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3D Printing Statistics (2022 Additive Manufacturing Data)

Posted by Rob Errera on 06/10/2022

 

3D printing is booming. Intricate parts and products are 3D printed around the world, layer by layer, using a process called additive manufacturing (AM).

From customized pieces for automobile interiors, spacecraft engines, face shields and masks for healthcare workers, to creative pen holders, 3D printing is becoming an integral part of worldwide manufacturing.

Let’s take a glance at the latest 3D printing statistics and industry data.

3D printing is great for prototyping and creating unique industry solutions.

The 3D Printing Industry Statistics

  • The global 3D printing market reached a value of $13.8 billion in 2021.
  • The value of the North American 3D printing market in 2021 was $5. 72 billion.
  • Various analysts predict that the 3D printing industry will grow at staggering speeds – between 18% and 27% per year.
  • About 2.2 million 3D printer units were shipped in 2021.
  • Equipment costs more: The 3D printing equipment market was valued at $4.5 billion in 2021, while the materials market was $1.7 billion.
  • The most profitable 3D printer manufacturers are AutoDesk, HP Inc., 3D Systems, Desktop Metal, and Proto Labs. The market value of AutoDesk is above $68.2 billion.
  • Investors understand the hype: back in 2018, VC funding for 3D printing start-ups surpassed $300 million.
  • Companies that already utilize 3D are hooked too: over 23% reported investing more than $100K into 3D printing tech in 2020.
  • When asked about the benefits 3D printing has over other production methods, 69% of respondents say they use it for its outstanding ability to create complex geometrical objects, 52% value the quick iteration of products, and 41% claim its mass customization abilities are important.
  • Out of companies that utilize 3D printing technologies, 38% consider it their main activity, while another 18% have in-house departments dedicated to it, and 16% use 3D print across multiple departments. 

Most Used 3D Printing Technologies

  • Fused deposition modeling (FDM) or fused filament fabrication (FFF), such as HP's Multi Jet Fusion, is the most established 3D printing technology in the market. Out of companies that use FDM / FFF, 71% use the technology in-house.
  • Selective laser sintering (SLS) is the second favorite. However, the majority of its users, 42%, use it as an external service.
  • Stereolithography (SLA) used to lead as a major technology in the past, but it's quickly getting replaced by quicker technologies. In 2020, the SLA market size was evaluated at $1.6 billion.
  • Metal 3D printing is becoming more popular by the day, as industries around the world face rising concerns over the use of plastic. In 2018, 65% of 3D printers used plastic, and 36% used metal.

What is 3D Printing Used For?

  • Many industries are adopting 3D printing: it’s broadly used in aerospace, automotive, and healthcare industries. For example, Boeing uses industrial 3D printing to make plane interior elements, NASA uses 3D printed elements in satellites and engines, and rapid tooling and interior customization bloom in the automobile industry.
  • With 3D printing in healthcare valued at $1,036 million in 2020, healthcare benefits from 3D printing: it’s widely used to make personal protection equipment (life-saving in light of COVID-19 shortages), surgical drill and cutting guides, and customized prosthetics (especially in dentistry) and organ replicas.

3D printed plastic cast for broken hand.

  • Many types of materials can be 3D printed – all kinds of plastics, resins, metals, cement, and even a sort of ceramic. People even 3D-print food for gourmet dining. The concept is simple - food like chocolate and purees, intricately shaped using additive manufacturing. The 3D food industry thrived in 2021 – reaching $76. 9 million.
  • Out of companies that reported significant investments in 3D printing tech, 70% use it for small series, 49% for large series, and 18% report mass production.
  • The sportswear company Adidas is among those that mass produces 3D printed products – their 4DFWD running shoes feature 3D printed soles.
  • Over 68% of companies that use 3D printing use it for prototyping and pre-series manufacturing.
  • The prototyping value of 3D printing was estimated at $4.4 billion in 2020.
  • Proof of concept is the second leading use with 59% of respondents saying they utilize it in 2020.
  • Out of companies that use 3D printing, 40% create 3D-printed functional parts, and 26% print tools.
  • 27% of companies that use 3D printing use it to create end-user consumer goods.
  • The molds and tooling sector is expected to grow from a value of $5.2 billion in 2020 to $20 billion within the next ten years.

Limitations and Growth Opportunities of 3D Printing

  • Many companies believe that 3D printing can help improve the flexibility of their supply chains: 55% of surveyed companies believe it can simplify their logistics, transport, and inventories. With 3D printing, it’s becoming a real option to ship actual products as digital files!
  • 69% of 3D printing users agree: 3D printing needs to grow more reliable as a technology, and have a lower cost of entry. In fact, 29% of responders claim that the lack of confidence in the reliability of 3D printing is a major deterring factor on a per-project basis.
  • Up to 71% of companies feel they lack the knowledge or training to efficiently use 3D printing technology.
  • It’s clear that the 3D printing market is constrained by the high costs of both the tech and materials.
  • Speed and scalability are two big limiting factors that slow the rate at which certain industries adopt 3D printing. For example, an aerospace company may only need 100 components a month, but a car manufacturer would need thousands. This limitation translates quite directly: The automotive sector sees the slowest growth in widespread adoption among major industries that utilize 3D.
  • Some analysts raise concerns about the traditional forms of intellectual property protection with the rise of 3D printing.
  • International 3D printing standards, quality assurance and control are the next challenges the 3D market needs to overcome. Governing bodies will likely need to tackle the issue of international standards and quality control in the near future.

Wrap Up

3D printing is a huge world of potential – and companies across the globe are starting to recognize that.

With a wider reach of 3D technologies, a bigger focus on education can boost the industry even further. 

Better training and more comprehensive knowledge base are bound to increase the companies’ confidence in practical applications of 3D printing. 

So, it’s no wonder universities around the world are including 3D printing engineering in their curriculums.

In addition, the rapid evolution of 3D printing will need to cross one more obstacle for faster development: printing speed. But with the growing investment in 3D printing startups, we’ll surely get there soon!

Further Reading:

  • How To Print on Fabric - The Freezer Paper Method
  • Our Eric Clapton Replica Guitar Made With Toner
  • Staggering E-Waste Facts & Statistics 2022

Sources:

https://www.grandviewresearch.com/industry-analys...
https://www.globenewswire.com/en/news-release/202...
https://amfg.ai/2020/01/14/40-3d-printing-industr...
https://all3dp.com/2/3d-printed-food-3d-printing-...
https://www.statista.com/statistics/560304/worldw...
https://www.fortunebusinessinsights.com/industry-...
https://www.futuremedicine.com/doi/10.2217/3dp-20...
https://formlabs.com/blog/3d-printing-materials/
https://news.adidas.com/running/4dfwd--data-drive...
https://www.statista.com/statistics/560271/worldw...
https://www.jabil.com/blog/overcoming-top-3d-prin. ..
https://www.ey.com/en_us/advanced-manufacturing/h...

Rob Errera

Rob Errera is an award-winning journalist embedded in the world of printers and printing supplies. Rob has nearly two decades of experience writing about cutting edge technology, business trends, and the ever-evolving industry of printing.

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  • #3D Printing

 

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What is 3D printing? How does a 3D printer work? Learn 3D printing

3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital file.

The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced cross-section of the object.

3D printing is the opposite of subtractive manufacturing which is cutting out / hollowing out a piece of metal or plastic with for instance a milling machine.

3D printing enables you to produce complex shapes using less material than traditional manufacturing methods.

Table of Contents

  • How Does 3D Printing Work?
  • 3D Printing Industry
  • Examples of 3D Printing
  • 3D Printing Technologies & Processes
  • Materials
  • Services

Jump to your field of interest:

  • Rapid Prototyping & Manufacturing
  • Automotive
  • Aviation
  • Construction
  • Consumer Products
  • Healthcare
  • Food
  • Education

Jump to process:

  • All Technologies & Processes
  • Vat Photopolymerisation
  • Material Jetting
  • Binder Jetting
  • Material Extrusion
  • Powder Bed Fusion
  • Sheet Lamination
  • Directed Energy Deposition

How Does 3D Printing Work?

It all starts with a 3D model. You can opt to create one from the ground up or download it from a 3D library.

3D Software

There are many different software tools available. From industrial grade to open source. We’ve created an overview on our 3D software page.

We often recommend beginners to start with Tinkercad. Tinkercad is free and works in your browser, you don’t have to install it on your computer. Tinkercad offers beginner lessons and has a built-in feature to export your model as a printable file e.g .STL or .OBJ.

Now that you have a printable file, the next step is to prepare it for your 3D printer. This is called slicing.

Slicing: From printable file to 3D Printer

Slicing basically means slicing up a 3D model into hundreds or thousands of layers and is done with slicing software.

When your file is sliced, it’s ready for your 3D printer. Feeding the file to your printer can be done via USB, SD or Wi-Fi. Your sliced file is now ready to be 3D printed layer by layer.

3D Printing Industry

Adoption of 3D printing has reached critical mass as those who have yet to integrate additive manufacturing somewhere in their supply chain are now part of an ever-shrinking minority. Where 3D printing was only suitable for prototyping and one-off manufacturing in the early stages, it is now rapidly transforming into a production technology.

Most of the current demand for 3D printing is industrial in nature. Acumen Research and Consulting forecasts the global 3D printing market to reach $41 billion by 2026.

As it evolves, 3D printing technology is destined to transform almost every major industry and change the way we live, work, and play in the future.

Examples of 3D Printing

3D printing encompasses many forms of technologies and materials as 3D printing is being used in almost all industries you could think of. It’s important to see it as a cluster of diverse industries with a myriad of different applications.

A few examples:

  • – consumer products (eyewear, footwear, design, furniture)
  • – industrial products (manufacturing tools, prototypes, functional end-use parts)
  • – dental products
  • – prosthetics
  • – architectural scale models & maquettes
  • – reconstructing fossils
  • – replicating ancient artefacts
  • – reconstructing evidence in forensic pathology
  • – movie props

Rapid Prototyping & Rapid Manufacturing

Companies have used 3D printers in their design process to create prototypes since the late seventies. Using 3D printers for these purposes is called rapid prototyping.

Why use 3D Printers for Rapid Prototyping?
In short: it’s fast and relatively cheap. From idea, to 3D model to holding a prototype in your hands is a matter of days instead of weeks. Iterations are easier and cheaper to make and you don’t need expensive molds or tools.

Besides rapid prototyping, 3D printing is also used for rapid manufacturing. Rapid manufacturing is a new method of manufacturing where businesses use 3D printers for short run / small batch custom manufacturing.

Automotive

Car manufacturers have been utilizing 3D printing for a long time. Automotive companies are printing spare parts, tools, jigs and fixtures but also end-use parts. 3D printing has enabled on-demand manufacturing which has lead to lower stock levels and has shortened design and production cycles.

Automotive enthusiasts all over the world are using 3D printed parts to restore old cars. One such example is when Australian engineers printed parts to bring a Delage Type-C back to life. In doing so, they had to print parts that were out of production for decades.

Aviation

Aviation loves additive manufacturing, largely due to the promise of lightweight and stronger structures offered by 3D printing. We’ve seen a whole bunch of innovations in the domain of aviation lately, with the appearance of more critical parts being printed.

Turbine Center Frame

One such large component printed this year was the turbine center frame which was printed by GE as part of the EU Clean Sky 2 initiative.

The Advanced Additive Integrated Turbine Centre Frame (TCF) is a 1 meter diameter part printed in nickel alloy 718 by GE and a consortium from Hamburg University of Technology (TUHH), TU Dresden (TUD) and Autodesk. It is one of the largest single metal parts printed for aviation.

Big turbine center frame. (Image credit: GE AAT Munich)

Typically components like this are manufactured using casting, and consist of multiple parts. In the case of the 3D printed version, it was reduced from an assembly of 150 parts down to just 1 single piece. The printed version also benefits from a reduction of both cost and mass by 30%, and a reduction in lead time from 9 months to just 10 weeks.

Metal Parts Certified by EASA

Back in June 2022 it was reported that Lufthansa Technik and Premium AEROTEC had created the first load-bearing metal part that had been approved for use in aviation.

The new A-link was produced using LPBF and had demonstrated higher tensile strength compared to the traditionally-forged version.

The part was made at Premium AEROTEC’s facility in Varel, Germany, and a large number of test parts were printed and tested to ensure quality and repeatability for certification.

Printed titanium A-links (Image credit: Lufthansa Technik)

Printing the part represented a cost saving for the component and set the stage for using this manufacturing method for creating structurally important metal parts in the future. It was also used to test the process and to demonstrate the certification process of load-bearing AM parts.

Hypersonic Fuel Injector

This next printed item was never destined to be fitted to an aircraft, but rather it was designed to be installed in a facility for testing flow conditions at hypersonic speeds.

When flying in the hypersonic flight regime above (Mach 5), the air passing around the vehicle becomes incredibly hot, and the pressure increases significantly. These conditions can cause the air itself to become chemically reactive, which causes issues for fuel burning vehicles.

Simulating flow conditions with CFD is computationally expensive (if not impossible), and so to replicate the flow conditions, researchers at Purdue fabricated a giant burner to recreate the hot, fast, high pressure experienced in hypersonic flight. In short, they basically built a rocket nozzle and they placed the test components in the exhaust plume to see how they performed.

3D Printed Fuel Injectors (Image credit: Purdue University)

The injectors that they printed feed fuel and air into the combustion chamber to create specific turbulent flow fields and a stable flame.

The injectors were printed with Hastelloy X, which is a superalloy with superior temperature resistance. The team printed multiple different injectors in rapid time, and tested them all in the burner to see which performed the best.

Now they are able to replicate the hypersonic conditions for flight on Earth at a fraction of the cost (and risk) associated with doing it miles above the Earth’s surface. This can benefit fast aircraft such as scramjet powered vehicles as well as space vehicles.

Relativity Space

We have covered US-based rocket printing company Relativity Space quite a lot on this website.

From their super large metal printer the “Stargate” to the rocket themselves, this company has been doing big things with both printing and rockets. The 4th gen Stargate 3D printer is capable of printing objects measuring 120ft long and 24ft in diameter, and 12x faster than their previous printers.

The new AI-assisted robotic printer has been able to achieve faster printing speeds thanks to its innovative multi-wire print head. This print head allows for multiple metal feedstock wires to be fed into it at the same time, resulting in higher deposition rates.

The company is scheduled to make their first LEO test flight of the printed Terran-1 rocket this month of January 2023, so we just thought we would give them an honorable mention in this article as a reminder.

You can see the Terran-1 undergoing a hot fire test in the video below.

Construction

Is it possible to print a building? – yes it is. 3D printed houses are already commercially available. Some companies print parts prefab and others do it on-site.

Most of the concrete printing stories we look at on this website are focused on large scale concrete printing systems with fairly large nozzles for a large flow rate. It’s great for laying down concrete layers in a fairly quick and repeatable manner. But for truly intricate concrete work that makes full use of the capabilities of 3D printing requires something a little more nimble, and with a finer touch.

Consumer Products

When we first started blogging about 3D printing back in 2011, 3D printing wasn’t ready to be used as a production method for large volumes. Nowadays there are numerous examples of end-use 3D printed consumer products.

Footwear

Adidas’ 4D range has a fully 3D printed midsole and is being printed in large volumes. We did an article back then, explaining how Adidas were initially releasing just 5,000 pairs of the shoes to the public, and had aimed to sell 100,000 pairs of the AM-infused designs by 2018.

With their latest iterations of the shoe, it seems that they have surpassed that goal, or are on their way to surpassing it. The shoes are available all around the world from local Adidas stores and also from various 3rd party online outlets.

Eyewear

The market of 3D printed eyewear is forecasted to reach $3.4 billion by 2028. A rapidly increasing section is that of end-use frames. 3D printing is a particularly suitable production method for eyewear frames because the measurements of an individual are easy to process in the end product.

But did you know it’s also possible to 3D print lenses? Traditional glass lenses don’t start out thin and light; they’re cut from a much larger block of material called a blank, about 80% of which goes to waste. When we consider how many people wear glasses and how often they need to get a new pair, 80% of those numbers is a lot of waste. On top of that, labs have to keep huge inventories of blanks to meet the custom vision needs of their clients. Finally, however, 3D printing technology has advanced enough to provide high-quality, custom ophthalmic lenses, doing away with the waste and inventory costs of the past. The Luxexcel VisionEngine 3D printer uses a UV-curable acrylate monomer to print two pairs of lenses per hour that require no polishing or post-processing of any kind. The focal areas can also be completely customized so that a certain area of the lens can provide better clarity at a distance while a different area of the lens provides better vision up close.

Jewelry

There are two ways of producing jewelry with a 3D printer. You can either use a direct or indirect production process. Direct refers to the creation of an object straight from the 3D design while indirect manufacturing means that the object (pattern) that is 3D printed eventually is used to create a mold for investment casting.

Healthcare

It’s not uncommon these days to see headlines about 3D printed implants. Often, those cases are experimental, which can make it seem like 3D printing is still a fringe technology in the medical and healthcare sectors, but that’s not the case anymore. Over the last decade, more than 100,000 hip replacements have been 3D printed by GE Additive.

The Delta-TT Cup designed by Dr. Guido Grappiolo and LimaCorporate is made of Trabecular Titanium, which is characterized by a regular, three-dimensional, hexagonal cell structure that imitates trabecular bone morphology. The trabecular structure increases the biocompatibility of the titanium by encouraging bone growth into the implant. Some of the first Delta-TT implants are still running strong over a decade later.

Another 3D printed healthcare component that does a good job of being undetectable is the hearing aid. It is estimated that 99% of hearing aids manufactured are made with the use of additive manufacturing, and it’s clear to see why.

Dental

In the dental industry, we see molds for clear aligners being possibly the most 3D printed objects in the world. Currently, the molds are 3D printed with both resin and powder based 3D printing processes, but also via material jetting. Crowns and dentures are already directly 3D printed, along with surgical guides.

Bio-printing

As of the early two-thousands 3D printing technology has been studied by biotech firms and academia for possible use in tissue engineering applications where organs and body parts are built using inkjet techniques. Layers of living cells are deposited onto a gel medium and slowly built up to form three dimensional structures. We refer to this field of research with the term: bio-printing.

Food

Additive manufacturing invaded the food industry long time ago. Restaurants like Food Ink and Melisse use this as a unique selling point to attract customers from across the world.

Education

Educators and students have long been using 3D printers in the classroom. 3D printing enables students to materialize their ideas in a fast and affordable way.

While additive manufacturing-specific degrees are fairly new, universities have long been using 3D printers in other disciplines. There are many educational courses one can take to engage with 3D printing. Universities offer courses on things that are adjacent to 3D printing like CAD and 3D design, which can be applied to 3D printing at a certain stage.

In terms of prototyping, many university programs are turning to printers. There are specializations in additive manufacturing one can attain through architecture or industrial design degrees. Printed prototypes are also very common in the arts, animation and fashion studies as well.

Types of 3D Printing Technologies and Processes

The American Society for Testing and Materials (ASTM), developed a set of standards that classify additive manufacturing processes into 7 categories. These are:

  1. Vat Photopolymerisation
    1. Stereolithography (SLA)
    2. Digital Light Processing (DLP)
    3. Continuous Liquid Interface Production (CLIP)
  2. Material Jetting
  3. Binder Jetting
  4. Material Extrusion
    1. Fused Deposition Modeling (FDM)
    2. Fused Filament Fabrication (FFF)
  5. Powder Bed Fusion
    1. Multi Jet Fusion (MJF)
    2. Selective Laser Sintering (SLS)
    3. Direct Metal Laser Sintering (DMLS)
  6. Sheet Lamination
  7. Directed Energy Deposition

Vat Photopolymerisation

A 3D printer based on the Vat Photopolymerisation method has a container filled with photopolymer resin. The resin is hardened with a UV light source.

Vat photopolymerisation schematics. Image source: lboro.ac.uk

Stereolithography (SLA)

SLA was invented in 1986 by Charles Hull, who also at the time founded the company, 3D Systems. Stereolithography employs a vat of liquid curable photopolymer resin and an ultraviolet laser to build the object’s layers one at a time. For each layer, the laser beam traces a cross-section of the part pattern on the surface of the liquid resin. Exposure to the ultraviolet laser light cures and solidifies the pattern traced on the resin and fuses it to the layer below.

After the pattern has been traced, the SLA’s elevator platform descends by a distance equal to the thickness of a single layer, typically 0.05 mm to 0.15 mm (0.002″ to 0.006″). Then, a resin-filled blade sweeps across the cross section of the part, re-coating it with fresh material. On this new liquid surface, the subsequent layer pattern is traced, joining the previous layer. Depending on the object & print orientation, SLA often requires the use of support structures.

Digital Light Processing (DLP)

DLP or Digital Light Processing refers to a method of printing that makes use of light and photosensitive polymers. While it is very similar to SLA, the key difference is the light source. DLP utilizes other light sources like arc lamps. DLP is relatively quick compared to other 3D printing technologies.

Continuous Liquid Interface Production (CLIP)

One of the fastest processes using Vat Photopolymerisation is called CLIP, short for Continuous Liquid Interface Production, developed by Carbon.

Digital Light Synthesis

The heart of the CLIP process is Digital Light Synthesis technology. In this technology, light from a custom high performance LED light engine projects a sequence of UV images exposing a cross section of the 3D printed part causing the UV curable resin to partially cure in a precisely controlled way. Oxygen passes through the oxygen permeable window creating a thin liquid interface of uncured resin between the window and the printed part known as the dead zone. The dead zone is as thin as ten of microns. Inside the dead zone, oxygen prohibits light from curing the resin situated closest to the window therefore allowing the continuous flow of liquid beneath the printed part. Just above the dead zone the UV projected light upwards causes a cascade like curing of the part.

Simply printing with Carbon’s hardware alone does not allow for end use properties with real world applications. Once the light has shaped the part, a second programmable curing process achieves the desired mechanical properties by baking the 3d printed part in a thermal bath or oven. Programmed thermal curing sets the mechanical properties by triggering a secondary chemical reaction causing the material to strengthen achieving the desired final properties.

Components printed with Carbon’s technology are on par with injection molded parts. Digital Light Synthesis produces consistent and predictable mechanical properties, creating parts that are truly isotropic.

Material Jetting

In this process, material is applied in droplets through a small diameter nozzle, similar to the way a common inkjet paper printer works, but it is applied layer-by-layer to a build platform and then hardened by UV light.

Material Jetting schematics. Image source: custompartnet.com

Binder Jetting

With binder jetting two materials are used: powder base material and a liquid binder. In the build chamber, powder is spread in equal layers and binder is applied through jet nozzles that “glue” the powder particles in the required shape. After the print is finished, the remaining powder is cleaned off which often can be re-used printing the next object. This technology was first developed at the Massachusetts Institute of Technology in 1993.

Binder Jetting schematics

Material Extrusion

Fused Deposition Modeling (FDM)

FDM schematics (Image credit: Wikipedia, made by user Zureks)

FDM works using a plastic filament which is unwound from a spool and is supplied to an extrusion nozzle which can turn the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism. The object is produced by extruding melted material to form layers as the material hardens immediately after extrusion from the nozzle.

FDM was invented by Scott Crump in the late 80’s. After patenting this technology he started the company Stratasys in 1988. The term Fused Deposition Modeling and its abbreviation to FDM are trademarked by Stratasys Inc.

Fused Filament Fabrication (FFF)

The exactly equivalent term, Fused Filament Fabrication (FFF), was coined by the members of the RepRap project to give a phrase that would be legally unconstrained in its use.

Powder Bed Fusion

Selective Laser Sintering (SLS)

SLS uses a high power laser to fuse small particles of powder into a mass that has the desired three dimensional shape. The laser selectively fuses powder by first scanning the cross-sections (or layers) on the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one layer thickness. Then a new layer of material is applied on top and the process is repeated until the object is completed.

SLS schematics (Image credit: Wikipedia from user Materialgeeza)

Multi Jet Fusion (MJF)

Multi Jet Fusion technology was developed by Hewlett Packard and works with a sweeping arm which deposits a layer of powder and then another arm equipped with inkjets which selectively applies a binder agent over the material. The inkjets also deposit a detailing agent around the binder to ensure precise dimensionality and smooth surfaces. Finally, the layer is exposed to a burst of thermal energy that causes the agents to react.

Direct Metal Laser Sintering (DMLS)

DMLS is basically the same as SLS, but uses metal powder instead. All unused powder remains as it is and becomes a support structure for the object. Unused powder can be re-used for the next print.

Due to of increased laser power, DMLS has evolved into a laser melting process. Read more about that and other metal technologies on our metal technologies overview page.

Sheet Lamination

Sheet lamination involves material in sheets which is bound together with external force. Sheets can be metal, paper or a form of polymer. Metal sheets are welded together by ultrasonic welding in layers and then CNC milled into a proper shape. Paper sheets can be used also, but they are glued by adhesive glue and cut in shape by precise blades.

Simplified schematics of ultrasonic sheet metal process (Image credit: Wikipedia from user Mmrjf3)

Directed Energy Deposition

This process is mostly used in the metal industry and in rapid manufacturing applications. The 3D printing apparatus is usually attached to a multi-axis robotic arm and consists of a nozzle that deposits metal powder or wire on a surface and an energy source (laser, electron beam or plasma arc) that melts it, forming a solid object.

Directed Energy Deposition with metal powder and laser melting (Image credit: Merlin project)

Materials

Multiple materials can be used in additive manufacturing: plastics, metals, concrete, ceramics, paper and certain edibles (e.g. chocolate). Materials are often produced in wire feedstock a.k.a. filament, powder form or liquid resin. Learn more about our featured materials on our materials page.

Services

Looking to implement 3D printing in your production process? Get a quote for a custom part or order samples on our 3D print service page.

Various file formats for 3D printing・Cults

With the development of digital technology, 3D printing has become much more accessible today. Individuals and professionals can have their own equipment and make various print models. All that is required is a good understanding of the basic concepts, especially in relation to the respective file formats. Indeed, depending on the field and for historical or practical reasons, certain file formats are preferred for 3D printing. Here are the most common 3D printing formats and their main characteristics.

STL is short for "Stereolithography", one of the oldest file formats for 3D printing. Developed in the late 1980s, this type of format is still widely used today. It describes the surface geometry of a 3D object without displaying color, texture, or other attributes. The STL format has the ".STL" extension. These files are generated by computer-aided design (CAD) software. Programs such as FreeCAD, Blender, MeshLab, MeshMixer, SketchUp, SculptGL, and 3DSlash can be used to edit and repair STL files.

The STL file simplifies a 3D surface into a "tessellation", a series of small triangles that increase in number when it is necessary to represent and recreate curved surfaces as best as possible. When a large number of triangles need to be used, the size of the 3D model STL file increases rapidly.

The OBJ file format is also very popular in the 3D printing industry. Its extension is ". OBJ". It has the advantage that it also encodes color and texture information, which is stored in a separate file with a ".MTL" extension. OBJ files allow the use of non-triangular faces, with one face adjoining another. They can be opened with programs such as Autodesk Maya 2013, Blender and MeshLab .

Developed in the 1990s, 3DS is a file format that stores only the most basic information about geometry, appearance, scenes, and animation. It allows you to save properties such as color, material, texture, transmissivity, etc. With the ".3DS" extension, this 3D printing file format also has the advantage that it can be read by most programs on the market, such as 3dsMax, ABViewer, Blender, MeshLab, messiahStudio, Rain Swift 3D, SketchUp, TurboCAD etc.

An SLDPRT file or its .SLDPRT extension is a 3D printing image format used by the SolidWorks CAD software. It contains a 3D object or "part" that can be combined with other parts into a single ". SLDASM" assembly file. SLDPRT files are usually opened with the SolidWorks program. However, they can be viewed using SolidWorks eDrawings Viewer, Autodesk Fusion 360, Adobe Acrobat 3D, Acrobat Pro 9 or later .

The SCAD format (.SCAD extension) is generated by OpenSCAD, a freeware modeling program used for various 2D and 3D projects. The SCAD file can be used to design 3D objects, specifying the object's geometry and positioning information. It can only be opened with OpenSCAD .

The .BLEND format is an extension used for 3D animation and projects designed with Blender's 3D modeling tool. This file type can contain multiple scenes as well as all project elements such as objects, textures, 3D meshes and real-time interaction data, sounds, lighting data, animation keyframes, display layouts, and interface settings. Please note that only Blender can work with this 3D file format.

The 3MF file (.3MF extension) is used by various design programs to save 3D models for printing. This format includes model, material, and property data compressed using ZIP compression. 3MF files also store a print ticket, a thumbnail image, and one or more digital signatures. They can be opened with programs such as Microsoft 3D Builder, Microsoft Paint 3D, Dassault Systemes SolidWorks, Dassault Systemes CATIA, McNeel Rhino, PTC Creo and Ultimaker Cura .

The .GCODE file contains commands that define how the 3D printer should print. It stores instructions such as print speed, set temperature, and where to move print items. This 3D file format is created with cutting software such as Simplify3D and Slic3r. Reading can be done with Simplify3D, as well as Blaze3D, GCode Viewer and NC Viewer .

A .SKP file is a 3D model format created by SketchUp. This takes into account wireframes, textures, shadows, and edge effects. This file type is also used to store components that will be inserted into the document. Of course it can be opened with SketchUp, but also with programs like IMSI TurboCAD Pro or Deluxe, Okino Computer Graphics PolyTrans, ACCA Edificius and Trimble 3D Warehouse .

FBX is a 3D printing file format popular in the film and video game industry. Developed by Kaydara and acquired by AutoDesk, it supports geometry and appearance properties such as color and texture, as well as skeletal animation and morphs. AutoDesk will use the ".FBX" FBX file as an interchange format for its software portfolio such as AutoCAD, Fusion 360, Maya, 3DS Max, etc.

Other file types are not exclusive to 3D, but are regularly used in the field.

A .RAR file is an archive containing one or more compressed files. The compression ratio of this format is greater than that of the classic ZIP compression. It is used to compress files to reduce their size for easier transportation and storage. You can extract files from RAR archive using various unpacking programs such as RARLAB WinRAR, Corel WinZip or B1 Free Archiver .

.DWG files are databases of 2D or 3D models created in AutoCAD. They consist of information about the vector image and metadata that describes the contents of the file. There are many utilities available to open this file format, including: Autodesk Auto CAD, Autodesk Inventor, Autodesk Design, Autodesk DWG, AutoDWG DWGSee, CADSoftTools ABViewer, Canvas X, Adobe Illustrator, Bricsys Bricscad, etc.

Used in 3D editing programs such as Adobe Photoshop and Autodesk Maya, the .MTL format is used to store material settings. This file is stored along with another in .OBJ format and is used to describe how textures should be applied and the 3D coordinates they should be applied to.

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File types for 3D modeling and 3D printing

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3D model storage features

Unlike images, the voxel (voxel - volumetric pixel) storage method has not taken root in the world of 3D models. Only a few craftsmen use it when creating games or in scientific research. This is due to the history of the emergence of three-dimensional graphics: unlike the appearance of photography, three-dimensional graphics were originally created on a computer, and were used for animation. Voxels are much more difficult to animate, so they began to use the polygon storage method instead: the entire model consists of many polygons - triangles that have three points. It's like creating sculptures out of paper - by putting together a lot of flat pieces, you can get something voluminous and even smooth.


Dolphin Polygon Model

Although this method of saving as polygons cannot be called raster, these methods have much in common: the impossibility of increasing the quality, the direct relationship between the quality and file weight, ease of editing. This is the most practical format for saving and using models in 3D printing, but not the only one. Next, we will look at the most popular formats for storing 3D models.

Universal 3D Model File Formats

In fact, there are as many different methods for storing 3D models as there are for storing photos and videos. But there are also universal formats that, although with some restrictions, can be opened in almost any program.

STL

Contrary to misconceptions, STL was not originally intended for artistic modeling. It was developed by the Albert Consulting Group and was intended for an early 3D printing method - stereolithography. Hence the name of the file - STereoLithography. After some time, the company openly published the format and since then it has gained immense popularity.

The STL format is widely used due to the simplicity of its structure: polygons (facets) and their normals. The former are needed to set the surface, and the latter to indicate where the outer side of the polygon is located. Therefore, this format can be considered the most universal.

Comparison of CAD model and STL model

Due to the fact that the model is defined using many triangles, it is impossible to accurately define curved surfaces, because this would require an infinite number of triangles, and therefore an infinite data store. But when used in 3D printing, this minus is not so important, since the accuracy specified using triangles is higher than the printing accuracy.

OBJ

This format is very similar to STL, but differs in the ability to apply textures, set the material and store other information. Therefore, OBJ can be called an extended version of STL and is mainly intended for artistic modeling programs such as Blender, Autodesk Maya, 3Ds Max, Meshlab and others.

OBJ model processing in Blender

STEP

Now we are moving on to the engineering side of 3D modeling, because STEP is the only format that can be opened in any engineering modeling program and freely edited with the tools built into the program. STEP was originally developed as a world standard format for storing products on a computer, and was intended for a complete development cycle of a part. That is why all serious engineering modeling and physical simulation programs can work with this format. A distinctive feature of STEP is its high accuracy: the model is created with tools that allow you to set curves using formulas. Therefore, the precision in this format is infinite: no matter how much you increase it, the curved line will remain a curve, and will not become a lot of straight lines.

Creating a model in CAD SolidWorks

To create models in STEP format, CAD (Computer-Aided Design) is used. Thanks to the ISO standard, all CAD programs can work in this format. But not all data is freely transferred from one program to another via STEP. For us, the most important thing is the transfer of model geometry, and simulations, material and other data that the STEP format does not store are of secondary importance.

Proprietary formats

This category includes file formats that can only be opened in one program - in which the files were created. They are intended only for storing projects, often they cannot be used in 3D printing. An exception is the Ultimaker Cura slicer, which has the ability to add plug-ins that allow you to open files of programs such as Inventor, Siemens NX, Solidworks and others directly from the slicer.

Engineering programs

As mentioned earlier, these programs are called CAD. Since this software is often intended for production, they also have a common file format (STEP). Some programs, often produced by one company, allow you to work in a common ecosystem. For example, in many of Autodesk's engineering software, format compatibility can be found: Fusion 360 can open a file created in Inventor. But with this method of opening, some information about the product will still be lost, for example, information about the physical simulations performed. Therefore, if the part is not developed to the end, you should not move it between different programs.

Art programs

This category includes programs created for visualization: animation, special effects, creation of figures and models for video games. Unlike the previous case, chaos reigns in artistic modeling programs. Each program has its own format, and the general STL format limits the functionality of each program to the simplest tools. But this is enough to create models that will later be printed on a 3D printer, since only the geometry of the model is important.

Gcode - format for 3D printing

Actually Gcode is more than just a file format. It is a separate programming language. But instead of executing commands by a computer, commands in this language are executed by a 3D printer. Initially, this language was developed for complex CNC machines, and a 3D printer is one of the simplest representatives of this type of device. Unlike previous formats, gcode can be easily edited manually, thereby giving commands to the printer directly, bypassing the computer. With this, you can create macros that make it easier to work with a 3D printer. You can read more about working with the gcode language and creating macros in an article on our website.

3D model file format conversion

If you have a need to move the model between programs for 3D modeling, then you should determine in which group the program is from where and where you want to move the model. If you are transferring it from one CAD program to another, then it is best to use the STEP format so as not to limit the number of tools for further modeling. In all other cases, the only option is the STL format, which some CAD systems can recognize and in which art programs can save the model. It should be taken into account that when transferring a model from an art program to CAD, each polygon is transferred as a separate surface, so working with STL files in engineering programs can cause difficulties both in processing and in simple viewing of the model. This is due to the principles of CAD: it performs the processing of each surface separately, and the more surfaces, the more calculations need to be performed for one operation.

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