Home » Misc » 3D printing system

3D printing system


Careers at 3D Systems | 3D Systems

Why 3D Systems?

Meaningful work, passionate and bright people, and a company that supports your life from day one. There’s a lot to explore at 3D Systems, we hope you’ll join us.

Be part of a team with brainpower, heart, and grit.

We have a diverse team with some of the world’s most dynamic and forward-thinking talent. Not only do we have the brainpower, we have people with heart, grit and a ton of curiosity. And the cornerstone of our work is to lead, explore, and innovate with the utmost integrity.

Be you, at your best.

We care about treating people right and we know that life is more than work. This is why we approach rewards and benefits at a personal level so that you have the resources you need to take care of yourself and be you, at your best. See a few of the rewards and benefits we offer.

Write your own story.

  • E-Verify

    3D Systems participates in E-Verify ENGLISH/SPANISH (PDF)

    Right to Work (English)

    Right to Work (Spanish)

    Equal Employment Opportunity

    3D Systems is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, gender identity, national origin, disability, or status as a protected veteran.

    EEO is the Law

    3D Systems Employment Opportunity, Anti-Discrimination, & Anti-Harassment Policy

    Pay Transparency Nondiscrimination Provision

  • Accessibility and Accommodations

    In compliance with the ADA Amendments Act, if you have a disability and would like to request an accommodation in order to apply for a position with 3D Systems, please call 803-326-3933.

    Federal Employment Laws

    Applicants have rights under Federal Employment Laws:

    Family and Medical Leave Act (FMLA)

    Employee Polygraph Protection Act (EPPA)

    3D Systems commitment to gender equality in the workplace 2021 – Phenix Systems, Riom-France

    Equality in the workplace means ensuring the absence of any discrimination within a company. The challenge for any company is to achieve true equality between men and women at work, in particular through action against day-to-day sexism at work, equal pay, gender parity at management level, and a gender-balanced workforce. 

    Under the law on freedom of choice in professional careers, the index uses five indicators for companies to monitor their commitment to workplace gender equality. These are:

    • Equal Pay
    • Pay Increase between the genders
    • Promotions of each gender
    • Pay increase when returning from maternity leave
    • Number of woman amongst the 10 most highly paid employees in the company ( in France) 

    For 2021, 3D Systems has achieved 60/100.

    Link to the gender equality website: https://www.gouvernement.fr/index-de-l-egalite-femmes-hommes-comment-ca-marche

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

The aviation industry uses 3D printing in many different ways. The following example marks a significant 3D printing manufacturing milestone: GE Aviation has 3D printed 30,000 Cobalt-chrome fuel nozzles for its LEAP aircraft engines. They achieved that milestone in October of 2018, and considering that they produce 600 per week on forty 3D printers, it’s likely much higher than that now.

Around twenty individual parts that previously had to be welded together were consolidated into one 3D printed component that weighs 25% less and is five times stronger. The LEAP engine is the best selling engine in the aerospace industry due to its high level of efficiency and GE saves $3 million per aircraft by 3D printing the fuel nozzles, so this single 3D printed part generates hundreds of millions of dollars of financial benefit.

GE’s fuel nozzles also made their way into the Boeing 787 Dreamliner, but it’s not the only 3D printed part in the 787. The 33-centimeter-long structural fittings that hold the aft kitchen galley to the airframe are 3D printed by a company called Norsk Titanium. Norsk chose to specialize in titanium because it has a very high strength-to-weight ratio and is rather expensive, meaning the reduction in waste enabled by 3D printing has a more significant financial impact than compared to cheaper metals where the costs of material waste are easier to absorb. Rather than sintering metal powder with a laser like most metal 3D printers, the Norsk Merke 4 uses a plasma arc to melt a metal wire in a process called Rapid Plasma Deposition (a form of Directed Energy Deposition) that can deposit up to 10kg of titanium per hour. A 2kg titanium part would generally require a 30kg block of titanium to machine it from, generating 28kg of waste, but 3D printing the same part requires only 6kg of titanium wire.

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. Nearly every hearing aid in the last 17 years has been 3D printed thanks to a collaboration between Materialise and Phonak. Phonak developed Rapid Shell Modeling (RSM) in 2001. Prior to RSM, making one hearing aid required nine laborious steps involving hand sculpting and mold making, and the results were often ill-fitting. With RSM, a technician uses silicone to take an impression of the ear canal, that impression is 3D scanned, and after some minor tweaking the model is 3D printed with a resin 3D printer. The electronics are added and then it’s shipped to the user. Using this process, hundreds of thousands of hearing aids are 3D printed each year.

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.

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


Metal 3D printing. Additive technologies.

SLM or DMLS: what's the difference?

Hello everyone, Friends! 3DTool is with you!

BLT metal 3D printer catalog

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

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


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

How 3D printing with SLM or DMLS metal works.

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

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

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

Scheme of operation of a 3D printer for metal.

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

Adhesion between coats.


3D metal printing on BLT 3D printers

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

3D model support structure and part orientation on the work platform.

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

Supports in metal 3D printing perform 3 functions:

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

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

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

Hollow sections and lightweight structures.


An example of printing on a BLT 3D printer

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

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

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

Consumables for 3D metal printing.

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

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

Metal post-processing.

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

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

Advantages and disadvantages of metal 3D printing.

Pros:

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

Cons:

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

Conclusions.

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

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

Catalog of 3D printers for metal BLT

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

• By email: [email protected]

• By phone: 8(800)775-86-69

• Or on our website: http://3dtool.ru

Also, don't forget to subscribe to our YouTube channel:


Subscribe to our groups in social networks:

INSTAGRAM

In contact with

Facebook

The Complete Guide to 3D Printing [Part 2]

3D printing is used in a variety of industries, both for rapid prototyping and short-term production.

In various industries, a key application of 3D printing is the rapid prototyping of new parts during R&D. No other technology has the capability to instantly produce plastic or metal parts - even in non-factory conditions.

3D printers can be used in-house by companies, while some businesses prefer to order 3D printed prototypes through service bureaus.

Medicine

3D printing can be used to make medical components such as titanium implants and surgical guides (SLM), 3D printed prostheses (SLS, FDM) and even 3D bioprinted human tissues. Components for medical equipment and technology - X-ray machines, MRI, etc. - can also be made by 3D printing.

SLA and SLS technologies are also widely used in the dental industry for model making, prostheses and restorations.

Aerospace

The aerospace industry has become a major consumer of 3D printing technology because it can produce very light parts with an excellent strength-to-weight ratio. Examples include things as simple as cab bulkheads (SLS) and down to revolutionary engine components (SLM) such as the 3D printed fuel injector tip designed and manufactured by GE.

Cars

Automotive companies regularly use 3D printers to make one-off parts and repairs, as well as rapid prototypes. Common 3D printed automotive parts include brackets, dashboard components, and antennas (FDM).

More extreme examples include vehicles with large 3D printed metal structural components, such as early models from automotive startup Divergent.

Jewelry and art

3D printing technologies such as SLA are widely used (as an indirect fabrication process) in the production and repair of jewelry, while almost all types of 3D printers can be used to create works of art and sculptures.

Engineering

Advances in additive manufacturing with high quality workmanship have expanded the scope of applications in construction and architecture. Concrete 3D printing, which is a bit like FDM but with very wide nozzle extruders, plays an important role in this industry, but more common 3D printing technologies such as SLM can be used for products such as bridge structures.

3D printing file formats:

3D printing parts can be designed with standard CAD software, but 3D printers can only read certain file formats. There are four main file formats for 3D printing.

STL: The most common file format for 3D printers, STL contains information about part geometry in the form of tessellated triangles. It does not contain information such as color, material, or texture. The file size is proportional to the detail, which can be a problem.

OBJ: Less common than STL, the OBJ file format encodes the geometry of a 3D model and can include curves and free-form surfaces in addition to tessellation. It can also contain color, material, and texture information, making it useful for full color processes.

3MF: Invented by Microsoft, 3MF is an XML-based format with small file sizes and a good level of error prevention. It has not yet been widely adopted, but is supported by companies such as Stratasys, 3D Systems, Siemens, HP, and GE.

AMF: The successor to the STL format, AMF is much more compact and allows you to tessellate both curved and flat triangles, making it much easier to encode parts of various shapes. Since its inception, the format has been slowly adopted.

3D printing settings and specifications:

3D printing uses specific terminology that may not be clear to beginners. These terms refer to printer settings and/or specifications that can affect how 3D printed parts turn out.

Infill

When making 3D printed parts, it may be necessary to specify an infill percentage, which refers to the internal density of the part. A low infill percentage will result in a mostly hollow part with minimal material holding the mold together; a high infill percentage will result in a stronger, denser, and heavier part.

Layer Height

Layer height, sometimes referred to as z-resolution, is the distance between one 2D part layer and the next. A smaller layer height means finer resolution (and higher possible level of detail) along the z-axis, i.e. top down. A low layer height is an indication of a high quality printer, but users can set a higher layer height for faster, more economical printing.

Print speed

The printer's print speed, measured in millimeters per second, indicates the speed at which the machine can process the source material. Like the layer height, this value can either be a measure of the printer's maximum speed or be user-defined: slower print speeds usually result in more accurate prints.

Print temperature

When applied to processes such as FDM, print temperature usually refers to the temperature of the hot end, the part of the print head that heats the thermoplastic filament. Some FDM printers are also equipped with a heated print bed, the temperature of which is specified by the manufacturer. In both cases, the temperature is usually controlled by the user.

Resolution

In 3D printing, resolution almost always refers to the smallest possible movement along the X and Y axes (width and depth) of either the laser beam (SLA, SLM, etc.) or the print head (FDM). This value is more difficult to measure than the height of the layer, and it is not always proportional to it.

Shells

Like wall thickness in injection molding, shell (or shell thickness) refers to the outer wall thickness of the 3D printed part. When 3D printing, users usually have to choose the number of shells: one shell = outer walls as thick as a 3D printer nozzle; 2 shells = twice the thickness, etc.

Color 3D printing:

Since 3D printing is primarily used as a prototyping tool, single color prints are sufficient for most applications. However, there are several options for color 3D printing, including high-end material inkjet printers, multi-extruder FDM printers, and post-processing options.

Inkjet Printing Technologies

Major 3D printing companies such as Stratasys, 3D Systems and Mimaki have developed 3D inkjet printers for printing materials and binders that can print 3D models in full color as well as 2D inkjet printers. However, these machines are expensive and the parts do not always have excellent mechanical properties.

Multi-extrusion

Several FDM 3D printers are equipped with two (or more) printheads, allowing you to simultaneously print on two spools of filament - different colors or even different materials - within the same print job. It's simple and affordable, but usually limited to two colors.

Filament replacement

Single extruder FDM 3D printer can produce multi-color prints. To do this, you need to pause printing at certain points and replace the spool of thread with a thread of a different color. This is a very slow method of applying color and does not allow precise control over where each color goes.

Adding color after printing

Many 3D printed parts can be dyed, tinted or painted after printing. While this adds another step to the process, it often strikes the best balance between quality and economy.

3D printed part post-processing:

Many 3D printed parts require at least some level of post-processing after leaving the print bed. This may include important processes such as the removal of supports, or additional cosmetic processes such as painting. Some processes apply to all or most 3D printing technologies, and some are specific to a particular technology.

Removing the support

3D printing technologies such as FDM and SLA require the installation of support structures (vertical posts between the printed layer and the part itself) so that the printed object does not collapse during the manufacturing process.

These supports must be removed when the part is finished. Some printers, such as dual-extrusion FDM machines, can print dissolvable support structures, allowing the support structures to be easily detached from the part using liquid chemicals. Insoluble supports must be manually cut from the part, leaving a mark that may need to be sanded down.

Washing and removing powder

Some 3D printing technologies (such as SLA) leave sticky marks on parts, while others (SLM, SLS) may leave powder marks. In these cases, the parts must be washed - manually or with a special machine - or the powder removed with compressed air.

Heat treatment

Many key 3D printing technologies print parts from materials that are not yet in their final chemical state after leaving the printing mold. Such details are sometimes called "green".

Many 3D printed metal parts require heat treatment after printing to increase layer fusing and remove contaminants. And bonded inkjet 3D printers, for example, produce parts that need to be stripped and sintered after printing to remove resin bond layers from inside metal parts.

Some 3D printed resin parts require post-curing after printing to increase their hardness and make them usable.

Surface treatment

3D printed parts can be subjected to a wide range of surface treatments, from textural treatments such as sanding and smoothing, to visual treatments such as painting and toning. Some technologies, such as FDM, can create a rather rough surface that requires sanding, while others, such as SLA, produce a much smoother surface.

Combination of 3D printing with other technologies:

3D printing does not have to be used as a separate process. Rather than being seen as a competitor to CNC machining and injection molding, it can actually complement these and other manufacturing processes.

Combination examples include:

  • 3D print the main body of the part and then CNC mill the thin parts to tighter tolerances;
  • 3D printable master pattern for investment casting or vacuum casting;
  • 3D print the part and then injection mold it using injection molding.

There are hybrid manufacturing systems that combine 3D printing with other technologies. For example, Mazak's INTEGREX i-400 AM and DMG MORI's Lasertec DED can perform both 3D printing and CNC milling.

Will 3D printing replace other manufacturing processes?

Analysts have long speculated about whether 3D printing could replace other manufacturing processes, including:

  • Processing;
  • Moulding;
  • Casting.

However, despite the desire of AM equipment manufacturers to position 3D printing as an end-to-end manufacturing technology, in practice, 3D printing is still limited to some specific manufacturing operations, especially low-volume production of specific materials.

In some areas, 3D printing has certainly outpaced other processes. For example, rapid prototyping with inexpensive plastics like ABS now dominates 3D printing, as ABS is cheaper to print than machined. 3D printing also seems to have established itself as the ideal tool for making objects such as patient-specific titanium medical implants: the speed and geometric flexibility of 3D printing is hard to beat in these specific situations.

In addition, 3D printing is an ideal tool for making objects such as patient-specific titanium medical implants.

Despite this, processes such as CNC machining currently remain the best for producing high quality parts and prototypes from engineering materials such as POM, PEI, PPS and PEEK, with surface finishes far superior to 3D printing. . In addition, processes such as injection molding are still infinitely faster for mass production of simple plastic parts.

In addition, while additive manufacturing is one of the most significant technological advances in manufacturing, placing it in a stronger position in manufacturing in general, more established processes such as CNC and injection molding are also being improved to produce higher quality parts. .

3D printing will continue to take an increasing share of manufacturing jobs, but it will not completely replace other technologies.

What did 3D printing look like 10 years ago?

A decade ago, the nascent 3D printing industry was gearing up for what it believed would be a 3D printing revolution: a 3D printer in every home, allowing families to print new items they might need, such as a spare part for a refrigerator, a new toy for kids, or even components to build a second 3D printer.

In 2012-2014, FDM 3D printer manufacturers such as MakerBot actively promoted their 3D printers in the consumer market, trying to convince ordinary people that a 3D printer can improve their home life and work. However, it was clear that these companies were trying to exploit the novelty factor of 3D printing and that their products had no practical application; a 2012 MakerBot press release seems to prove it: Make an entire chess set at the touch of a button. Friends, classmates, colleagues and family members will see what you are doing and say "Wow!".

Just a few years later, this so-called 3D printing revolution clearly failed, and many 3D printer manufacturers began to rethink their goals, moving from consumer to professional and industrial markets, where there were more concrete (and profitable) applications of additive technology.

In addition, those who were already working in the professional and industrial fields - companies such as 3D Systems and Stratasys - began to try to destroy the image of 3D printing as a prototyping technology, positioning it as a viable mass production tool (which, obviously, , could be more profitable for the 3D printing industry, as manufacturers would have to fill entire factories with 3D printers, buy 3D printer management software, and hire 3D printing consultants).

What will 3D printing look like in 10 years?

3D printing companies have abandoned the prospect of putting a 3D printer in every home. However, in 10 years, they can expect some form of additive manufacturing to appear in more factories.

Although there is less talk about 3D printing today than in 2012, the technology continues to gain momentum in the professional and industrial world.

According to a recent report, market research firm 3DPBM Research expects the value of additive metal manufacturing to rise from $1.6 billion in 2020 to $30 billion by 2030, and this is largely due to the repositioning of AM as a manufacturing tool and the development of more high-performance engineering materials. (That said, 3D printing will remain a valuable prototyping tool in many industries, and prototyping applications will benefit just as much from technological advances.)

However, not only metal AM is being developed. Technologies such as HP's Multi Jet Fusion have opened up new possibilities for plastic printing, and innovators such as Carbon have developed new high-speed processes in the photopolymerization category. Niche areas such as 3D bioprinting and micro 3D printing are also regularly opening up new opportunities, and composite 3D printing (such as continuous carbon fiber 3D printing) is also on the rise: IDTechEX predicts that by 2030, the market size of composite 3D printing will be $1.7 billion

In short, 3D printing will gradually become a serious competitor to other manufacturing processes in many disciplines.

How to outsource 3D printing services?

Investments in 3D printing hardware and software are not suitable for all businesses, which is why many successful companies outsource their 3D printing needs to third parties, such as online 3D printing service bureaus (for one-time projects) or prototyping partners and production, such as 3ERP (for one-time projects or repeat orders).

When outsourcing 3D printing services, it is important to consider whether your business needs design and manufacturing services or just manufacturing services. (Keep in mind that a poorly executed 3D model may fail for 3D printing).

Learn more