D printing could be used to produce chemical compounds, including hitherto unknown ones. The project printed chemical storage vessels into which “chemical ink” was injected using additive machines and then reacted. The viability of the technology was proven by the production of new compounds, but a specific practical application was not pursued during the experiment. Cornell Creative Machines has confirmed the feasibility of creating food products using hydrocolloid 3D printing. Professor Leroy Cronin of the University of Glasgow has suggested using "chemical ink" to print medicines.

The use of 3D scanning technology makes it possible to create replicas of real objects without the use of casting methods, which are expensive, difficult to perform and can have a damaging effect in cases of precious and fragile objects of cultural heritage.

An additional example of 3D printing technologies being developed is the use of additive manufacturing in construction. This could make it possible to accelerate the pace of construction while reducing costs. In particular, the possibility of using technology to build space colonies is being considered. For example, the Sinterhab project aims to explore the possibility of additive manufacturing of lunar bases using lunar regolith as the main building material. Instead of using binding materials, the possibility of microwave sintering of regolith into solid building blocks is being considered.

Additive manufacturing allows you to create waveguides, sleeves and bends in terahertz devices. The high geometric complexity of such products could not be achieved by traditional production methods. A commercially available professional EDEN 260V setup was used to create structures with a resolution of 100 microns. The printed structures were galvanized with gold to create a terahertz plasmonic apparatus.

China allocated almost $500 million. for the development of 10 national institutes for the development of 3D printing technologies. In 2013, Chinese scientists began printing living cartilage, liver and kidney tissue using specialized 3D bioprinters. Researchers at Hangzhou Dianqi University have even developed their own 3D bioprinter for this challenging task, dubbed Regenovo. One of Regenovo's developers, Xu Mingeng, said it takes less than an hour for the printer to produce a small sample of liver tissue or a four to five inch sample of ear cartilage. Xu predicts the emergence of the first full-fledged printed artificial organs within the next 10-20 years. That same year, researchers at the Belgian Hasselt University successfully printed a new jaw for an 83-year-old woman. After the implant is implanted, the patient can chew, talk and breathe normally.

In Bahrain, sandstone-like 3D printing has created unique structures to support coral growth and restore damaged reefs. These structures have a more natural shape than previously used structures and do not have the acidity of concrete.

Intellectual property



Section of liver tissue printed by Organovo, which is working to improve 3D printing technology for the production of artificial organs
3D printing has been around for decades, and many aspects of the technology are subject to patents, copyrights, and trademark protection. However, from a legal point of view, it is not entirely clear how intellectual property protection laws will be applied in practice if 3D printers become widely used.
distribution and will be used in household production of goods for personal use, non-commercial use or for sale.

Any of these protective measures may negatively affect the distribution of designs used in 3D printing or the sale of printed products. The use of protected technologies may require the permission of the owner, which in turn will require the payment of royalties.

Patents cover certain processes, devices, and materials. The duration of patents varies from country to country.

Often, copyright extends to the expression of ideas in the form of material objects and lasts for the life of the author, plus 70 years. Thus, if someone creates a statue and obtains copyright, it will be illegal to distribute designs for printing of an identical or similar statue.

Influence of 3D printing


Additive manufacturing requires manufacturing companies to be flexible and constantly improve available technologies to stay competitive. Advocates of additive manufacturing predict that the opposition between 3D printing and globalization will escalate as home production displaces trade in goods between consumers and large manufacturers. In reality, the integration of additive technologies into commercial production serves as a complement to traditional subtractive methods, rather than a complete replacement for the latter.

Space exploration


In 2010, work began on the application of 3D printing in zero gravity and low gravity. The main goal is to create hand tools and more complex devices "as needed" instead of using valuable cargo volume and fuel to deliver finished products to orbit.
Even NASA is interested in 3D printing
At the same time, NASA is conducting joint tests with Made in Space to assess the potential of 3D printing to reduce the cost and increase the efficiency of space exploration. Nasa's additive-manufactured rocket parts were successfully tested in July 2013, with two fuel injectors performing on par with conventionally produced parts during operational tests subjecting the parts to temperatures of around 3,300°C and high pressure levels. It is noteworthy that NASA is preparing to launch a 3D printer into space: the agency is going to demonstrate the possibility of creating spare parts directly in orbit, instead of expensive transportation from the ground.

Social change


The topic of social and cultural change as a result of the introduction of commercially available additive technologies has been discussed by writers and sociologists since the 1950s. One of the most interesting assumptions was the possible blurring of boundaries between everyday life and workplaces as a result of the massive introduction of 3D printers into the home. It also points to the ease of transferring digital designs, which, in combination with local production, will help reduce the need for global transportation. Finally, copyright protection may change to reflect the ease of additive manufacturing of many products.

Firearms


In 2012, US company Defense Distributed released plans to create a "design of a functional plastic weapon that could be downloaded and played by anyone with access to a 3D printer." Defense Distributed has developed a 3D printed version of the receiver for the AR-15 rifle, capable of withstanding more than 650 shots, and a 30-round magazine for the M-16 rifle.


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