Fabricated 3d printing

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Fabricated tells the story of 3D printers, humble manufacturing machines that are bursting out of the factory and into schools, kitchens, hospitals, even onto the fashion catwalk. Fabricated describes our emerging world of printable products, where people design and 3D print their own creations as easily as they edit an online document.

A 3D printer transforms digital information into a physical object by carrying out instructions from an electronic design file, or 'blueprint.' Guided by a design file, a 3D printer lays down layer after layer of a raw material to 'print' out an object. That's not the whole story, however. The magic happens when you plug a 3D printer into today’s mind-boggling digital technologies. Add to that the Internet, tiny, low cost electronic circuitry, radical advances in materials science and biotech and voila! The result is an explosion of technological and social innovation.

Fabricated takes the reader onto a rich and fulfilling journey that explores how 3D printing is poised to impact nearly every part of our lives.

Aimed at people who enjoy books on business strategy, popular science and novel technology, Fabricated will provide readers with practical and imaginative insights to the question 'how will this technology change my life?' Based on hundreds of hours of research and dozens of interviews with experts from a broad range of industries, Fabricated offers readers an informative, engaging and fast-paced introduction to 3D printing now and in the future.

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About the Author

Hod Lipson and Melba Kurman put innovative technologies into context. Lipson is a leading researcher and speaker on 3D printing, digital materials, and the transformative power of intelligent machines. His lab at Cornell University has pioneered interdisciplinary research in 3D printing, product design, artificial intelligence, and smart materials. Kurman is an author and technology analyst who covers game-changing technologies in language that intelligent (and busy) non-experts can understand.

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Table of contents

Preface xiii

Chapter 1: Everything is becoming science fiction 1

Chapter 2: A machine that can make almost anything 7

Printing three-dimensional things 11

The ten principles of 3D printing 20

Chapter 3: Nimble manufacturing: Good, fast, and cheap 25

Somewhere between mass production and the local farmer’s market 27

The blank canvas of the 21st century 35

Chapter 4: Tomorrow’s economy of printable products 45

Like ants with factories 46

The experience economy 51

A future economy of printable products 56

Chapter 5: Printing in layers 65

A manufacturing process at heart 65

Two families of printers 68

Cleaning up design files 77

The raw materials 81

Chapter 6: Design software, the digital canvas 85

A word processor for drawing 85

Today’s design software 91

What you design is not (necessarily) what you print 100

The next generation of design software: digital capture 102

Chapter 7: Bioprinting in "living ink" 105

The printer of youth 105

Tissue engineering 111

CAD for the body 120

The future 124

Chapter 8: Digital cuisine 129

Digital gastronomy 130

Feeding the quantified self 142

Processed food 144

Chapter 9: A factory in the classroom 153

Make to learn: Children's engineering 154

Not a national crisis. . . but learning should be enjoyable 161

Now let's see you draw that abstract equation on a graph 166

Barriers to classroom adoption 171

The road ahead 173

Chapter 10: Unleashing a new aesthetic 175

Computers that act like nature 176

Printing wavy walls and custom gargoyles 191

Chapter 11: Green, clean manufacturing 197

A tale of two plastic toys 200

Greener manufacturing 202

3D printing a more beautiful landfi ll 206

Chapter 12: Ownership, safety, and new legal frontiers 217

Printing weapons, drugs, and shoddy products 218

Rip, mix, and burn physical things 224

Exclusivity vs. the freedom to innovate 230

Chapter 13: Designing the future 241

Tea. Earl Grey. Hot. 241

A bicycle for our imagination 243

The language of shapes 252

Changing the shape of design tools 260

Chapter 14: The next episode of 3D printing 263

The three episodes of 3D printing 265

Cofabrication of multiple materials 266

Moving from printing passive parts to active systems 271

The final episode—from analog to digital 275

Machines making machines 280

References 283

Index 291

Steel 3D Printing - A Quick Guide / Sudo Null IT News

Any metal 3D printing technology can print with steel. This is the most popular material. But which steel grades and which technology is best for your application? Will printed steel parts really be as strong and durable as traditionally made parts? nine0003

Let's see how a 3D printed steel part is revolutionizing manufacturing and opening doors to new applications in aerospace, medical equipment, automotive, tool making, heavy industry, architecture and more. In addition, more affordable desktop printers are expanding the scope and scope of real steel 3D printed parts.

Strength of steel printed parts. nine0009 Cast steel part (left), 3D printed version (center). On the right, a fully 3D printed hinge requires no assembly. (Source: Desktop Metal)

The most common question when it comes to a 3D printed metal model is "Will it be as strong as a forged or cast part?" ?". The short answer is yes... and no.

3D printed steel parts can be just as strong, and sometimes even stronger, than those made in the traditional way. It depends on many factors such as: end use, type of steel, choice of 3D printing method, post-processing and shape of the part. Also, the comparison depends on which of the strength characteristics you focus on: tensile strength, static load strength, fatigue strength, etc. nine0003

Parts printed from steel are used in the aerospace industry, for the military, and also, for example, for the manufacture of a footbridge, shown below. Therefore, the strength of printed products is beyond doubt, but let's take a closer look.

A 3D printed or laser powder sintered (LPBF) steel part has a finer grain structure than cast metal products. This provides better tensile strength characteristics, but in other respects the cast parts are currently still stronger. Most often, LPBF 3D printing is used to replace cast components, but in some cases, 3D printed components can replace forged parts. nine0003

One study showed that, under certain conditions, stainless steel parts made using LPBF 3D printers were three times stronger than parts made from the same steel using the traditional method.

In experiments comparing 3D printed steel parts to traditionally made steel parts, researchers create identical parts using two methods and compare their performance. However, head-to-head comparison of details is only part of the big picture. nine0003

The main advantage of printing with steel is not only its strength, but also the unique ability to create internal channels and lattice fillings in parts, which is impossible using traditional manufacturing methods. Metal 3D printing makes it possible to produce parts faster than traditional production, since this method does not require the use of special equipment and tools, it allows you to create assemblies as a whole, eliminating the need for subsequent assembly and welding. Designing a printed part usually means that less metal is needed to make it, and therefore less weight, for the same strength. nine0003 MX3D Wire Arc Additive Manufacturing (WAAM) printed steel architectural support (Source: MX3D)

Steel 3D printing is also more stable and cost effective as it reduces waste. When using subtractive manufacturing methods, such as CNC machining, you make a part by cutting it out of a large one, with a lot of waste. With additive manufacturing, you only use the material you need to make the finished product. nine0003

Steel 3D printing is not intended to replace traditional methods in all areas, but it may be a better choice for a wide range of applications. Particularly when the required parts are unique and designed for specific applications, such as rocket engines, racing cars or the oil and gas industry. 3D printing is the fastest and most flexible technology for mass production and prototype production. For military and industrial applications, steel 3D printing is a faster and more efficient way to create individual parts for vehicles and machines. Stainless steel 3D printing is rapidly finding applications in medicine to create unique surgical instruments and implants. nine0003

If you know what characteristics your final product should have (tensile strength, compressive strength, hardness, density, etc.), then all these parameters can be incorporated into the product at the production stage.

Types of steel for 3D printing

There are thousands of different grades of steels and alloys with different mechanical properties, used in traditional manufacturing but in 3D printing there are only a few dozen of them, and some of them are unique, created specifically for this technology. Among the steel options, the following can be distinguished:

• Stainless steel (316L, 304L , 17-4PH, 15-5PH, 420, 254, Ph2, GP1, 630, 410).

• Tool steel (D2, M2, h23, h21, MS1, 1.2709).

• Low alloy steel (4140).

• Structural alloyed (20MnCr5).

Recently, unique alloys have been developed specifically for 3D printing, designed to solve the problems that occur with classical production methods. nine0003

For example, 3D printer manufacturer Desktop Metal released a patented stainless steel in 2022 that the company says combines the tensile strength, ductility, and corrosion resistance of 13-8 PH stainless steel, combined with the hardness low alloy steel like 4140. The company says customers can go to market with this material and skip the galvanizing step to protect products from corrosion.

ExOne offers two special blends of steel and bronze that the company says allows 3D printed steel parts to achieve increased corrosion resistance while being easy to machine and polish. nine0003

While most of the metal powders used in 3D printing are similar to those used for other manufacturing methods, their numbers are on the rise as more companies adopt the technology. Some metal powder manufacturers, such as GKN, also make custom powders for specific 3D printing applications.

How to print with steel

The strength, properties and applications of 3D printed steel products largely depend on which 3D printing technology you use. Some methods produce stronger parts, other methods provide better hardness or abrasion resistance, and some technologies are simply very fast. nine0003

Below are the main metal 3D printing methods, their properties and some of the most common application examples.

Fused Deposition Printing (FDM)

FDM media was once limited to thermoplastics. Companies like BASF Forward AM and The Virtual Foundry now offer metal filaments that can be used on almost any FDM printer as long as it has a hardened steel nozzle for abrasive media.

These materials are approximately 80% metal and 20% plastic. After printing, the post-processing process removes the plastic, resulting in 100% metal parts. nine0003

Due to the removal of the bonding plastic, FDM metal parts shrink during post-processing. The amount of shrinkage is constant and can be taken into account in CAD systems, which allows to obtain relatively accurate finished parts.

Forward AM's 316L Stainless Steel Ultrafuse filament produces finished parts with material properties that the company claims are comparable to injection molded metal parts. nine0003 (Source: BCN3D)

While 3D printing with metallic materials may not be suitable for demanding applications such as aerospace, the economics of producing simple metal components without critical loads on an affordable FDM printer can outweigh the impossibility of applying them in some areas.

Metal prototype parts and finished parts that will not be subjected to extreme stress are ideal uses for this technology. nine0003

Bound Metal Deposition (BMD)

Similar to FDM, Metal mesh deposition method (BMD) or bonded powder extrusion (BPE) is a 3D printing process based on extrusion. This method uses bonded metal rods or bonded powdered metal filaments, which consist of a much higher percentage of metal powder than the filaments used in FDM. As with FDM, post-treatment to remove the binder and heat treatment in a final sintering oven are required. nine0003

There are only a few 3D printers using this method such as Desktop Metal, Markforged and more recently 3DGence, but more companies are entering this market, so stay tuned. These printers are valued as a convenient solution for office 3D metal printing, they are more expensive than most FDM printers, but cheaper than the powder-based metal 3D printing technologies described below.

These printers use their own proprietary filament. Desktop Metal and Markforged offer four types of steel. nine0003

Ideal niches for this technology are metal prototype parts, where it is necessary to test the functionality of a part before mass production using traditional methods. Popular applications are molds, punching dies, nozzles, impellers, fasteners and heat exchangers.

For example, Shukla Medical uses Markforged's Metal X printer to print steel prototypes of its orthopedic implant removal instruments. nine0003

Laser powder sintering.

This method uses powerful lasers to selectively sinter metal powder layer by layer. nine0003

LPBF 3D printers are available in a wide range of sizes, prices and laser powers. These and other characteristics affect the properties of the finished part, print speed and other parameters of the finished products.

Steel and steel alloys are the most popular material for LPBF equipment and, unlike FDM and BMD, metal powders are commercially available as they are most commonly used in traditional production methods.

LPBF is a technology that maximizes the quality of a 3D printed part. Applications include aerospace components such as monolithic thrust chambers, rocket engine components and heat exchangers, molds, tools and other applications, as well as high wear parts and surgical instruments. nine0003

Binder Jetting

Binder application stands out for its high printing speed compared to other 3D printing methods or traditional manufacturing, and metal parts made with this technology have material properties equivalent to those made by metal injection molding. nine0003

The number of manufacturers producing metal-bonded inkjet 3D printers is much smaller than that of LPBF machines. Leading manufacturers include ExOne, Desktop Metal, Digital Metal, GE Additive and HP.

Binder blasting is ideal for medium to high volume production of metal tools and spare parts.

In fact, HP claims that its Metal Jet 3D printer was designed specifically for mass production of 316L stainless steel products. HP has partnered with Parmatech to produce metal parts for the medical industry. Pennsylvania-based ExOne uses this technology to manufacture hard metal cutting tools and tool steels. nine0003

Electron Beam Melting (EBM)

Electron Beam Melting (EBM) is another powder cladding technology. It works in a similar way to selective laser melting (SLM), but instead of using a laser as the energy source, it uses a much more powerful beam of charged particles.

The recoater moves the powder onto the printing plate and an electron beam selectively melts each layer of powder. After each layer is printed, the plate is lowered and another one is applied on top of the previous layer. nine0003

EBM can be much faster than SLM, but SLM produces smoother and more accurate pieces. The electron beam is wider than the laser beam, so EBM cannot produce the same precise parts as SLM. Another difference is that the manufacturing process takes place in a vacuum chamber, which reduces the amount of impurities in the material that can lead to defects. That is why EBM is often chosen for printing components for the aerospace, automotive, defense, petrochemical and medical implant industries. nine0003

Titanium is the most popular metal for most EBM applications, however steel can be used.

Cold Spray

Cold spray 3D printing is done by injecting metal powders through a jet nozzle into a supersonic stream of pressurized gases such as air, nitrogen or helium. The process is called "cold" because the metal particles do not melt, but hit the metal substrate and adhere to its surface during the so-called plastic deformation. nine0003

Cold spray printed products are not prone to porosity, thermal cracking and other defects associated with melt-based technologies. This method has several advantages over other production methods. The technology is used in the military and aerospace industries around the world. For example, the US Army uses cold spray to repair the mounts of a worn Bradley 25mm steel turret gun.

In the automotive industry, cold spray steel is used for crash repairs because the high strength steel substrates in cars can be susceptible to thermal repair methods such as welding. nine0003

Direct Energy Deposition (DED) and Wire Arc Additive Manufacturing (WAAM)

Direct Energy Deposition (DED) uses welding powder or wire that enters through a nozzle and is fed into the power source to melt the metal. A melt region is created and applied to the substrate. DED is a new process, reminiscent of an old building technology known as "cladding", in which a coating is applied to a substrate, often for thermal insulation or weather resistance. DED is useful for fabricating large objects as a whole, as well as complex geometries that require extensive machining. DED can get such parts much closer to finished than traditional CNC machining. nine0003

Because DED uses a coating process, it can be used to add complex geometries to existing steel parts, thus combining complexity with cost reduction. For example, the French company AddUp advertises a rocket nozzle that uses a preformed large 304 stainless steel hopper cone printed with an isogrid structure, usually made from a larger piece by traditional methods.

A technology related to DED is wire-arc additive manufacturing (WAAM). Instead of powder, WAAM uses a metal wire that is melted by an electric arc. The process is controlled by robotic arms. WAAM is also capable of producing large-sized metal parts, as demonstrated by the Dutch company MX3D and its nine thousand-pound 41-foot stainless steel bridge in Amsterdam, as well as an oil and gas equipment repair part, proving that parts can be made in the field. nine0003

Micro 3D printing

Micro scale additive manufacturing, or micro 3D printing, can produce products with a resolution of a few microns (or less). There are three micro 3D printing methods to produce metal parts.

LMM (lithography-based metal fabrication) is a light-based technology that creates tiny parts from raw materials, including stainless steel, for applications such as surgical instruments and micro-mechanical parts. nine0003

Electrochemical deposition is the latest micrometal 3D printing process developed by the Swiss company Exaddon. In this process, the printing nozzle applies liquid with metal ions, creating details at the atomic level.

A third micrometal 3D printing method is microselective laser sintering, in which a layer of metal nanoparticle ink is applied to a substrate, then dried to produce a uniform layer of nanoparticles.

German researchers have successfully tested micro SLS printing of hollow microneedles using 316L stainless steel. nine0003 Metal parts from 3D Systems, Desktop Metal, MX3D and Materalise. 90,000 manufacturing miniatures 28mm, dioram, gaming locations using 3D printer

09. 03.2022

Content

• • How to choose a 3D printer for miniature
    • Advantage of 3D printing for miniatures
      • FDM
      900 LCD/ DLP
    • Printing Examples
    • Best Printer Ranking
      • FDM
      • LCD
    • Totals

3D printing finds its application in various fields, not only as a production machine, but also as a reliable hobby assistant.

Miniature figurines with amazing detail attract the eye. A little grotesqueness and slightly wrong proportions (otherwise it would be inconvenient to play or transport such a “little one”) are more than compensated by detailed elaboration and an abundance of small, at first glance, insignificant details. These are no longer just small table soldiers, but heroes with their own unique history. nine0003

Warhammer 40k miniature soldier

Miniatures come in different sizes: from 6mm and more. The most popular today is the 28mm format. The creation of such figurines is really almost jewelry work.

A 3D printer will help not only in the production of miniatures, but also in related areas, such as the creation of figurines, details of game locations, or, for example, elements of dioramas. To understand the advantages of 3D printing over classical manufacturing methods, it is worth remembering how such models are usually made at home. nine0003

Advantage of 3D printing for miniatures

Not everyone was ready to shell out a substantial amount for the purchase of a set of table soldiers, and sometimes the necessary heroes simply were not on sale. Then baked and self-hardening plastics for modeling were used.

First you need to make a wire frame, so the finished figure will turn out to be more durable, and it will be much easier to keep all the proportions. The wire frame can be attached to the stand, which will make the miniature statue more stable, and it can be easily fixed in any position without fear of smearing small parts with your fingers. nine0003

Wire frame for miniature

Gradually, layer by layer, the volume of plastic increases on the frame. Each layer must be baked or dried well, depending on which plastic is used - self-hardening or baked.

Gradually, we begin to add small details and work out the details. In fact, this is a very painstaking process that requires perseverance and some sculpting abilities. For a convenient study of small details, you may need special stacks for modeling, but they can be successfully replaced with improvised tools. nine0003

Sculpting tool kit

The result is such a miniature statue.

Miniature 28mm baked plastic

By the same principle, large table figures, or some elements of dioramas, can be made.

Sometimes a sculptor is more accustomed to working with plasticine. Then, after sculpting, the stage of preparation and casting of the figurine into a silicone mold is added. This method is suitable for small-scale production of a small desktop army. nine0003

But it is necessary to properly prepare the figurine for casting. The finished "warrior", most likely, will have to be divided into several parts, so that it would be more convenient for the caster to remove the molds and make castings. During the cutting process, it is worth adding a few locks so that the finished castings can be easily assembled, like pieces of a puzzle.

Molded figurine against silicone mold

Some craftsmen have learned to cast metal copies. Such soldiers are usually made of low-melting metals (for example, lead) and cast in plaster molds. Sometimes a special silicone is used, but it is a little more difficult to achieve good shedding of a small product in a silicone mold. nine0003

Metal soldier casting

In addition to making figurines from scratch, some craftsmen remake ready-made miniatures. This is called conversion.

Conversion in miniatures is a refinement, stylization or alteration of a finished figure. Unfortunately, not every hobbyist has good sculpting skills, and this alteration helps to achieve good results regardless of artistic skills. The main thing is to act very carefully. nine0200