3D printing explained simply

What is 3D Printing? - Technology Definition and Types

3D printing, also known as additive manufacturing, is a method of creating a three dimensional object layer-by-layer using a computer created design.

3D printing is an additive process whereby layers of material are built up to create a 3D part. This is the opposite of subtractive manufacturing processes, where a final design is cut from a larger block of material. As a result, 3D printing creates less material wastage.

This article is one of a series of TWI frequently asked questions (FAQs).

3D printing is also perfectly suited to the creation of complex, bespoke items, making it ideal for rapid prototyping.

What materials can be used?
History
Technologies
Process types
How long does it take?
Advantages and disadvantages
What is an STL file?
Industries
Services
FAQs

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There are a variety of 3D printing materials, including thermoplastics such as acrylonitrile butadiene styrene (ABS), metals (including powders), resins and ceramics.

Who Invented 3D Printing?

The earliest 3D printing manufacturing equipment was developed by Hideo Kodama of the Nagoya Municipal Industrial Research Institute, when he invented two additive methods for fabricating 3D models.

When was 3D Printing Invented?

Building on Ralf Baker's work in the 1920s for making decorative articles (patent US423647A), Hideo Kodama's early work in laser cured resin rapid prototyping was completed in 1981. His invention was expanded upon over the next three decades, with the introduction of stereolithography in 1984. Chuck Hull of 3D Systems invented the first 3D printer in 1987, which used the stereolithography process. This was followed by developments such as selective laser sintering and selective laser melting, among others. Other expensive 3D printing systems were developed in the 1990s-2000s, although the cost of these dropped dramatically when the patents expired in 2009, opening up the technology for more users.

There are three broad types of 3D printing technology; sintering, melting, and stereolithography.

Sintering is a technology where the material is heated, but not to the point of melting, to create high resolution items. Metal powder is used for direct metal laser sintering while thermoplastic powders are used for selective laser sintering.
Melting methods of 3D printing include powder bed fusion, electron beam melting and direct energy deposition, these use lasers, electric arcs or electron beams to print objects by melting the materials together at high temperatures.
Stereolithography utilises photopolymerization to create parts. This technology uses the correct light source to interact with the material in a selective manner to cure and solidify a cross section of the object in thin layers.

Types of 3D printing

3D printing, also known as additive manufacturing, processes have been categorised into seven groups by ISO/ASTM 52900 additive manufacturing - general principles - terminology. All forms of 3D printing fall into one of the following types:

Binder Jetting
Direct Energy Deposition
Material Extrusion
Material Jetting
Powder Bed Fusion
Sheet Lamination
VAT Polymerization

Binder Jetting

Binder jetting deposits a thin layer of powered material, for example metal, polymer sand or ceramic, onto the build platform, after which drops of adhesive are deposited by a print head to bind the particles together. This builds the part layer by layer and once this is complete post processing may be necessary to finish the build. As examples of post processing, metal parts may be thermally sintered or infiltrated with a low melting point metal such as bronze, while full-colour polymer or ceramic parts may be saturated with cyanoacrylate adhesive.

Binder jetting can be used for a variety of applications including 3D metal printing, full colour prototypes and large scale ceramic moulds.

Direct Energy Deposition

Direct energy depositioning uses focussed thermal energy such as an electric arc, laser or electron beam to fuse wire or powder feedstock as it is deposited. The process is traversed horizontally to build a layer, and layers are stacked vertically to create a part.

This process can be used with a variety of materials, including metals, ceramics and polymers.

Material Extrusion

Material extrusion or fused deposition modelling (FDM) uses a spool of filament which is fed to an extrusion head with a heated nozzle. The extrusion head heats, softens and lays down the heated material at set locations, where it cools to create a layer of material, the build platform then moves down ready for the next layer.

This process is cost-effective and has short lead times but also has a low dimensional accuracy and often requires post processing to create a smooth finish. This process also tends to create anisotropic parts, meaning that they are weaker in one direction and therefore unsuitable for critical applications.

Material Jetting

Material jetting works in a similar manner to inkjet printing except, rather than laying down ink on a page, this process deposits layers of liquid material from one or more print heads. The layers are then cured before the process begins again for the next layer. Material jetting requires the use of support structures but these can be made from a water-soluble material that can be washed away once the build is complete.

A precise process, material jetting is one of the most expensive 3D printing methods, and the parts tend to be brittle and will degrade over time. However, this process allows for the creation of full-colour parts in a variety of materials.

Powder Bed Fusion

Powder bed fusion (PBF) is a process in which thermal energy (such as a laser or electron beam) selectively fuses areas of a powder bed to form layer, and layers are built upon each other to create a part. One thing to note is that PBF covers both sintering and melting processes. The basic method of operation of all powder bed systems is the same: a recoating blade or roller deposits a thin layer of the powder onto the build platform, the powder bed surface is then scanned with a heat source which selectively heats the particles to bind them together. Once a layer or cross-section has been scanned by the heat source, the platform moves down to allow the process to begin again on the next layer. The final result is a volume containing one or more fused parts surrounded by unaffected powder. When the build is complete, the bed is fully raised to allow the parts to be removed from the unaffected powder and any required post processing to begin.

Selective laser sintering (SLS) is often used for manufacture of polymer parts and is good for prototypes or functional parts due to the properties produced, while the lack of support structures (the powder bed acts as a support) allows for the creation of pieces with complex geometries. The parts produced may have a grainy surface and inner porosity, meaning there is often a need for post processing.

Direct metal laser sintering (DMLS), selective laser melting (SLM) and electron beam powder bed fusion (EBPBF) are similar to SLS, except these processes create parts from metal, using a laser to bond powder particles together layer-by-layer. While SLM fully melts the metal particles, DMLS only heats them to the point of fusion whereby they join on a molecular level. Both SLM and DMLS require support structures due to the high heat inputs required by the process. These support structures are then removed in post processing ether manually or via CNC machining. Finally, the parts may be thermally treated to remove residual stresses.

Both DMLS and SLM produce parts with excellent physical properties - often stronger than the conventional metal itself, and good surface finishes. They can be used with metal superalloys and sometimes ceramics which are difficult to process by other means. However, these processes can be expensive and the size of the produced parts is limited by the volume of the 3D printing system used.

Sheet Lamination

Sheet lamination can be split into two different technologies, laminated object manufacturing (LOM) and ultrasonic additive manufacturing (UAM). LOM uses alternate layers of material and adhesive to create items with visual and aesthetic appeal, while UAM joins thin sheets of metal via ultrasonic welding. UAM is a low temperature, low energy process that can be used with aluminium, stainless steel and titanium.

VAT Photopolymerization

VAT photopolymerization can be broken down into two techniques; stereolithography (SLA) and digital light processing (DLP). These processes both create parts layer-by-layer through the use of a light to selectively cure liquid resin in a vat. SLA uses a single point laser or UV source for the curing process, while DLP flashes a single image of each full layer onto the surface of the vat. Parts need to be cleaned of excess resin after printing and then exposed to a light source to improve the strength of the pieces. Any support structures will also need to be removed and additional post-processing can be used to create a higher quality finish.

Ideal for parts with a high level of dimensional accuracy, these processes can create intricate details with a smooth finish, making them perfect for prototype production. However, as the parts are more brittle than fused deposition modelling (FDM) they are less suited to functional prototypes. Also, these parts are not suitable for outdoor use as the colour and mechanical properties may degrade when exposed to UV light from the sun. The required support structures can also leave blemishes that need post processing to remove.

The printing time depends on a number of factors, including the size of the part and the settings used for printing. The quality of the finished part is also important when determining printing time as higher quality items take longer to produce. 3D printing can take anything from a few minutes to several hours or days - speed, resolution and the volume of material are all important factors here.

The advantages of 3D printing include:

Bespoke, cost-effective creation of complex geometries:
This technology allows for the easy creation of bespoke geometric parts where added complexity comes at no extra cost. In some instances, 3D printing is cheaper than subtractive production methods as no extra material is used.
Affordable start-up costs:
Since no moulds are required, the costs associated with this manufacturing process are relatively low. The cost of a part is directly related to the amount of material used, the time taken to build the part and any post processing that may be required.
Completely customisable:
Because the process is based upon computer aided designs (CAD), any product alterations are easy to make without impacting the manufacturing cost.
Ideal for rapid prototyping:
Because the technology allows for small batches and in-house production, this process is ideal for prototyping, which means that products can be created faster than with more traditional manufacturing techniques, and without the reliance on external supply chains.
Allows for the creation of parts with specific properties:
Although plastics and metals are the most common materials used in 3D printing, there is also scope for creating parts from specially tailored materials with desired properties. So, for example, parts can be created with high heat resistance, water repellency or higher strengths for specific applications.

The disadvantages of 3D printing include:

Can have a lower strength than with traditional manufacture:
While some parts, such as those made from metal, have excellent mechanical properties, many other 3D printed parts are more brittle than those created by traditional manufacturing techniques. This is because the parts are built up layer-by-layer, which reduces the strength by between 10 and 50%.
Increased cost at high volume:
Large production runs are more expensive with 3D printing as economies of scale do not impact this process as they do with other traditional methods. Estimates suggest that when making a direct comparison for identical parts, 3D printing is less cost effective than CNC machining or injection moulding in excess of 100 units, provided the parts can be manufactured by conventional means.
Limitations in accuracy:
The accuracy of a printed part depends on the type of machine and/or process used. Some desktop printers have lower tolerances than other printers, meaning that the final parts may slightly differ from the designs. While this can be fixed with post-processing, it must be considered that 3D printed parts may not always be exact.
Post-processing requirements:
Most 3D printed parts require some form of post-processing. This may be sanding or smoothing to create a required finish, the removal of support struts which allow the materials to be built up into the designated shape, heat treatment to achieve specific material properties or final machining.

An STL file is a simple, portable format used by computer aided design (CAD) systems to define the solid geometry for 3D printable parts. An STL file provides the input information for 3D printing by modelling the surfaces of the object as triangles that share edges and vertices with other neighbouring triangles for the build platform. The resolution of the STL file impacts the quality of the 3D printed parts - if the file resolution is too high the triangle may overlap, if it is too low the model will have gaps, making it unprintable. Many 3D printers require an STL file to print from, however these files can be created in most CAD programs.

Due to the versatility of the process, 3D printing has applications across a range of industries, for example:

Aerospace

3D printing is used across the aerospace (and astrospace) industry due to the ability to create light, yet geometrically complex parts, such as blisks. Rather than building a part from several components, 3D printing allows for an item to be created as one whole component, reducing lead times and material wastage.

Automotive

The automotive industry has embraced 3D printing due to the inherent weight and cost reductions. It also allows for rapid prototyping of new or bespoke parts for test or small-scale manufacture. So, for example, if a particular part is no longer available, it can be produced as part of a small, bespoke run, including the manufacture of spare parts. Alternatively, items or fixtures can be printed overnight and are ready for testing ahead of a larger manufacturing run.

Medical

The medical sector has found uses for 3D printing in the creation of made-to-measure implants and devices. For example, hearing aids can be created quickly from a digital file that is matched to a scan of the patient's body. 3D printing can also dramatically reduce costs and production times.

Rail

The rail industry has found a number of applications for 3D printing, including the creation of customised parts, such as arm rests for drivers and housing covers for train couplings. Bespoke parts are just one application for the rail industry, which has also used the process to repair worn rails.

Robotics

The speed of manufacture, design freedom, and ease of design customisation make 3D printing perfectly suited to the robotics industry. This includes work to create bespoke exoskeletons and agile robots with improved agility and efficiency.

TWI has one of the most definitive ranges of 3D Printing services, including selective laser melting, laser deposition, wire and arc additive manufacturing, wire and electron beam additive manufacturing and EB powder bed fusion small-scale prototyping, and more.

Additive Manufacturing

TWI provides companies with support covering every aspect of metal additive manufacturing (AM), from simple feasibility and fabrication projects to full adoption and integration of metal AM systems.

Laser Metal Deposition

TWI has been developing LMD technology for the last ten years. For full details of our capabilities in this area, and to find out more about the process and the benefits it can bring to your business.

Selective Laser Melting

TWI has been developing selective laser melting technology for the last decade. Find out full details of our capabilities in this area and the benefits it can bring to your business.

Can 3D Printing be used for Mass Production?

While there have been great advances in 3D printing, it still struggles to match other manufacturing techniques for high volume production. Techniques such as injection moulding allow for much faster mass production of parts.

Where is 3D Printing Heading in the Future?

As 3D printing technology continues to improve it could democratise the manufacture of goods. With printers becoming faster, they will be able to work on larger scale production projects, while lowering the cost of 3D printing will help its use spread outside of industrial uses and into homes, schools and other settings.

Which 3D Printing Material is most Flexible?

Thermoplastic polyurethane (TPU) is commonly deemed to be the most flexible material available to the 3D printing industry. TPU possesses bendable and stretchy characteristics that many other filaments do not have.

Which 3D Printing Material is the Strongest?

Polycarbonate is seen as the strongest 3D printing material, with a tensile strength of 9,800 psi, compared to nylon, for example, with just 7,000 psi.

Why is 3D Printing Important?

3D printing is important for the many benefits it brings. It allows users to produce items that have geometries which are difficult or impossible for traditional methods to produce. It also allows users with a limited experience to edit designs and create bespoke, customised parts. On-demand 3D printing also saves on tooling costs and provides an advanced time-to-market. 3D printing is important for industries such as aerospace, where it can create lightweight yet complex parts, offering weight saving, the associated fuel reductions and a better environmental impact as a result. It is also important for the creation of prototypes that can advance industry.

Will 3D Printing Replace Traditional Manufacturing?

3D printing has the capability to disrupt traditional manufacturing through the democratisation of production along with the production of moulds, tools and other bespoke parts. However, challenges around mass production mean that 3D printing is unlikely to replace traditional manufacturing where high volume production of comparatively simple parts is required.

Are 3D Printing Fumes Dangerous?

3D printing fumes can be dangerous to your health as the process produces toxic filament fumes. These emissions are produced as the plastic filaments are melted to create the product layer-by-layer. However, correct procedures such as ensuring sufficient ventilation or using extractors can solve this issue.

How Exactly Does 3D Printing Work? Explained Simply – 3D Printerly

I was sitting here thinking, 3D printing is pretty complex and it’s not very straightforward how it works. That’s why I decided to do this post and explain in simple terms just how 3D printing works to clear any confusion that people may have.

Keep reading to find out how exactly 3D printing works from start to finish!

How exactly does 3D printing work? It works in 3 main different stages: 3D modelling to create the look and design of a print, 3D slicing software to create the digestible information that the 3D printer can understand and implement, then 3D printing to build layer upon layer of material to physically create the actual print itself, called additive manufacturing.

This is the simple way of explaining how it works, but I’m going to dive into more depth about each process so you understand how it’s really done. There is a lot of technical processes at work, which is made simpler for beginners to be able to understand and 3D print in a matter of hours.

Firstly, What is a 3D Printer?

3D printers are a modern machine created with several moving parts which work together to create real life objects, directly from 3D design models. They generally use a gear to push material, a hot end to melt the material and a nozzle to lay the material down.

3D printers can use a variety of materials to print objects with, and more materials are being designed on a regular basis such as composite/hybrid filaments.

3D printing or additive manufacturing comes in many forms but they all follow a general process to print objects:

Create or a find a 3D CAD (Computer Aided Design) model
Get your CAD model and convert it into an STL file/format (most popular for 3D printers)
Transfer the STL file to your 3D printer using either an SD card, Wi-Fi, or an Ethernet cable
Load the file on your 3D printer and begin your print
Wait for the printer to create your object then remove it from the build plate
Depending on what you printed, clear up the print using post-processing techniques like sanding, washing etc.

Now that we have a good idea of what a 3D printer is, lets move into how exactly they work through each stage of the process.

1. 3D Printing & CAD Modelling

The first step for 3D printing is creating a blueprint or design for the object that you want to print. You can use modelling software like Blender to create your own unique designs, or go to a 3D print design archive website like Thingiverse, Shapeways or Cults3D to find designs that other users have created and shared for free.

The best part about 3D printing is its open-source and community-rich nature where people aim to help out others whether it comes to customization for a specific application or giving advice on how to do things efficiently.

There are plenty of videos that you can watch as a beginner, or even an expert to learn new skills in 3D modelling to get the results and object creation that you desire. It will take some time to learn, but before you know it, you’ll be designing useful, functional objects that make your life easier.

Once you’ve either created your 3D model or used one from another user, it’s time to send the model to your slicing software.

2. 3D Printing & Model Slicing

There are many different slicing software which all aim to do the same job, which is convert your 3D model to an STL file. This STL file is a language that your 3D printer understands and uses to guide its movements and details of your print in real time.

Essentially, slicing is the process of dividing your 3D model into numerous tiny horizontal layers, similar to how your 3D printer will create your print, layer by layer.

In some cases, your 3D printer will have a built-in slicer which will allow you to transfer the CAD files or the direct STL files without edits.

Once your file is sliced and ready to go, it can be transferred to your 3D printer using a number of different methods, being through a USB, SD card, or through the internet. After your printer receives the sliced file, you simply have to tell your printer to start printing.

Now the slicer is where a lot of things are determined, and where you will hear a lot about settings being adjusted. It gives you the ability to edit your file in a way that gives your prints extra strength, by using techniques such as different infill patterns like honeycombs or triangles.

The settings that your slicer usually contains are:

Layer Height
Perimeters
Infill
Infill Patterns
Fill Density
Infill Optimization
Support Material
Raft, Skirt or Brim Layers
Speed
Acceleration & Jerk
Extrusion Width and many more.

There are many types of slicing software, some of the popular ones being Cura, AstroPrint, Slic3r, and KISSlicer. They have different suitability levels and features depending on what you desire.

Many slicing software is created for one specific brand of printer, while others are open-source and are cross-platform apps that give you more freedom to slice in your preferred app.

The slicing stage of 3D print gives many advantages to your final printed object, in the form of strength, durability and customization.

Since 3D printed objects can’t be printed in midair, your slicing software can automatically add supporting structures to give your prints a foundation to be built upon.

After all is complete with your slicing software, the file to send to your 3D printer is ready to be processed and turned into your awaited object.

3. 3D Printing Your Object

When your modelled and sliced file has been created, it can simply get sent to your 3D printer usually in the form of an STL file.

These are the 3D printing industry standard for files to send to your printer in a language it can understand to begin the printing process.

The language is called G-Code which is a long series of very precise movements for your printer to create the object using a layer by layer technique.

Whether you are using the more popular FDM (Fusion Deposition Modelling) printer, resin, or sintering, the 3D printing process is additive manufacturing meaning it is done layer by layer.

With FDM, your materials come in the form of plastic filament spool which is heated and pushed through a nozzle through a device called an extruder.

The extruder consists of a geared system either called a Bowden setup or a Direct Drive setup to physically push the filament through, and a hot end which melts the plastic filament and gets pushed through a small nozzle, normally 0.4mm wide.

When your melted plastic filament is pushed through the nozzle, your printer has instructions to move, using the G-Code and this is how your object is 3D printed. Layer by layer you’ll see the object you designed or used be created right in front of you with great accuracy and detail.

After plastic is extruded onto a printer surface, it must be cooled with fans so it sets in place, or it would be a gooey mess.

Using a smaller nozzle allows you to get more detailed prints because the lines/layers are smaller and show up less, similar to a picture having smaller pixels making a clearer image.

How Does Each Type of 3D Printing Work?

How Does FDM (Fused Deposition Modelling) Printing Work?

It is an layer additive manufacturing technique which uses specially prepared thermoplastic materials to create an object in layers. It accurately produces fine details and objects and results in a high strength, durable product.

Thin thread-like spools of plastic are melted and extruded through a thin nozzle, which is then laid down several times on a printing surface to create an object.

You’ll usually be left with layer lines with FDM printing but they can be processed to reduce the visibility of these line and make the parts smoother.

This type of printing is ideal for concept models, functional prototypes, manufacturing aids, and low-volume end use parts. It has a wide range of applications from the automotive industry, to aviation, to medical uses and simple functional objects for your home.

You can build threads and snap fitted mechanisms to connect your prints together to build into a bigger object.

How Does Resin/SLA (Stereolithography) Printing Work?

Stereolithography is a type of printing which uses a photochemical process of light cross-linking with specific materials which react to it to create a solid object.

It’s known to be one of the faster types of 3D printing and has many applications in the medical field, computer hardware and prototype development.

It’s more accurate than FDM printing and is also referred to as rapid prototyping. A vat of UV curable photopolymer (resin) is needed within an SLA 3D printer to create the object. It’s printed layer by layer using an ultraviolet laser that is directed by X and Y scanning mirrors.

Although more accurate and faster than FDM printing, it also comes at a higher cost on average. This is where you can decide whether you want to pay extra for quicker, more accurate prints or not.

How Does SLS (Selective Laser Sintering) Printing Work?

Selective laser sintering is a type of 3D printing that uses lasers as its main tool to create a 3D object. It uses powdered material such as Nylon or Polyamide and aims a laser at specific points from your 3D model, resulting in the material binding together to make a hardened object.

SLS is usually used for rapid prototyping and low-volume production of component parts.

It’s a fairly modern type of 3D printing and is definitely on the rise in terms of its development and ability to produce specific models.

Typical uses for SLS 3D printing are tools and fixtures, flight-rated components for aviation, fuel tanks, air ducts, architectural models, automotive designs and much more.

PolyJet Technology

PolyJet printing is done through jetting numerous photopolymer droplets onto a printer’s surface then hardening the material using a UV light. To date, it’s one of the most accurate and fastest types of 3D printing available out there.

PolyJet is the patented name by Stratsys, with the general printing term being called MultiJet, but there are slight differences between the two.

How this works is a liquid photopolymer resin is poured into the printer’s material container then heated. Once the photopolymer gets to a certain state of liquidity, the printing process arts by moving the carriage across the build platform.

While moving, the print heads ‘jet’ the resin into droplet form straight onto the build platform where the UV light then cures these droplets, gradually creating a solid object throughout the process.

The good thing about this type of printing is that there are several print heads, which give you the opportunity to print different materials on the same platform. If you have a part requiring supports, it can be built at the same time as your main object.

What Kind of Ink or Material Does a 3D Printer Use?

Now, 3D printers don’t use ink, but they have their own specific materials which you can print with. These depend on what type of printing you are doing as discussed above.

The most popular materials that 3D printer users print with has to be PLA, followed by ABS then probably PETG.

Printing with PLA

This is the most popular material for a number of reasons, the main one being its ease of use and cheap price. The material itself has great properties that thrive when used for the average prints that people make around the home and with other functional parts.

It is pretty durable, is widely used in other products that you have around the home, and is a great base material for many other composite materials to be created. PLA is also the safest material to print with and is used for food containers and other products.

Printing with ABS

ABS is similarly present in many household products and is the material that Legos are made out of. It is more durable than PLA but has the downside of being harder to print with.

Beginners usually stay away from ABS until they have a bit more experience with printer settings and temperatures to be successful printing with ABS.

ABS tends to give issues while printing such as warping, which is when the plastic cools too quickly compared to the rest of the print, causing the plastic to shrink at different rates and start curving. It also gives off bad fumes which can affect people with high sensitivity to pollutants.

Once you have your settings optimized and you troubleshoot some common issues, printing with ABS can be great, so don’t be put off with it.

Printing with PETG

PETG is another good all-round filament which has good strength, durability and is pretty easy to print with. You will have seen PETG used in products like plastic bottles, cups and even phone cases.

I would say PETG is in the middle of PLA and ABS in terms of its properties, price and ease of use. The good thing about it is its shock and impact resistant, has a very low amount of warping, great adhesion to the print bed when printing and fully recyclable.

Other Materials That Users Print With

There are numerous materials that you can print with, even solely with FDM printing. When you get into different types of 3D printing it opens up another huge selection of materials to print with, from resins, to powders to even metals.

I’ve put together an extensive post of 3D printing filament & materials to give you a proper insight of what kind of materials people right now are printing with.

A quick list of materials you can print with are:

PLA+ – Stronger version of PLA
Nylon – One of the best filaments
HIPS – Great support material, stronger than ABS and PLA
PVA – Water soluble filament
Polycarbonate – Transparent plastic, one of the strongest filaments
ASA – Alternative to ABS, improved weather resistance
TPU – Flexible filament used for wearable, mechanical parts etc.

If you have certain functions and applications in mind with an object, you can choose a material to best do what you desire. If you want a food container, you can pick a food-safe printing material and even post-process it to be more food safe.

If you want a mechanical part for a vehicle, you can pick a strong, durable material which is ideal for moving parts.

There are many possibility and creative ideas that arise from 3D printing due to its customization and specialized manufacturing nature. It is a industry that thrives on open-source creations and constant development to make things better.

PLA+ is an example of these ideas being put to use, which is a developed version of PLA to give it the desired strength and durability, while being easy to print with.

How Fast Can You Do 3D Printing?

Technically, from the time you unbox your 3D printer to set it up and have it running, you could start 3D printing within an hour.

There are 3D printers out there that are almost ready out-of-the-box so you simply need an STL file which already contains your 3D model and it’s G Code language that your 3D printer understands.

From there it’s simply starting your print, which if a small object, can be printed in a matter of minutes.

I’ve written a post about how long it takes to 3D print different objects and how settings affect timing so check it out if you’re interested.

An experienced designer can create a simple, unique CAD model in 30 minutes. If you want to design something basic like a container, vase, or holder of some kind, this could be done in 10 minutes or less with little experience.

More complex models can definitely take several hours of modelling to get perfect so it really depends what you are trying to achieve on how fast you can get it done.

Slicing is a fairly simple process where you are playing around with settings such as temperature, infill, perimeters and so on. Many slicer software will have default options that are input for your specific 3D printer.

A few adjustments here and there shouldn’t take long at all, and sometimes doesn’t actually need any edits to get printing.

The printing itself can be a few minutes to a few days depending on the size, resolution, complexity and 3D printer’s capabilities. If you want to print something quick it can be pretty quickly, for example, a 3D Benchy with normal settings should take about an hour.

What Applications Does a 3D Printer Have & What Can it Make?

3D printers have a very wide range of applications in basically all the fields you can think of. Think of 3D printing as a hobby for other hobbies.

In recent times, 3D printing has been used in the following fields:

Dental
Optometry & glass frames
Prototyping architecture & new products
Prosthetics
Fossil & artifact reconstruction
Reconstructing damaged evidence from crime scenes
Movie props
Cosplay
Aviation & aerospace
Nerf guns
Remote control cars & drones
Home construction
Automotive parts & repairs
Jewelry
Footwear
Bio-printing organs

That’s a pretty long list and not at all extensive either. 3D printing really has taken over some fields and forms of manufacturing in record timing. One prime example is in the hearing aid industry.

Think about how big this industry is, and realize that 3D printing, in a matter of a few years took over this industry by being the main manufacturing method of over 90% of hearing aids.

The manufacturing methods of 3D printing gave users fast delivery on personally customized hearing aids at a much lower price, so it was a no-brainer for companies to switch to 3D printing.

Now after reading this post I hope you guys have a better understanding of how 3D printing works and know how useful it is in today’s world. If you want to read more about 3D printing I would recommend reading the 25 best upgrades you can do for your printer & whether 3D printing is a worthy investment or waste of money.

What is 3D printing and how it can be used! Interesting!

What is 3D printing

3D printing technology was patented in the 80s of the last century, but gained popularity relatively recently. New, promising techniques have been developed and the possibilities of 3D technologies have reached a completely new level. However, to this day, the technique is not known in all circles, and not everyone is aware of what 3D printing is. In today's article, we will try to explain in detail and in an accessible way what 3D printing is and where it is used.

In short, 3D printing is a technique for manufacturing three-dimensional products based on digital models. Regardless of the specific technology, the essence of the process is the gradual layer-by-layer reproduction of objects.
This process uses a special device - a 3D printer, which prints certain types of materials. More details about it are written here. Other names for the technology are rapid prototyping or additive manufacturing. Often the phrase "additive technologies" is used in the meaning of "3D technologies".

3D printing steps

To make it clearer what 3D printing is, let's take a look at the playback process step by step. Below are the specific stages of 3D printing. How it works:

3D modeling of the required object is performed according to certain rules;
The file with the digital model is loaded into the slicer program, which generates the control code for the 3D printer;
Sets required 3D printing options;
The code is written to a removable memory that connects to the 3D printer;
3D model reproduced.

Objects are reproduced gradually. According to the required shape, the selected material is applied layer by layer, forming the finished product. It is worth noting that the possibilities of 3D printing are almost limitless, that is, anything can be made. In some technologies, very thin overhanging elements are provided with supports, thanks to which they can be avoided from sagging.
Naturally, this is a very simplified description of the stages of 3D printing, but they give a very clear idea of the essence of the technique.

Other questions and answers about 3D printers and 3D printing:

Basics What is 3D scanning?
Basics What is a 3D model?

3D Printing Technologies

Different 3D printing technologies are used to reproduce different objects. They differ both in the consumables used, and in the speed and accuracy of printing. Here are the main 3D printing technologies:

Fused deposition modeling (FDM) . One of the most common 3D printing technologies, used in most desktop 3D printers, and represents an ideal price / quality ratio. Printing occurs by layer-by-layer supply of a thread of molten plastic;
Laser stereolithography (SLA) . The formation of the object occurs due to the layer-by-layer illumination of a liquid photopolymer resin by a laser, which hardens under the influence of radiation. One of the variations of this technology is DLP 3D printing. It uses a special projector instead of a laser. Both 3D printing methods are used to create objects with a high degree of detail. In the case of DLP printing, speed is also an added advantage;
Selective laser sintering (SLS) . Reproduction is performed by layer-by-layer melting of a special powder under the action of laser radiation. This 3D printing method is widely used in the industry for the manufacture of durable metal elements

3D Printing Applications

As you may have guessed by now, 3D printing is extremely versatile. The second name of the technology - rapid prototyping - speaks for itself. In the manufacture of prototypes and models of models, 3D printing can be simply indispensable. It is also a very cost-effective solution for small-scale production. In the aerospace and automotive industries, 3D technologies are already being used with might and main due to the high profitability and speed of manufacturing components. Culinary professionals are working on the development of 3D food printers, and in medicine, 3D printing has become something of a technology of the future. With the help of 3D bioprinting, it is planned to produce bones, organs and living tissues, but for now, implants and full-fledged medicines are printed on 3D printers. Desktop 3D printers can be used for domestic purposes: for repairs, making various household items, and so on. And designers, fashion designers, sculptors and artists appreciate the possibilities of 3D printing and 3D modeling as an unusual way to realize their talent.

Well, that was a brief description of what 3D printing is. We hope we were able to provide the necessary information in an accessible way. If you have additional questions that we have not covered, write to us by e-mail and we, if necessary, will add your questions! Best regards, 3DDevice team.

We also want to remind you about the possibility to order 3D printing, 3D scanning, 3D modeling services or purchase of related equipment and consumables with delivery throughout Ukraine in 3DDevice. If you have any questions, please contact us at one of the phone numbers listed here. We look forward to collaborating!

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3D printing for dummies or "what is a 3D printer?"

1 3D printing term
2 3D printing methods

2.1 Extrusion printing
2.2 Melting, sintering or gluing
2.3 Stereolithography
2.4 Lamination

3 Fused Deposition Printing (FDM)

3. 1 Consumables
3.2 Extruder
3.3 Working platform
3.4 Positioners
3.5 Control
3.6 Varieties of

4 Laser stereolithography (SLA)

4.1 Lasers and projectors
4.2 Cuvette and resin
4.3 Varieties of

The term 3D printing

The term 3D printing has several synonyms, one of which quite briefly and accurately characterizes the essence of the process - "additive manufacturing", that is, production by adding material. The term was not coined by chance, because this is the main difference between multiple 3D printing technologies and the usual methods of industrial production, which in turn received the name "subtractive technologies", that is, "subtractive". If during milling, grinding, cutting and other similar procedures, excess material is removed from the workpiece, then in the case of additive manufacturing, material is gradually added until a solid model is obtained.

Soon 3D printing will even be tested on the International Space Station

Strictly speaking, many traditional methods could be classified as "additive" in the broad sense of the word - for example, casting or riveting. However, it should be borne in mind that in these cases, either the consumption of materials is required for the manufacture of specific tools used in the production of specific parts (as in the case of casting), or the whole process is reduced to joining ready-made parts (welding, riveting, etc.). In order for the technology to be classified as “3D printing”, the final product must be built from raw materials, not blanks, and the formation of objects must be arbitrary - that is, without the use of forms. The latter means that additive manufacturing requires a software component. Roughly speaking, additive manufacturing requires computer control so that the shape of final products can be determined by building digital models. It was this factor that delayed the widespread adoption of 3D printing until the moment when numerical control and 3D design became widely available and highly productive.

3D printing techniques

There are many 3D printing technologies, and even more names for them due to patent restrictions. However, you can try to divide technologies into main areas:

Extrusion printing

This includes techniques such as deposition fusion (FDM) and multi-jet printing (MJM). This method is based on the extrusion (extrusion) of consumables with the sequential formation of the finished product. As a rule, consumables consist of thermoplastics or composite materials based on them.

Melting, sintering or bonding

This approach is based on bonding powdered material together. Formation is done in different ways. The simplest is gluing, as is the case with 3D inkjet printing (3DP). Such printers deposit thin layers of powder onto the build platform, which are then selectively bonded with a binder. Powders can be made up of virtually any material that can be ground to a powder—plastic, wood, metal.

This model of James Bond's Aston Martin was successfully printed on a Voxeljet SLS printer and blown up just as successfully during the filming of Skyfall instead of the expensive original

sintering (SLS and DMLS) and smelting (SLM), which allow you to create all-metal parts. As with 3D inkjet printing, these devices apply thin layers of powder, but the material is not glued together, but sintered or melted using a laser. Laser sintering (SLS) is used to work with both plastic and metal powders, although metal pellets usually have a more fusible shell, and after printing they are additionally sintered in special ovens. DMLS is a variant of SLS installations with more powerful lasers that allow sintering metal powders directly without additives. SLM printers provide not just sintering of particles, but their complete melting, which allows you to create monolithic models that do not suffer from the relative fragility caused by the porosity of the structure. As a rule, printers for working with metal powders are equipped with vacuum working chambers, or they replace air with inert gases. Such a complication of the design is caused by the need to work with metals and alloys subject to oxidation - for example, with titanium.

Stereolithography

How an SLA printer works

Stereolithography printers use special liquid materials called "photopolymer resins". The term "photopolymerization" refers to the ability of a material to harden when exposed to light. As a rule, such materials react to ultraviolet irradiation.

Resin is poured into a special container with a movable platform, which is installed in a position near the surface of the liquid. The layer of resin covering the platform corresponds to one layer of the digital model. Then a thin layer of resin is processed by a laser beam, hardening at the points of contact. At the end of illumination, the platform together with the finished layer is immersed to the thickness of the next layer, and illumination is performed again.

Lamination

3D printers using lamination technology (LOM)

Some 3D printers build models using sheet materials - paper, foil, plastic film.

Layers of material are glued on top of each other and cut along the contours of the digital model using a laser or blade.

These machines are well suited for prototyping and can use very cheap consumables, including regular office paper. However, the complexity and noise of these printers, coupled with the limitations of the models they produce, limit their popularity.

Fused deposition modeling (FDM) and laser stereolithography (SLA) have become the most popular 3D printing methods used in the home and office.

Let's take a closer look at these technologies.

Fused Deposition Printing (FDM)

FDM is perhaps the simplest and most affordable 3D construction method, which is the reason for its high popularity.
High demand for FDM printers is driving device and consumable prices down rapidly, along with technology advances towards ease of use and improved reliability.

Consumables

ABS filament spool and finished model

FDM printers are designed to print with thermoplastics, which are usually supplied as thin filaments wound on spools. The range of "clean" plastics is very wide. One of the most popular materials is polylactide or "PLA plastic". This material is made from corn or sugar cane, which makes it non-toxic and environmentally friendly, but makes it relatively short-lived. ABS plastic, on the other hand, is very durable and wear-resistant, although it is susceptible to direct sunlight and can release small amounts of harmful fumes when heated. Many plastic items that we use on a daily basis are made from this material: housings for household appliances, plumbing fixtures, plastic cards, toys, etc.

In addition to PLA and ABS, printing is possible with nylon, polycarbonate, polyethylene and many other thermoplastics that are widely used in modern industry. More exotic materials are also possible, such as polyvinyl alcohol, known as "PVA plastic". This material dissolves in water, which makes it very useful for printing complex geometric patterns. But more on that below.

Model made from Laywoo-D3. Changing the extrusion temperature allows you to achieve different shades and simulate annual rings

It is not necessary to print with homogeneous plastics. It is also possible to use composite materials imitating wood, metals, stone. Such materials use all the same thermoplastics, but with impurities of non-plastic materials.

So, Laywoo-D3 consists partly of natural wood dust, which allows you to print "wooden" products, including furniture.

The material called BronzeFill is filled with real bronze, and models made from it can be ground and polished, achieving a high similarity to products made from pure bronze.

One has only to remember that thermoplastics serve as a connecting element in composite materials - they determine the thresholds of strength, thermal stability and other physical and chemical properties of finished models.

Extruder

Extruder - FDM print head. Strictly speaking, this is not entirely true, because the head consists of several parts, of which only the feed mechanism is directly "extruder". However, by tradition, the term "extruder" is commonly used as a synonym for the entire print assembly.

FDM extruder general design

The extruder is designed for melting and applying thermoplastic thread. The first component is the thread feed mechanism, which consists of rollers and gears driven by an electric motor. The mechanism feeds the thread into a special heated metal tube with a small diameter nozzle, called a "hot end" or simply a "nozzle". The same mechanism is used to remove the thread if a change of material is needed.

The hot end is used to heat and melt the thread fed by the puller. As a rule, nozzles are made from brass or aluminum, although more heat-resistant, but also more expensive materials can be used. For printing with the most popular plastics, a brass nozzle is quite enough. The “nozzle” itself is attached to the end of the tube with a threaded connection and can be replaced with a new one in case of wear or if a change in diameter is necessary. The nozzle diameter determines the thickness of the molten filament and, as a result, affects the print resolution. The heating of the hot end is controlled by a thermistor. Temperature control is very important, because when the material is overheated, pyrolysis can occur, that is, the decomposition of plastic, which contributes both to the loss of the properties of the material itself and to clogging of the nozzle.

PrintBox3D One FDM Extruder

To prevent the filament from melting too early, the top of the hot end is cooled by heatsinks and fans. This point is of great importance, since thermoplastics that pass the glass transition temperature significantly expand in volume and increase the friction of the material with the walls of the hot end. If the length of such a section is too long, the pulling mechanism may not have enough strength to push the thread.

The number of extruders may vary depending on the purpose of the 3D printer. The simplest options use a single print head. The dual extruder greatly expands the capabilities of the device, allowing you to print one model in two different colors, as well as using different materials. The last point is important when building complex models with overhanging structural elements: FDM printers cannot print “over the air”, since the applied layers require support. In the case of hinged elements, temporary support structures have to be printed, which are removed after printing is completed. The removal process is fraught with damage to the model itself and requires accuracy. In addition, if the model has a complex structure with internal cavities that are difficult to access, building conventional supports may not be practical due to the difficulty in removing excess material.

Finished model with PVA supports (white) before and after washing

In such cases, the very water-soluble polyvinyl alcohol (PVA) comes in handy. Using a dual extruder, you can build a model from waterproof thermoplastic using PVA to create supports.

After printing, PVA can be simply dissolved in water and a complex product of perfect quality can be obtained.

Some FDM printers can use three or even four extruders.

Work platform

Heated platform covered with removable glass work table

Models are built on a special platform, often equipped with heating elements. Preheating is required for a wide range of plastics, including the popular ABS, which are subject to a high degree of shrinkage when cooled. The rapid loss of volume by cold coats compared to freshly applied material can lead to model distortion or delamination. The heating of the platform makes it possible to significantly equalize the temperature gradient between the upper and lower layers.

Heating is not recommended for some materials. A typical example is PLA plastic, which requires a fairly long time to harden. Heating PLA can lead to deformation of the lower layers under the weight of the upper ones. When working with PLA, measures are usually taken not to heat up, but to cool the model. Such printers have characteristic open cases and additional fans blowing fresh layers of the model.

Calibration screw for work platform covered with blue masking tape

The platform needs to be calibrated before printing to ensure that the nozzle does not hit the applied layers and move too far causing air-to-air printing resulting in plastic vermicelli. The calibration process can be either manual or automatic. In manual mode, calibration is performed by positioning the nozzle at different points on the platform and adjusting the platform inclination using the support screws to achieve the optimal distance between the surface and the nozzle.

As a rule, platforms are equipped with an additional element - a removable table. This design simplifies the cleaning of the working surface and facilitates the removal of the finished model. Stages are made from various materials, including aluminum, acrylic, glass, etc. The choice of material for the manufacture of the stage depends on the presence of heating and consumables for which the printer is optimized.

For a better adhesion of the first layer of the model to the surface of the table, additional tools are often used, including polyimide film, glue and even hairspray! But the most popular tool is inexpensive, but effective masking tape. Some manufacturers make perforated tables that hold the model well but are difficult to clean. In general, the expediency of applying additional funds to the table depends on the consumable material and the material of the table itself.

Positioning mechanisms

Operation of positioning mechanisms

Of course, the print head must move relative to the working platform, and unlike conventional office printers, positioning must be done not in two, but in three planes, including height adjustment.

Positioning pattern may vary. The simplest and most common option involves mounting the print head on perpendicular guides driven by stepper motors and providing positioning along the X and Y axes.

Vertical positioning is carried out by moving the working platform.

On the other hand, it is possible to move the extruder in one plane and the platforms in two.

SeemeCNC ORION Delta Printer

One option that is gaining popularity is the delta coordinate system.

Such devices are called "delta robots" in the industry.

In delta printers, the print head is suspended on three manipulators, each of which moves along a vertical rail.

The synchronous symmetrical movement of the manipulators allows you to change the height of the extruder above the platform, and the asymmetric movement causes the head to move in the horizontal plane.

A variant of this system is the reverse delta design, where the extruder is fixed to the ceiling of the working chamber, and the platform moves on three support arms.

Delta printers have a cylindrical build area, and their design makes it easy to increase the height of the working area with minimal design changes by extending the rails.

In the end, everything depends on the decision of the designers, but the fundamental principle does not change.

Control

Typical Arduino-based controller with add-on modules

FDM printer operation, including nozzle and platform temperature, filament feed rate, and stepper motors for positioning the extruder, is controlled by fairly simple electronic controllers. Most controllers are based on the Arduino platform, which has an open architecture.

The programming language used by printers is called G-code (G-Code) and consists of a list of commands executed in turn by the 3D printer systems. G-code is compiled by programs called "slicers" - standard 3D printer software that combines some of the features of graphics editors with the ability to set print options through a graphical interface. The choice of slicer depends on the printer model. RepRap printers use open source slicers such as Skeinforge, Replicator G and Repetier-Host. Some companies make printers that require proprietary software.

Program code for printing is generated using slicers

As an example, we can mention Cube printers from 3D Systems. There are companies that offer proprietary software but allow third-party software, as is the case with the latest generation of MakerBot 3D printers.

Slicers are not intended for 3D design per se. This task is done with CAD editors and requires some 3D design skills. Although beginners should not despair: digital models of a wide variety of designs are offered on many sites, often even for free. Finally, some companies and individuals offer 3D design services for custom printing.

Finally, 3D printers can be used in conjunction with 3D scanners to automate the process of digitizing objects. Many of these devices are designed specifically to work with 3D printers. Notable examples include the 3D Systems Sense handheld scanner and the MakerBot Digitizer handheld desktop scanner.

MakerBot Replicator 5th Generation FDM Printer with built-in control module on the top of the frame

The user interface of a 3D printer can consist of a simple USB port for connecting to a personal computer. In such cases, the device is actually controlled by the slicer.

The disadvantage of this simplification is a rather high probability of printing failure when the computer freezes or slows down.

A more advanced option includes an internal memory or memory card interface to make the process standalone.

These models are equipped with control modules that allow you to adjust many print parameters (such as print speed or extrusion temperature). The module may include a small LCD display or even a mini-tablet.

Varieties of FDM printers

Stratasys Fortus 360mc professional FDM printer that allows printing with nylon

FDM printers are very, very diverse, ranging from the simplest home-made RepRap printers to industrial installations capable of printing large-sized objects.

Stratasys, founded by Scott Crump, the inventor of FDM technology, is a leader in the production of industrial installations.

You can build the simplest FDM printers yourself. Such devices are called RepRap, where "Rep" indicates the possibility of "replication", that is, self-reproduction.

RepRap printers can be used to print custom made plastic parts.

Controller, rails, belts, motors and other components can be easily purchased separately.

Of course, assembling such a device on your own requires serious technical and even engineering skills.

Some manufacturers make it easy by selling DIY kits, but these kits still require a good understanding of the technology.

A variant of the popular late 3rd generation Prusa RepRap printer

If you like to make things with your own hands, then RepRap printers will pleasantly please you with the price: the average cost of the popular early generation Prusa Mendel design is about $500 in a complete set.

And, despite their "do-it-yourself nature", RepRap printers are quite capable of producing models with quality at the level of expensive branded counterparts.

Ordinary users who do not want to delve into the intricacies of the process, but require only a convenient device for household use, can purchase a ready-made FDM printer.

Many companies are focusing on the development of the consumer market segment, offering 3D printers for sale that are ready to print "straight out of the box" and do not require serious computer skills.

3D Systems Cube consumer 3D printer

The most famous example of a consumer 3D printer is the 3D Systems Cube.

While it doesn't boast a huge build area, ultra-fast print speeds, or superb build quality, it's easy to use, affordable, and safe: This printer has received the necessary certification to be used even by children.

Mankati FDM printer demonstration: http://youtu. be/51rypJIK4y0

Laser Stereolithography (SLA)

Stereolithographic 3D printers are widely used in dental prosthetics

Stereolithographic printers are the second most popular and widespread after FDM printers.

These units deliver exceptional print quality.

The resolution of some SLA printers is measured in a matter of microns - it is not surprising that these devices quickly won the love of jewelers and dentists.

The software side of laser stereolithography is almost identical to FDM printing, so we will not repeat ourselves and will only touch on the distinctive features of the technology.

Lasers and projectors

Projector illumination of a photopolymer model using the Kudo3D Titan DLP printer as an example

The cost of stereolithography printers is rapidly declining, due to growing competition due to high demand and the use of new technologies that reduce the cost of construction.

Although the technology is generically referred to as "laser" stereolithography, most recent developments use UV LED projectors for the most part.

Projectors are cheaper and more reliable than lasers, do not require the use of delicate mirrors to deflect the laser beam, and have higher performance. The latter is explained by the fact that the contour of the whole layer is illuminated as a whole, and not sequentially, point by point, as is the case with laser options. This variant of the technology is called projection stereolithography, "DLP-SLA" or simply "DLP". However, both options are currently common - both laser and projector versions.

Cuvette and resin

Photopolymer resin is poured into a cuvette

A photopolymer resin that looks like epoxy is used as consumables for stereolithographic printers. Resins can have a variety of characteristics, but they all share one key feature for 3D printing applications: these materials harden when exposed to ultraviolet light. Hence, in fact, the name "photopolymer".

When polymerized, resins can have a wide variety of physical characteristics. Some resins are like rubber, others are hard plastics like ABS. You can choose different colors and degrees of transparency. The main disadvantage of resins and SLA printing in general is the cost of consumables, which significantly exceeds the cost of thermoplastics.

On the other hand, stereolithography printers are mainly used by jewelers and dentists who do not need to build large parts but appreciate the savings from fast and accurate prototyping. Thus, SLA printers and consumables pay for themselves very quickly.

An example of a model printed on a 3D laser stereolithography printer

Resin is poured into a cuvette, which can be equipped with a lowering platform. In this case, the printer uses a leveling device to flatten the thin layer of resin covering the platform just prior to irradiation. As the model is being made, the platform, together with the finished layers, is “embedded” in the resin. Upon completion of printing, the model is removed from the cuvette, treated with a special solution to remove liquid resin residues and placed in an ultraviolet oven, where the final illumination of the model is performed.

Some SLA and DLP printers work in an "inverted" scheme: the model is not immersed in the consumable, but "pulled" out of it, while the laser or projector is placed under the cuvette, and not above it. This approach eliminates the need to level the surface after each exposure, but requires the use of a cuvette made of a material transparent to ultraviolet light, such as quartz glass.

The accuracy of stereolithographic printers is extremely high. For comparison, the standard for vertical resolution for FDM printers is considered to be 100 microns, and some variants of SLA printers allow you to apply layers as thin as 15 microns. But this is not the limit. The problem, rather, is not so much in the accuracy of lasers, but in the speed of the process: the higher the resolution, the lower the print speed. The use of digital projectors allows you to significantly speed up the process, because each layer is illuminated entirely. As a result, some DLP printer manufacturers claim to be able to print with a vertical resolution of one micron!

Video from CES 2013 showing Formlabs Form1 stereolithography 3D printer in action: http://youtu.be/IjaUasw64VE

Stereolithography Printer Options

Formlabs Form1 Desktop Stereolithography Printer

As with FDM printers, SLA printers come in a wide range in terms of size, features and cost. Professional installations can cost tens if not hundreds of thousands of dollars and weigh a couple of tons, but the rapid development of desktop SLA and DLP printers is gradually reducing the cost of equipment without compromising print quality.

Models such as the Titan 1 promise to make stereolithographic 3D printing affordable for small businesses and even home use at prices in the region of $1,000.