3D printers benefits

What are the Advantages and Disadvantages of 3D Printing?

3D printing, also known as additive manufacturing, is becoming popular with manufacturers. The demand is growing due to some of the revolutionary benefits that it can provide. Like almost all technologies it has its own drawbacks that need considering.

This page aims to help with the selection process. We will cover each of the advantages and disadvantages of 3D printing.

This production process offers a range of advantages compared to traditional manufacturing methods. These advantages include those related to design, time and cost, amongst others.

1. Flexible Design

3D printing allows for the design and print of more complex designs than traditional manufacturing processes. More traditional processes have design restrictions which no longer apply with the use of 3D printing.

2. Rapid Prototyping

3D printing can manufacture parts within hours, which speeds up the prototyping process. This allows for each stage to complete faster. When compared to machining prototypes, 3D printing is inexpensive and quicker at creating parts as the part can be finished in hours, allowing for each design modification to be completed at a much more efficient rate.

3. Print on Demand

Print on demand is another advantage as it doesn’t need a lot of space to stock inventory, unlike traditional manufacturing processes. This saves space and costs as there is no need to print in bulk unless required.

The 3D design files are all stored in a virtual library as they are printed using a 3D model as either a CAD or STL file, this means they can be located and printed when needed. Edits to designs can be made at very low costs by editing individual files without wastage of out of date inventory and investing in tools.

4. Strong and Lightweight Parts

The main 3D printing material used is plastic, although some metals can also be used for 3D printing. However, plastics offer advantages as they are lighter than their metal equivalents. This is particularly important in industries such as automotive and aerospace where light-weighting is an issue and can deliver greater fuel efficiency.

Also, parts can be created from tailored materials to provide specific properties such as heat resistance, higher strength or water repellency.

5. Fast Design and Production

Depending on a part’s design and complexity, 3D printing can print objects within hours, which is much faster than moulded or machined parts. It is not only the manufacture of the part that can offer time savings through 3D printing but also the design process can be very quick by creating STL or CAD files ready to be printed.

6. Minimising Waste

The production of parts only requires the materials needed for the part itself, with little or no wastage as compared to alternative methods which are cut from large chunks of non-recyclable materials. Not only does the process save on resources but it also reduces the cost of the materials being used.

7. Cost Effective

As a single step manufacturing process, 3D printing saves time and therefore costs associated with using different machines for manufacture. 3D printers can also be set up and left to get on with the job, meaning that there is no need for operators to be present the entire time. As mentioned above, this manufacturing process can also reduce costs on materials as it only uses the amount of material required for the part itself, with little or no wastage. While 3D printing equipment can be expensive to buy, you can even avoid this cost by outsourcing your project to a 3D printing service company.

8. Ease of Access

3D printers are becoming more and more accessible with more local service providers offering outsourcing services for manufacturing work. This saves time and doesn’t require expensive transport costs compared to more traditional manufacturing processes produced abroad in countries such as China.

9. Environmentally Friendly

As this technology reduces the amount of material wastage used this process is inherently environmentally friendly. However, the environmental benefits are extended when you consider factors such as improved fuel efficiency from using lightweight 3D printed parts.

10. Advanced Healthcare

3D printing is being used in the medical sector to help save lives by printing organs for the human body such as livers, kidneys and hearts. Further advances and uses are being developed in the healthcare sector providing some of the biggest advances from using the technology.

Like with almost any other process there are also drawbacks of 3D printing technology which should be considered before opting to use this process.

1. Limited Materials

While 3D Printing can create items in a selection of plastics and metals the available selection of raw materials is not exhaustive. This is due to the fact that not all metals or plastics can be temperature controlled enough to allow 3D printing. In addition, many of these printable materials cannot be recycled and very few are food safe.

2. Restricted Build Size

3D printers currently have small print chambers which restrict the size of parts that can be printed. Anything bigger will need to be printed in separate parts and joined together after production. This can increase costs and time for larger parts due to the printer needing to print more parts before manual labour is used to join the parts together.

3. Post Processing

Although large parts require post-processing, as mentioned above, most 3D printed parts need some form of cleaning up to remove support material from the build and to smooth the surface to achieve the required finish. Post processing methods used include waterjetting, sanding, a chemical soak and rinse, air or heat drying, assembly and others. The amount of post processing required depends on factors including the size of the part being produced, the intended application and the type of 3D printing technology used for production. So, while 3D printing allows for the fast production of parts, the speed of manufacture can be slowed by post processing.

4. Large Volumes

3D printing is a static cost unlike more conventional techniques like injection moulding, where large volumes may be more cost effective to produce. While the initial investment for 3D printing may be lower than other manufacturing methods, once scaled up to produce large volumes for mass production, the cost per unit does not reduce as it would with injection moulding.

5. Part Structure

With 3D printing (also known as Additive Manufacturing) parts are produced layer-by-layer. Although these layers adhere together it also means that they can delaminate under certain stresses or orientations. This problem is more significant when producing items using fused deposition modelling (FDM), while polyjet and multijet parts also tend to be more brittle. In certain cases it may be better to use injection moulding as it creates homogenous parts that will not separate and break.

6. Reduction in Manufacturing Jobs

Another of the disadvantages of 3D technology is the potential reduction in human labour, since most of the production is automated and done by printers. However, many third world countries rely on low skill jobs to keep their economies running, and this technology could put these manufacturing jobs at risk by cutting out the need for production abroad.

7. Design Inaccuracies

Another potential problem with 3D printing is directly related to the type of machine or process used, with some printers having lower tolerances, meaning that final parts may differ from the original design. This can be fixed in post processing, but it must be considered that this will further increase the time and cost of production.

8. Copyright Issues

As 3D printing is becoming more popular and accessible there is a greater possibility for people to create fake and counterfeit products and it will almost be impossible to tell the difference. This has evident issues around copyright as well as for quality control.

Get Further Advice On 3D Printing

Need help with determining whether 3D printing is the right process for you?

Contact our team of world-leading experts with over 20 years of experience in the additive manufacturing field.

Our technology experts help to ensure our customers apply the correct technology process depending on each individual or company requirements:

[email protected]

10 Advantages of 3D Printing

Are you aware of the many advantages of 3D printing technology? Follow along as we break down our top ten here.

There are 3 main methods used for product development, that is, taking a design from idea to a physical, 3-dimensional prototype of the product.

Subtractive manufacturing is a product development process that continuously cuts away material from a solid block, such as metal. This can be done manually or using CNC (Computer Numeric Controlled) machinery.

Injection molding is a manufacturing process used for producing products in large volumes. As the name suggests, parts are produced by injecting heated material into a mold.

So, what is 3D printing? Additive manufacturing, aka 3D printing, is the process of producing 3-dimensional objects from a computer file, where the part is built by adding material layer-by-layer.

Today, more companies in a variety of industries are embracing the 3D printing process as it presents many significant advantages over the more traditional manufacturing methods of subtractive manufacturing and injection molding.

1. Speed

One of the biggest advantages of 3D printing technology is Rapid Prototyping. Rapid prototyping is the ability to design, manufacture, and test a customized part in as little time as possible. Also, if needed, the design can be modified without adversely affecting the speed of the manufacturing process.

Before 3D printing industry came to flourish, a prototype would take weeks to manufacture. Every time a change was made, another few weeks of time were added to the process. With shipping times figured in, fully developing a product from start to finish could easily take a year.

With 3D printing techniques, a business can design a part, manufacture it in-house on a professional 3D printer, and test it, all within a few days (and sometimes even less).

For small businesses or even individuals, this difference is significant. The freedom and creativity enabled by 3D printing means that almost anything can be created without the need for warehouses full of expensive machinery. There are no long lead times typically associated with having to outsource complex manufacturing projects. It means freedom from the constraints of minimum orders, that parts and products can be created and customized with ease.

For small production runs and prototyping, 3D printing is the best option as far as speed is concerned.

2. Cost

For small production runs and applications, 3D printing is the most cost-effective manufacturing process. Traditional prototyping methods like CNC machining and injection molding require a large number of expensive machines plus they have much higher labor costs as they require experienced machine operators and technicians to run them.

This contrasts with 3D printing process, where only 1 or 2 machines and fewer operators are needed (depending on the system) to manufacture a part. There is far less waste material because the part is built from the ground up, not carved out of a solid block as it is in subtractive manufacturing and usually does not require additional tooling.

3. Flexibility

Another big advantage of 3D printing is that any given printer can create almost anything that fits within its build volume.

With traditional manufacturing processes, each new part or change in part design, requires a new tool, mold, die, or jig to be manufactured to create the new part.

In 3D printing, the design is fed into slicer software, needed supports added, and then printed with little or no change at all in the physical machinery or equipment.

3D printing allows the creation and manufacture of geometries impossible for traditional methods to produce, either as a single part, or at all. Such geometries include hollow cavities within solid parts and parts within parts.

3D printing, in contrast to traditional methods, allows the inclusion of multiple materials into a single object, enabling an array of colors, textures, and mechanical properties to be mixed and matched.

3D printing allows any user, even those with limited CAD experience, to edit designs however they like, creating unique, customized new parts. This also means any given design can be manufactured in a wide range of different materials.

4. Competitive Advantage

Because of the speed and lower costs of 3D printing, product life cycles are reduced. Businesses can improve and enhance a product allowing them to deliver better products in a shorter amount of time.

3D printing allows the physical demonstration of a new product to customers and investors instead of leaving it to their imaginations, therefore reducing the risk of information being misunderstood or lost during communication.

It also allows for cost-effective market testing, obtaining feedback from potential customers and investors on a tangible product, without the risk of large upfront expenditures for prototyping.

5. Tangible Design and Product Testing

As previously described in competitive advantages, seeing a product on a screen cannot compare with actually touching and feeling a prototype. A physical prototype can be tested and if flaws are found, the CAD file can be modified and a new version printed out by the next day.

10 Benefits of a 3D Printer: Save Time and Money

More recently, 3D printing has been viewed as something completely new. The technology was underdeveloped, the hardware was too expensive for widespread use. But only a few years have passed, and the situation has changed radically. Not only did more and more 3D printers begin to appear in stores, but also some enthusiasts began to assemble this equipment themselves.

1. Economy

Although large-scale projects with thousands of 3D printed parts are not cheap, they are still much more profitable than other technologies. Many manufacturers use 3D printing for small runs or for prototyping. Plastic can also be used for injection molding, but casting small batches can require expensive equipment. But even in this case, manufacturers can produce cast 3D parts several times cheaper than using aluminum.

Prototype parts printed on Prusa i3 Bizon 3D printer, layer height 0.1mm, PLA material

2. Faster production cycle

Compared to traditional production methods, the entire process can take weeks or days, and most products are printed in hours. Some manufacturers have even begun to make parts to order, which has also allowed them to optimize their warehouse capacity and resource management scheme, making them more flexible. With this new approach, the manufacturer does not need to store every single part or component, they can simply be printed as needed and immediately put into action.

Miniature parts printed by Wanhao Duplicator 7 photopolymer 3D printer, layer height 0.5mm, photopolymer resin material

It not only affects the reputation of the company in its industry, insufficient technical control can lead to injury to employees and customers. Since 3D printing uses a completely different production method than most machine tool operations, the process has significantly fewer weaknesses and flaws overall.

Model printed on Picaso Designer X PRO 3D printer, 0.2 mm layer, ABS materials, HIPS

4. Less waste

The press is gaining more and more support in the form of supporters of the "green" movement. Because 3D printing produces significantly less waste than traditional processing, the technology is more environmentally friendly while reducing costs. 3D printing has even made its way into the textile industry, allowing clothing and prototypes to be printed.

Hercules Strong 3D printed yacht steering parts. Details printed in 15 hours with a 0.5 mm nozzle and a layer height of 0.3 mm at a speed of 60 mm/s.

5. Greater customization

3D printed products are also highly customizable. Parts can be printed not only with light plastic, some next-generation models may also have a metal coating. As a result, objects are not only aesthetic, but also functional. In addition, they can acquire thermal and chemical resistance. The existing metallization method can also be used for plastic.

Functional parts printed on Hercules. Material ABS, nozzle diameter 0.5 mm, layer height 150 µm, filling 100%. The model consists of 3 parts: the body and 2 halves of the latch, after printing and processing, the parts were glued together with acetone.

6. Customer Accessibility

If some craftsmen set up small mechanical workshops, for example, in garages, then most of us cannot afford such a luxury. 3D printing allows you to bring a significant part of the manufacturing process directly into the home, made possible by the availability of user-grade 3D technology. While it turns out to be quite expensive for one-off projects, the price of 3D printers and consumables is dropping rapidly.

Technical wing caps in REC RUBBER or REC FLEX. The models are printed on a Prusa i3 Steel 3D printer.

7. High complexity

In most cases, when it comes to complex parts and elements, the manufacturing process imposes certain limitations. Techniques used in casting and finishing objects may not be subtle enough for sophisticated design details. 3D manufacturing processes make it possible to realize almost any design solution, regardless of its complexity, and in a reasonable time. This not only eliminates the extra assembly steps required by traditional methods, but also provides more freedom to create future-proof designs.

Zenit 3D Printing Big Details From Engine 3D Printer

8. Less risk

While there are inherent risks associated with these new technologies, in terms of day-to-day business, 3D printing risks are significantly lower than with traditional manufacturing methods. Not only is 3D printing much cheaper when it comes to testing a new design or product, the printed prototypes themselves can stir up investor and customer interest and get them to decide whether to proceed with mass production of a product, whether it is worth the time and effort required.

Wanhao Duplicator i3 3D Printer Miniature Printing

9. Variety of materials

The materials used in today's 3D printers are much more diverse than most raw materials in traditional production methods. 3D printing also provides the ability to mix different substances, a luxury that is not always available with conventional methods. Although many 3D printer manufacturers offer their own, very limited set of sources, 3D printers can work not only with original materials, allowing you to simulate ceramics, metal, glass and more.

Wanhao D6 3D Printer PEGT, ABS-PC, PLA, SBS

The manufacturer not only needs to clearly understand what the customer wants, the manufacturer must also be able to explain what he himself can. Drawings, diagrams, diagrams are all good, of course, but there is nothing better than a real prototype that you can hold, look at and study. The fact that the materials are inexpensive, coupled with the short prototyping time on today's 3D printers, helps a lot during the prototyping phase, keeping all stakeholders connected.

THE PAST, PRESENT AND FUTURE OF 3D PRINTING

Despite a relatively slow start, the concept of 3D printing is finally gaining momentum and popularity among manufacturers and customers. We already see a lot of benefits of 3D printing, including shorter production cycles, more complex designs and improved quality, and the peak of the popularity and functionality of this technology is yet to come.

3D printer advantages and disadvantages

If you ask any owner of a 3D printer what the main advantage of his device is, he will start talking about high quality printing and the ability to make any prototypes. When asked about the shortcomings, the answer is usually about some shortcomings in the design of the printer: someone is not satisfied with an insufficiently rigid frame, some complain about too slow printing rates. In the article, we understand what advantages most 3D printers have and find out what disadvantages their owners have to face.

Despite a relatively slow start, additive technologies are finally gaining momentum. Now 3D printers have gained well-deserved popularity both in the user environment and in the field of production. We have already appreciated the many benefits of 3D printing, including the ability to print complex models, but the peak of popularity and functionality of 3D technologies is yet to come. We talk about the main advantages and disadvantages of 3D printers.

Benefits of 3D printers

Let's start with the benefits: 3D printing allows you to quickly and relatively inexpensively produce the desired prototypes with high accuracy, independently adjusting the printer settings and choosing the optimal parameters. Let's dwell on each plus of 3D printers in more detail.

Value - speed of production

3D printers can significantly reduce the time spent on each project. Unlike traditional manufacturing methods, when using additive technologies, the entire printing process will take from several weeks or days, and the bulk of the models can be printed in a matter of hours. Some manufacturers have decided to optimize their inventory by starting to make parts to order. This approach allows you to take mass production to a new level: now you do not need to store a lot of parts in stock, because you can simply print them as needed, immediately sending them to sale.

Advantage - cost of production

Large-scale projects with a large number of 3D printed parts are not cheap, but additive manufacturing still remains more profitable than traditional technologies. Many manufacturers use 3D printing for short runs or prototyping. For example, it is much more profitable for jewelers to print wax prototypes of jewelry than to cast them from metal. The plastic used in 3D printing is relatively inexpensive, and even the simplest printer can help save money.

Product quality

Modern 3D printers demonstrate high product quality. In our opinion, the quality depends on the following characteristics of the device:

Photopolymer printing. This technology allows you to get the highest possible quality of the finished product.
FDM technology. Despite the fact that FDM printers are in demand, they simply cannot create detail above 100 microns.
Metal housing. When choosing FDM printers, you should give preference to models whose body is made of metal. Such printers demonstrate the best quality of products at high print speeds.
Regardless of which printer model is chosen, the finished product printed at low speed and quality materials is almost the same as that produced on high speed equipment.

Thus, it is possible to achieve decent print quality on inexpensive printers using high-quality filament at low speeds.

Copy Accuracy

3D Printing Accuracy is the minimum layer height allowed. Modern devices can produce high quality down to 20 microns, but in order to actually obtain prototypes of such accuracy, the user will need to meet certain conditions.

First of all, the accuracy of the finished copies depends on the 3D printer itself - on its technical characteristics, layout, etc. You should not rely only on the layer height value that is indicated in the device description.

The accuracy of prototypes depends on many factors. For example, printers made in a closed case are able to produce much better model accuracy than their counterparts in an open case, due to the uniform temperature regime inside the printer.

In addition, it is required to correctly set all print settings, monitor the calibration of the table, the operating conditions of the device, and the temperature regime. High-quality plastic plays an important role in the accuracy of the copies made.

Production flexibility

The introduction of 3D printing in various areas of production is due to the fact that the technology makes it possible to create geometric shapes of almost any size and unlimited complexity.

Printers print with a wide variety of materials, making the production process as flexible as possible. For example, on the same device, you can create both waxes for jewelers and dentures for dentists. Such versatility cannot be achieved using standard production equipment. 3D printers open up new horizons and prospects for the development of their own business and additive technologies for engineers, designers and device owners.

Availability

The availability of 3D printing makes it possible to experiment using printers both at home and at work. Even the most inexpensive 3D printer can be used in architecture, construction, small-scale production, medicine, education, jewelry, printing, souvenirs, and advertising. A standard spool of filament will last for a long time, and almost everyone can afford to buy a 3D printer. One of the most budget models costs about $100.

Any technique has its downsides, and 3D printers are no exception. Therefore, today additive technology has a certain number of significant drawbacks.

Minus - the small size of the camera

Perhaps the most significant drawback of printers are the small size of the print area. Look at any 3D printer, evaluate its dimensions - that's it, everything is limited to them. The device can only print the model that will fit on its platform. If you need to create a larger prototype, you will have to resort to various tricks: for example, you can print the model in parts, and then assemble them in some way. Despite the fact that there is already a prototype of a 3D printer with an unlimited size of the working platform, it is not yet possible to talk about the mass introduction of such a technology.

Minus - inaccuracies of the part

It is impossible to completely get rid of thermal contraction or shrinkage of the finished model. This is a physical process - you can only compensate for it. The layers floated, the vertical is not observed, the layers do not lie exactly on top of each other. The protrusions on the top layer of the part can be either open or closed. Essentially, this is due to the sagging of the plastic, which does not have time to cool when printed in the air without supports.

Disadvantage - post-processing

Most finished products printed on a 3D printer require post-processing and cleaning. The process helps to achieve the best look and smoothness of the model. Finished models are processed in various ways. Users grind parts, chemically process them, cut supports, dry products. The need for post-treatment depends on many factors. For example, the scope of work varies depending on the size of the model, the material, the type of technology chosen in the manufacture of the prototype. Thus, given that 3D printing allows fast production of parts, the speed of production can be reduced through subsequent post-processing.

Strength properties of models

As a rule, the production of a three-dimensional model using additive technologies occurs by layer-by-layer application of a filament. Despite the fact that the layers are well glued together, this is not a guarantee of the perfect solidity of the finished product, and it can delaminate under certain loads. This problem is especially common when using FDM printers. Experienced users advise using injection molding to improve the strength properties of parts. Using this method, the structure of the finished part is more uniform and less brittle.

3D printers are not user-friendly

Manufacturers claim that 3D printers are easy to use. Some companies produce devices specifically for beginners. However, even for the initial assembly and preparation of the printer for operation, the user will need certain skills. Calibrating the desktop on your own, setting up the slicer program, and setting the desired print settings is not as easy as the manufacturers assure. Some models are delivered already assembled - we advise you to choose them as your first printer.

Harmful emissions

The size of the device and the amount of thermoplastic produced by the printer significantly affect the amount of harmful aerosol emissions into the atmosphere. The chemicals settle in our lungs and also contribute to the increase in the size of the ozone hole. A team of researchers led by Professor Brent Stevens conducted their own experiment, which tested five models of 3D printers. As a result, scientists were able to calculate the concentration of nanometer particles that are formed during the 3D printing process.

The results of the experiment did not please either printer manufacturers or device owners and users. The fact is that 3D printers using polylactic acid (PLA) in printing have demonstrated extremely high levels of ultrafine particles - from 20 billion per minute. Acrylonitrile butadiene styrene (ABS)-powered gadgets emit up to 200 billion particles per minute into the atmosphere.

Scientists have stated that harmful emissions in such quantities are similar to emissions into the atmosphere from burning tobacco or scented candles, burning natural gas. In addition, when using a laser printer using powder as a printing material, no less harmful emissions are produced.

Slow

3D printers are actually very slow. Some manufacturers claim high print speeds, but this figure is relative. Especially when it comes to making a lot of prototypes. Many users who own budget printers leave them running all night to have a small finished model by morning. Depending on the dimensions and quality of the printed product, the process may be delayed. On average, the process of creating a model can take from several hours to several days. The duration is directly proportional to the size of the object: the larger the future prototype, the more time it will take to print.

Environmental pollution

Waste plastic by-products of additive printing have long been of interest to conservationists. Production waste ends up in landfills, creating a negative additional burden on the environment. Scientists believe that the ABS plastic used in most 3D printers is quite toxic. This type of filament has a long period of decomposition in the soil. However, ABS is the most common type of material used in additive printing. PLA is a greener alternative to ABS. This material is more biodegradable and less toxic. The problem of environmental pollution can be solved with the spread of household plastic convertors into 3D printing filament.

Three-dimensional printers open up a wide range of possibilities for their owners. The list of advantages of such devices is endless, but we have chosen only the main ones. In our opinion, one of the main advantages of 3D printers is their affordability. Finished models are of sufficient quality even on budget models. The main thing is that the user sets the correct settings and fills the printer with good material.

But 3D printers also have their drawbacks. In addition to the fact that they are not very easy to calibrate and prepare for work, they produce harmful emissions into the atmosphere, and production waste in the form of plastic practically does not decompose, polluting the environment. Another disadvantage of the devices is the low print speed. However, 3D printing is too useful to pass up.