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Can you print anything with a 3d printer


Can 3D Printers Print Anything? – 3D Printerly

3D printing is a fairly modern technology which has had its capabilities questioned many times over the years. Many people wonder whether 3D printers can print absolutely anything so I’ve decided to make a post on it and try to answer it as good as I can.

Can a 3D printer print anything? No, 3D printers can’t print anything in terms of materials and shapes. 3D printers require specific properties in materials to 3D print such as thermoplastics like PLA that soften when heated rather than burn. They can print almost any shape, structure and object with the right orientation and help of supports.

That’s the simple answer but I will go into more important details about what a 3D printer can print and its limitations.

What Can a 3D Printer Actually Print?

So generally, a 3D printer does a wonderful job at printing most objects in terms of their shapes and structures and there are several examples of 3D printers doing almost the impossible.

A 3D printer can print almost any shapes no matter how complex and detailed because it’s done in extremely fine layers and builds up an object from the bottom, up from the printing surface.

The usual layer height that people use is 0.2mm but they can go as low as 0.05mm per layer, but this would take an extremely long time to print!

It means that even if there are curves, gaps or sharp edges, a 3D printer will print right through these obstacles.

I’ve created a nice post on 51 Functional, Useful Objects Created with 3D Printing which showcases many examples of the beneficial objects you can create.  Here’s a brief list of functional objects that 3D printers have created:

  • A whole house
  • The body of a vehicle
  • An electric guitar
  • Prototypes of all kinds
  • Detailed action figures and characters
  • Battery size converter to change those small AA batteries to C size
  • A phone lockbox that you put your phone in and hide the key in another room!
  • Tesla Cybertruck doorstop
  • DSLR lens cap replacements
  • Pet food dispenser if your pets usually eat too fast
  • 3D printed heart valves
  • Replacement coolant cap for your car

The list of items that people 3D print with are growing at insane rates each year, so we can only imagine the abilities and expansions we will see with 3D printing in the future.

3D printing is used in the automotive, medical, aerospace, home improvement, arts & design, cosplay, nerf gun, drone industries and tons more.

It’s the perfect hobby for a hobbyist because it can really expand into any hobby with a little bit of creativity and a can-do attitude. Imagine being a decorator and you find a hole behind a particular area where it’s hard to fill.

One individual actually 3D printed a wall cavity by 3D scanning it then inserting it into place and painting over it.

You might be thinking, what about shapes that hang over too far so it has no foundation underneath? You can’t just print in midair right?

Technically, no, but the advancement in 3D printing technology has created and made use of something called ‘supports’.

These are pretty self-explanatory and what they do is build a foundation underneath such objects to essentially support the object being printed. Once the object is finished and printed, the supports are then removed so it looks like nothing was ever there.

The possibilities of 3D printing really are endless.

The limitations of 3D printers have definitely been gradually decreasing over time.

Say, 10 years ago, a 3D printer had nowhere near the capabilities that it has today, from the materials that it can process to even the advancement in types of printing such as metals.

You have multiple technologies within 3D printing that aren’t held back by the same limitations as other technologies, so if you have a specific project, you can figure out what would work best for you.

Check the video out below that goes through some of the different 3D printing technologies.

What Are the Limitations of A 3D Printer?

Manufacturing Speed

Although 3D printing has the ability to create objects that traditional manufacturing methods would find extremely hard to create, it’s manufacturing speed per product does hold it back.

You can create customized, unique products that give huge benefits to an individual but being able to scale such items is a limitation of 3D printing.

That’s why it’s unlikely that 3D printing will be taking over the manufacturing industry any time soon, but this is a topic that is being looked at in the 3D printing industry. It did, however, take over the hearing aid industry in a very short space of time.

There are 3D printers out there that are extremely fast compared to how they used to be.

Below is a video that shows exactly that. They showcase a 3D printer which prints at 500mm per second which is exceptionally fast compared to your normal speeds of around 50mm per second.

There are types of printing which print in layers at a time rather than extruding every part of an object so speed can definitely be upgraded.

Can be Overwhelming for Beginners

It’s easy for individuals to get involved in 3D printing but there are many aspects that make it quite difficult. For 3D printing to really progress and develop into a common household product, it needs fewer steps and a simpler process for people to get started.

Many 3D printers are being made in a plug-and-play type of deal so this is certainly a problem being solved.

Other aspects such as designing your own prints can have quite the learning curve so when a complete beginner thinks about getting involved with 3D printing, they can get quite overwhelmed.

3D Scanner Applications

Rather than having to design, you have the choice to use a 3D scanner, with even smartphones giving 3D scanner options that you can make use of. The very accurate 3D scanners that are out there are pretty expensive so it’s definitely a deterrent for most people to try out.

I think in due time, as things progress, we will start to get cheap 3D scanners that work very well.

The great thing is that many people design things that are free for people to download and print directly. It saves you having to go through the creative process to make use of 3D printing.

Wrong Ideas of What 3D Printing Can Do

Sure, 3D printing can do tons of things that wouldn’t have been possible for the majority of people to begin to attempt, but people don’t know the real limitations.

As previously mentioned, the remarkable progress that manufacturers have made in the 3D printing space can only be applauded and I think they will continue to push through.

We cannot print objects outside the scope of what the actual material is extruded, so we can’t print electronic parts, wiring, motors, drivers etc. We can, however, print many of the parts which attach to these mechanical and electronic parts as a mount, holder or connector for these objects.

For example, many people out there have 3D printed prosthetic limbs, hearing aids, cosplay suits and accessories, DIY home modifications and much more.

Can a 3D Printer Print Another 3D Printer?

The age-old question, if 3D printers are so remarkable, why don’t you just 3D printer another 3D printer right? Well, you might be pleasantly surprised at just how much a good quality 3D printer can do for you.

A well-known 3D printer company called RepRap set out to do exactly what you’re asking and they got pretty good at it.

Now because there are motors, drivers, power supply units and other objects that cannot be 3D printed, we won’t be able to completely 3D print a 3D printer, but we can basically do everything else.

RepRap started the first step towards 3D printing a 3D printer and many other creators have taken part and added to the wealth of knowledge to develop more efficient and easily replicated products that do the same thing.

Check out the video below for a great visual on exactly what I’m talking about.

There’s another popular 3D printed 3D printer called ‘Snappy’ which actually snaps together each part so you don’t need many external products to get it combined. We’ve come very far in the 3D printing journey and it’s still a relatively new technology.

Can You Print Paper Money with a 3D Printer?

You’re probably not the first person with this idea unfortunately! But no, a 3D printer cannot print paper money. What it can print similarly is something called a lithophane.

These are pretty cool objects that create 3D objects out of 2D ones. Many people use it to emboss photos and other cool designs onto a surface.

It works by printing the design and ‘thickness’ of a print to show different levels of shading which when light shines through, produces a nice clear image.

How Small of an Object Can a 3D Printer Print?

You might be quite surprised at just how small an object can be printed from a 3D printer. How about smaller than an ant’s forehead? That’s exactly what artist Jonty Hurwitz specializes in and does extremely effectively.

He created the world’s smallest sculpture called nano sculptures, made using 3D printed photosensitive material. When putting an object in comparison to it’s size, you’d find that it’s no wider than the width of a human hair and would resemble a spec of dust in the sunlight.

The creation was made using a specialized version of 3D printing called Multiphoton Lithography, which was designed using Quantum Physics by using two photon absorption, really high-level stuff here. It just shows the strides that 3D printing can really go to when research and development is put into it.

You definitely wouldn’t be able to see these amazingly small prints with the naked eye, it would take a very strong microscope to make out the details as you can make out in the picture above.

Even a jewellers 400x magnification-powered microscope doesn’t have the facilities to do this. It took a 30-year specialist in human-cell studies to acquire a machine powerful enough to produce a detailed image.

Can A 3D Printer Print Something Bigger Than Itself?

A 3D printer can only print something within its build volume, but what you can do is print off parts which can be assembled to create one larger object. The same way a 3D printer can create another 3D printer.

A printer that can produce many of its own parts is the RepRap snappy, which (as the name suggests) consists of plastic parts that – while they each fit within the build volume – snap together to make up the larger parts for the printer.

What many people do when printing whole costumes such as a full Iron Man suit or storm-trooper outfit, they will design the whole model then split the model within a slicer application which is where you

Any specific 3D printer will have a limited build volume so techniques have been devised to get around this limitation. You can 3D print objects that snap together, like the snappy 3D printer that is a whole 3D printer frame that snaps into place.

You can also create a print that requires screws to put together or actually 3D print the screws and threads yourself.

Can a 3D Printer Print Anything? – 3dprintscape.

com

I’ve been tinkering with 3D printers for quite a while and a question I had back when I was a beginner was what can a 3d printer print? Based on my extensive experience and research here’s what I found.

A 3D printer can print virtually anything. Hobbyist 3D printers will typically only print plastic, however, industrial 3D printers can print metal. Metal 3D printers can create metal objects with extreme precision. For example, they can make engine parts and circuit boards.

3D printers can also only print 3d objects that are as big as the 3D printer is. So, if you want to print something really large, you need to buy a much larger 3D printer. However, with that comes a much bigger price tag. A regular 3D printer that you’d use at home can print objects that are around 1 ft by 1 ft (30 cm x 30 cm) comfortably.

In this article, I will explain what can be printed with a 3d printer, what materials can not be 3D printed with a 3D printer, whether you can print a phone, as well as, other helpful info about what the limits are to objects you can 3D print.

What can be printed with a 3D printer?

Some objects are very detailed and to create the design by hand using computer software would take a long time. But, how difficult is it to print anything on a 3d printer, and what exactly can be printed with a 3d printer?

You can virtually 3D print anything. The main limitation is how long it takes to create the 3D print design in a 3D printing software, how long it will take to print, and the size of the 3D printer you need.

However, there is now interesting technology that can create a 3D design based on photos of an object. And it takes dramatically less time.

Here’s a video showing the process of taking the photos, and creating the 3D print design:

But, waiting for the software to convert your images into a final 3D design can take many hours or days depending on how detailed it is.

Once it’s done though, you can export the file to your 3D printer for printing. Typically there’s some tidying work that needs to be done on it.

Although this method takes a lot less time than creating the design by hand, you do still need to take quite a lot of photos. Around 100 to 200 photos from lots of different angles will give you the best result.

Here’s a quick overview of the entire process of converting ANY object into a 3D print:

  1. Take 100 to 200 photos from lots of different angles
  2. Upload photos to software like Autodesk Remake (free version available)
  3. Use the software to convert the photos into a 3D print (does it in 1 click)
  4. Send the 3D print file to your 3D printer
  5. Print the file

Certain objects though are best printed in parts. As a simplified example, if you wanted to print a plastic skateboard, you would print the wheels separately from the axel. That way the wheel can spin.

When people talk about 3D printing they normally mean 3D printing at home as a hobby. However, steel manufacturing facilities will use 3D printers to print metal parts. For example, they can print parts used in a car engine, circuit boards for computers, and electronic parts for devices like toasters and kettles.

What materials cannot be 3D printed and why?

As you may know, you can print plastic, and metal, however, what materials can you not print on a 3d printer?

Virtually all man-made materials can be 3D printed. However, some materials are extremely difficult and impractical to 3D print. Glass, for example, is not practical to 3D print because it has an extremely high melting point. Certain metals also have an extremely high boiling temperature and are thus impractical to 3D print.

A 3D printer is essentially a mechanical arm that is attached to a computer that can give it step-by-step instructions. Therefore, as long as a material is runny enough it can be printed using a 3D printer For example, there are also 3D printers that are designed to 3D print concrete.

Other materials won’t hold up when 3d printed because they are too soft or won’t go hard. Therefore, the sky is technically the limit when it comes to what material you can use in a 3D printer. However, a hobbyist type of 3D printer is typically only designed to work with plastics that have a specific formula. Which are commonly called 3D printer filaments.

Can a 3D printer print a phone?

A smartphone is an amazing device, and it has the power of a computer in a very compact size. I’ve often wondered how you would make a phone using a 3D printer and whether it can be done. Here’s what I found…

As a general rule, you can not 3D print a phone. However, you can 3D print a lot of the components for a phone. For example, you can 3D print the plastic exterior. 3D printers that can print metal are expensive and after you’ve printed the individual parts you still need to solder the parts together.

You can easily make an object that looks like a phone using a 3D printer. However, you couldn’t use it to make calls or send text messages.

3D printers that print metal are very expensive, and they cost around $50,000. After that, it needs to be set up, and you need to do special training, which requires the help of professionals that can be quite costly. And it isn’t really suited to a hobbyist 3D printer.

What are the limits of 3D printing?

With 3D printing objects as a whole, I wanted to know whether there are any limitations to what you can create, and if so what are they?

The limits to 3D printing are:

  • It takes more time to create bigger objects
  • More intricate objects take more time to print
  • You cannot print certain materials such as glass
  • Size – to make a big object you need a big 3D printer

A 3D printer creates an object a very small amount at a time. So, a big object can often take a week to print. Also, with intricate objects, the nozzle has to make more back and forth movements. And as a result, it takes much more time to print an intricate object.

Other materials are impractical to print. Glass, for example, requires temperatures of around 1300 °F (700 °C) to begin to melt. Recent work by scientists to 3D print glass has been successful, but it is extremely difficult to create precise objects. And most designs are lop-sided and don’t look like the design at all (source: link).

Well, that about covers everything you need to know about whether you can 3D print anything.

Related Articles

  • How to Print a File from Thingiverse (The Easy Way!)
  • Create a Temperature Tower Using Cura – The Easy Way
  • Cura Profiles
  • Do 3D Printers Use a Lot of Power? (The Numbers Inside)
  • Can You 3D Print Food?

Make sure you check out our YouTube channel, and if you would like any additional details or have any questions, please leave a comment below or join us on Discord. If you liked this article and want to read others click here.

How to 3d print another 3d printer

Already have a 3D printer? Want another one?!

Why is this needed?

Well, let's say you have your own large printer and you can print fairly large objects. Do you believe in the idea of ​​the reprap movement, the printer should be able to reproduce itself!

Or you want to challenge yourself and finally understand how the 3D printer works. nine0005

Or your current 3D printer is just sitting around gathering dust in the corner of the room, because you have already printed everything that came to mind, and the most difficult task that worries all 3d printing professionals is how to clone existing equipment on itself.

Step 1: Preface

Let's be honest... the is not the ultra cheap printer. This is not Chery 3D printer for $60. This not is a way to save money or time. This is not first printer.

Now let's talk about what is .

B 3Dtje mini 3D printer is:

  • Damn easy to print
    • Printed parts from PLA
    • Everything fits within 200x200 print volume
      • Most parts can be printed in 100x100 print volume
    • Most parts are printed without supports , only in some cases they may be needed to improve quality
  • Very few few needed tools
    • Unlike most crafts that require a laser cutter, CNC
    • You can probably get away with a drill and a hacksaw to prepare 2 rods of the required size
      • nine0053 No source of MDF, or wood, or acrylic sheets or aluminum profiles, which can be expensive
  • A Prusa i3 Clone
    • This design is not new, nothing revolutionary, but it is reliable, prints well and works with any slicer
  • Open source
    • All model files can be downloaded free of charge
    • You can download them and modify them as you like
    • You can even sell them if you need to!
  • Simple and interesting printing
    • 19 models
    • All parts are different and look very interesting together
  • Easy to assemble
    • All parts are connected with M3 screws and nuts.
    • Cutting 2 to 4 metal rails
    • Some 3d printed parts are assembled intuitively , you can even ignore photo
  • Really fucking cool!
    • Small, portable, low moving parts! This printer can print fast! (when properly configured)
    • This 3D printer you will DIY , completely!!

Let's get started!

Step 2: Prerequisites

You will need a 3D printer , well, or find someone with this device.

  • Printable area must be at least 200x200mm XY and maybe 200mm Z if you want to print with
    • refills
  • PLA 1 kg, can be different, but this is the most convenient option
    • I honestly don't know how much it will take. Likely 500g or so
  • Tools
    • Screwdrivers for screws
    • Pliers, cleaning tools for printed objects (a clerical knife is enough)
    • Metric drills for opening / cleaning the printed hole (you can also use a screwdriver)
  • Knowledge on how to build a 3D printer from scratch
    • These are not hard requirements, but knowing how to deal with common printer problems will reduce the amount of swearing when things aren't perfect the first time.
      • If you understand firmware Marlin it would be very cool to talk about this, as there is a desire to improve some things. nine0058

    Step 3: Parts

    Right off the bat, I've made a list of exactly what you need and what you can buy to make the best possible quality. But it will be more expensive. Therefore, you choose which set to buy - in principle, they will not differ. In addition, you can order all this from China, it will be cheaper, but the wait will be longer. In any case, you need to look for all the components in English, so we take them from the table and, for example, insert in alliexexspress search .

    The table is located at this link.

    Step 4: Printing Parts

    Now let's move on to the most interesting part, in my opinion - prototyping models. To be honest, I really like to print different things, you feel that you can handle any task when you have a 3d printer at hand. Okay, it's all lyrics.

    Here is the project itself, where you can download 3d models for printer for free . Download and start preparing for printing.

    The most important thing is to arrange the parts correctly on the table . The idea is to make the models have as few parts hanging in the air as possible. This will allow to drop support for . After all, they spoil the quality very much if you do slicing through Repetier Host with their auto-generation, and not draw them yourself.

    You can watch a video showing the optimal arrangement of parts. Print settings I think you know how to do it, if not - there are articles about it with configuration files.

    Step 5: Mounting

    Let's assume that we have printed everything. Someone may have decided to use metal guides, buying them, for example, from IKEA, and cutting them into sections of the desired length. In any case, writing how to assemble this 3d printer does not make much sense, and it's too lazy, to be honest. In my opinion, there is nothing better than pictures! nine0005

    Frame assembly

    First, I'll lay out how our miracle should look like at the moment of medium readiness. Then we will see how the modules were assembled.

    Assault Axis Y

    This Axis drives The so -called bed . First we need to install the motor, put a pulley on it . Then we install a freely rotating pulley on the other side and measure 9 for them0003 belt .

    And now we will install the bed itself, which will fasten the two ends of the belt to us. Just don't forget to tighten the pulleys and anything that isn't tight yet. The substrate will be massive and it will be inconvenient to crawl there already. The connection will require 200mm x 6mm bolts, so have them ready right away.

    It should be noted that the belt must be very tight . This will greatly affect the print quality of . If you cannot do this at the time of assembly, you can use special tensioner . It's basically a simple spring. As for the axes, in this case they are printed, although this is far from mandatory, just the name of the project obliges))

    X-axis assembly

    Depending on your printer, you may need to make a hole with a 3mm drill in the belt tensioner. This hole should be quite free. nine0005

    1. Attach the motor to the end of the x axis with the connector down
    2. Attach 20T gear
    3. Insert 6mm rods 6mm x 180mm into the holes on the motor side. You need to cut these rods if you bought 200mm.
    4. Assemble the x-axis tensioner with either your own or printed tensioner bearing. Make sure the m3 nut is in the tensioner before proceeding.
    5. Pass the belt from the left side (engine side), through the gearbox, through the idler bearing to the right side
    6. At this point, install belt tensioner
      7. to the right of the x-axis on the rods
    7. If you are happy with the length (make sure the x-axis of the tensioner is recessed quite a bit) you can cut the belt. Don't forget to leave extra belt length
    8. Attach LM6UU bearings in bottom bracket x
    9. All assembled, attach the straps to the carriage x
    10. Then it remains to adjust everything a little to make sure that nothing touches each other

    Assembling the Z axis

    Now we assemble the Z axis. If you have not installed the engines in the course of past work, it's time to do it. As you understand, they should stand on the left and on the right. We will install adapters for screw rods on them, where we will put them, holding them with a hexagon.

    We stick the guides (parallel to the screw rods). We can say that we have finished assembling the case.

    Step 6: Assembly of the electrical circuit.

    How to lay the wiring is everyone's business. Here the options will be shown in the photo, but it's up to you to decide. The most important thing is to connect everything correctly. I'll also lay out the scheme, but it's better to see how this is done in ordinary 3d printers. For example, in order not to go far, you can go over the following articles directly on this site:

    • Exploring the features of a 3D printer

    • 3D printer setup and calibration

    • Ramps 1.4 connection in 3d printer

    It is not necessary to read everything - you can see the key places from the pictures and delve into their study.

    The picture below shows the green power terminal. This is a very dangerous and unreliable thing that sometimes ignites - it is dangerous to leave a working 3d printer at home unattended. Therefore, in an article about Ramps, it is better to read how to be in this case. nine0005

    Step 7: Firmware

    Since you will (most likely) have an Arduino Mega as the brain of a 3d printer, uploading firmware to it will be quite simple. All you need is the Arduino IDE. The most standard firmware from Marlin. The main thing is to choose the correct configs for the board. I have not seen an article about the firmware on this resource, but it can be easily found on the Internet. Here are useful links:

    • Firmware Marlin manual
    • May be useful to someone info about reprap electronics, how is it functioning

    Step 8: Testing

    Finally time to print something! We note right away that the table must be covered with molar tape or Kapton, since we have it without heating. Otherwise there will be no adhesion. Also, before printing, be sure to correctly adjust the distance between the nozzle and the bed . How to do it correctly is discussed here. 3d printer calibration - our everything!!! nine0004

    Since you were able to print parts for this printer, you can also slicing your own models for its small copy, assembled by yourself. Therefore, we will not talk about the slicer, just do not forget to reduce the print area!

    And so that's what each of you can have at the end of this article!

    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
        • FDM printers
    • 4 Laser Stereolithography (SLA)
      • 4.1 Lasers and projectors
      • 4.2 Cuvette and resin
      • 4.3 Varieties of
        • Stereolithography Printers

    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. nine0005

    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. nine0005

    3D printing techniques

    There are a lot of 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 methods 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. nine0005

    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. nine0005

    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. nine0005

    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. nine0005

    Lamination

    Laminating (LOM) 3D printers workflow

    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 a 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. nine0005

    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, as technology advances towards ease of use and improved reliability. nine0005

    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. nine0005

    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. nine0005

    One has only to remember that thermoplastics serve as a binding 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. nine0005

    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. nine0005

    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. nine0005

    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. nine0005

    The number of extruders may vary depending on the purpose of the 3D printer. The simplest options use a single printhead. 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. nine0005

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

    In such cases, the same 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 simply be dissolved in water and a complex product of perfect quality can be obtained.

    Some FDM printers can use three or even four extruders. nine0005

    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. nine0005

    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. nine0005

    Positioning mechanisms

    Scheme of operation of positioning mechanisms

    Of course, the print head must move relative to the working platform, and unlike conventional office printers, positioning must be carried out 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. nine0005

    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. nine0005

    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, are controlled by relatively simple electronic controllers. Most controllers are based on the Arduino platform, which has an open architecture. nine0005

    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. nine0005

    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. nine0005

    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. nine0005

    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. nine0005

    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 homemade 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. nine0005

    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 built 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. nine0005

    Some manufacturers make it easy by selling DIY kits, but these kits still require a good understanding of the technology. RepRap Printers nine0005

    And, despite their "homemade 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 focus on the development of the consumer segment of the market, offering 3D printers for sale that are ready to print "straight out of the box" and do not require serious computer skills. nine0005

    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 speed, or unsurpassed model 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 nine0005

    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. nine0005

    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 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. nine0005

    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. nine0005

    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. nine0005

    On the other hand, stereolithographic 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 laser stereolithographic 3D 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. nine0005

    Some SLA and DLP printers work in an “inverted” way: 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! nine0005

    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.

    Learn more