Fff in 3d printing

Introduction to Fused Filament Fabrication (FFF) 3D printing technology

This White Paper will get you familiar with the process of Fused Filament Fabrication (FFF) for plastics, in which layers of material are built up to create a solid object.

Download the full White Paper here>

What does FFF mean in 3D printing?

Fused Filament Fabrication (FFF) is an extrusion process where the object is built by depositing melted material layer-by-layer. The plastics used correspond to the same thermoplastics that can be found in conventional manufacturing processes, like ABS and Nylon.

FFF led the expansion of desktop 3D printers and is now the most widespread 3D Printing Technology, essentially due to the low initial investment needed, the immense variety of applications offered, and the little specific knowledge required to successfully use this technology.

How does FFF work?

As mentioned above, FFF consists of an extrusion process of melted plastic. In order to generate the part, a print head travels around the printing surface depositing the material.

The workflow is as follows:

The first stage consists of generating the 3D model with any design software, such as Solidworks or Catia. The 3D model needs to be exported in STL format.
In file preparation, the model is configured using a slicing software including all the printing requirements. This configuration will contain the material selection and the nozzle size. The software also separates the model into layers, and you can configure the printing quality, and movement commands.
The printing phase is the deposition of the melted plastic.

In-house desktop 3D printers: FFF vs SLA

The most popular 3D printing technologies are FFF and SLA. SLA is a liquid photopolymer selectively cured by UV light.

Both technologies have their own benefits and disadvantages depending on your business’ needs.

Professional desktop 3D printers compared to industrial printers and outsourcing

Within the FFF technology market, there are different printer categories based on the relation between price and printing quality.

Should the number of parts to produce be low and the usage planned to be sporadic, there is the option to outsource the 3D printing service through a 3D printing service bureau.

If the plan is to work on a medium-long term project, the acquisition of 3D printers can reduce costs significantly. This acquisition implies an initial investment, but then the price per part becomes approximately 30 times cheaper.

Which solution best fits your needs

It is important to take into consideration parameters such as cost and lead time:

In-house FFF printers offer the best combination of costs and lead times. However, investing in both FFF and SLA printing technologies will give your company full versatility when producing parts. To weigh the benefits for your company, read our white paper and have a think about your answers to these questions:

What is my budget?
Does my company have specialized equipment to support a 3D printer?
Do I need to print mechanically demanding parts?
Will there be designing and application versatility?
How many printed parts does my company require?
What is the lead time my company requires?

Would you like to know more about 3D printing? Check out the following white papers:

• Introduction to FFF technology and its most important parameters
• Anatomy of Sigma & Sigmax R19 extrusion system

Ready to save time and cut costs with a BCN3D printer? Request a customized quotation for a BCN3D Printer.

Fused filament fabrication technology for 3D printing

David Roberson7 January 2021

Trends

FFF 3D printing, or fused filament fabrication, is an additive manufacturing (AM) process in which thermoplastic material is pushed through a heated nozzle to create objects layer by layer.

What Is FFF 3D Printing?

While it has its origins as a proprietary manufacturing technology from the 1980s, desktop FFF really took off just over 10 years ago when patents expired and projects like the open-source RepRap initiative led to greater innovation and affordability.

Today, FFF technology is typically a lower-cost solution compared to other 3D printing processes, both in terms of initial investment and running costs. It’s also renowned for being easy to understand and use – making it ideal for busy engineers and elementary school kids alike.

But it has proven so reliable, accurate, and capable of producing robust parts over the years that most of the world’s leading manufacturing, design, and education organizations now use it to drive innovation.

The FFF 3D printing process

FFF 3D printing uses

Let’s look more closely at the applications of FFF 3D printing:

Manufacturing. With faster lead times than outsourcing and a wide range of engineering materials, FFF 3D printing is used widely in manufacturing industries. 3D printers deliver rapid tooling and replacement parts to maintain maximum uptime and productivity on the production line. And they are used to flexibly create end-use parts, such as bespoke quality gauges or small batch first runs, to speed up time to market of a product
Prototyping. Low-cost materials and short print times make FFF 3D printing ideal for the iterative design process. 3D printed prototypes can be used to visualise concepts or functionally test technical parts
Education. Affordable and easy-to-use FFF hardware enables a variety of education applications – from engaging younger students with STEAM basics to providing production labs for college and university students to work on engineering projects and develop skills for the modern workplace

Ford saved roughly $1,000 per tool by developing 3D printed manufacturing aids using Ultimaker printers

Learn more about the range of 3D printing applications and how experienced AM engineers identify them in this episode of the Talking Additive podcast.

FFF materials

Plastic polymers are the most used materials for FFF technology, of which there are many for countless uses.

Composites that combine a polymer with fibers of carbon, metal, glass, or other materials are also widely used for various structural benefits, although these cannot be printed reliably on all FFF 3D printers. Technically it is also possible to print food and biological pastes using 3D printing technology, although this is typically reserved for experimental or research applications.

Another important category of material for FFF printers is known as “support” material. This is needed when the orientation or shape of a part makes it impossible to print from bottom to top – for example, a part with a large overhang. Support materials are designed to be easy to remove.

Material for FFF 3D printers is typically sold as spools of filament, each containing from 250 g to 1 kg of material.

Some 3D printers can print parts with multiple materials or colors

Loading filament on an Ultimaker S5 Pro Bundle printer

If you’re thinking of buying a 3D printer, always check the compatible materials.

For some, you may be limited to using two or three materials. Other printers may claim to work with any material, but soon develop technical issues from wearing caused by printing abrasive composite materials. And some FFF 3D printers are limited to using the manufacturer’s proprietary materials only, while others offer an open filament system (like Ultimaker) compatible with third-party products.

Some of the most common FFF 3D printing polymers are PLA (polylactic acid), which is often used as a “beginners” material due to its ease of use, and ABS (acrylonitrile butadiene styrene), which offers some superior mechanical properties and heat resistance.

But with thousands of filaments on the market, it’s worth diving a little deeper into their properties to get an understanding of how many applications are possible with a high-quality FFF 3D printer.

Material	Properties
PLA (polylactic acid)	Excellent surface quality and detail. Mechanical and heat properties not suitable for some applications
ABS (acrylonitrile butadiene styrene)	Strong, ductile material with wear resistance and heat tolerance
Nylon (polyamide)	Strong yet flexible, with good chemical, impact, and abrasion resistance
PETG (polyethylene terephthalate glycol-modified)	Good toughness and wear resistance, with chemical resistance against many industrial fluids.
CPE (copolyester)	Durable and flexible with a glossy finish and good impact and heat resistance
PC (polycarbonate)	Strong and tough material with heat resistance up to 110 °C
TPU (thermoplastic polyurethane)	Flexible material with rubber-like properties. Provides high impact and wear resistance
PP (polypropylene)	Durable, tough, and fatigue resistant. Retains shape after torsion, bending, or flexing
PVA (polyvinyl alcohol)	Water-soluble material used to create supports for overhangs and cavities

The table above covers the main polymers you can print on a professional 3D printer. Want to find the right composite material for your 3D printing applications? Watch our webinar on composites for 3D printing.

FFF 3D printers

Although FFF 3D printers are all built on the same process, their capabilities differ a lot.

One of the biggest differences can be in material compatibility (see the section above), with the hardware being especially important in defining what sort of composites can be printed.

Size is another key differentiator of FFF 3D printers. The printable space (which limits the size of a single print or batch) is called the build volume or build envelope. This can vary considerably – from 10 cm (3.9 inches) of printable space in the X, Y, and Z dimensions, up to around 1 meter (39 inches) in one or more of these dimensions in the largest units. Note that a stiff, stable build platform aids the FFF process – so large format printers generally mean a trade-off in quality.

An example of the different sizes and configurations possible with FFF 3D printers

The different features of a FFF printer are too many to highlight in an introduction, so here are definitions of a few of the most important:

Build plate or platform. The surface onto which the material is extruded and then cools to form the printed part. It is typically made of glass or metal. A professional standard 3D printer should offer a heated build plate, which enables use of more materials
Nozzle. The nozzle extrudes the molten material. It is housed in the print head and positioned via a gantry operated by stepper motors. The number of nozzles a printer has will determine how many materials can be combined in one print – typically one or two (known as single or double extrusion)
Feeder. The mechanism that feeds filament from the spool to the printer
Display. The interface through which the printer is controlled
Connectivity. Many 3D printers offer local network or cloud connectivity for remote operation
Environment control. While some FFF 3D printers are little more than open platforms, enclosing the build chamber and adding environment control (such as the Ultimaker S5 Pro Bundle) offer both print quality and safety benefits
Material handling. Filament is loaded and stored in many different ways on FFF 3D printers. This can range from basic printers, where the spool must sit separately, to professional solutions that offer front-loading and automatically switch spools when a filament finishes

You can compare the features of Ultimaker 3D printers here.

Finally, it’s important to mention software. Unless you have all the 3D prints you will ever need sitting on a USB stick, you will not be able to do much without the right software.

In 3D printing, software plays two important roles. First, a “slicing” program like Ultimaker Cura is essential for preparing a design file (such as an STL) for print. Load the file into this software, choose your desired print settings (such as fast or extra detail), and it will “slice” it into layers then create a file format the printer understands.

Preparing a model to be 3D printed using Ultimaker Cura software

This print job can then be transferred to the printer manually (such as on a USB stick) or sent remotely over the network or cloud. This is where software can play the role of sending, queuing, and tracking these print jobs. Cloud software such as the Ultimaker Digital Factory is enabling the next generation of FFF technology, delivering distributed manufacturing across multiple locations.

Watch this video to see how one manufacturer has created a "digital warehouse" by combining FFF 3D printers and software.

Watch the video

Want to learn more about how the 3D printing workflow could look for you?

Read our ‘How to design for FFF 3D printing’ white paper for valuable tips for getting started with an FFF printer, more detail about the role of support materials, and design for FFF insights from 3D printing experts.

Learn the modeling tips and tricks that we use to maximize our print success, including:

• How to 3D print faster

• Easy ways to use less support material

• Best practices for finer print details

• And lots more!

FDM printing technology in 3D printers. Pros and Cons, Applications

FDM or FFF technology involves the creation of objects by layer-by-layer application of molten material. FDM literally stands for fused deposition modeling or layer-by-layer deposition technology.

It sounds complicated, but the technology is actually very simple. It's basically like a hot glue gun. On the one hand, thermoplastic or any other material is pushed through, which melts from heat, and then solidifies without losing its properties. The thermoplastic passes through a hot nozzle, melts and solidifies immediately. The extruder and table are driven by stepper motors, leaving plastic behind them, layer by layer, from bottom to top, recreating a 3D model.

MJM technology can be called an analogue of FDM. Only MJM uses wax or photopolymer. On the print head there are many small nozzles (from 96 to 448) through which molten wax is supplied, or droplets of photopolymer that are immediately illuminated by the lamp.

Plastic thread is used as a material for making models. There are 2 diameters of plastic thread - 1. 75 and 2.85 (3mm). Printers that need 3mm filament are rare, mostly Ultimaker and its clones. Most printers use 1.75 filament for printing.

The first material for 3D printing was a plastic welding filament with a diameter of 3mm, so for a long time this size was the standard for 3D printing.

A 3D model is prepared using a slicer program before printing. The slicer separates the model into layers and prepares commands for moving the print head. The sliced model can be saved in different formats, but GCode is used by default. Therefore, the printer is basically a CNC machine.

History

The method was invented by S. Scott Crump in the late 1980s. The patent was received in 1988. And already in 1990, Stratasys appeared on the market with the first industrial 3D printer using FDM technology.

Scott Crump is one of the founders of Stratasys.

The first 3D printers were rather expensive industrial machines designed for large companies. Everything began to change in 2006, after the founding of the RepRap project (from the English Replicating Rapid Prototyper - a self-replicating mechanism for rapid prototyping).

First version of RepRap 3D printer.

The goal of the project was to create a self-copying 3D printer. Shafts were used as a frame and guides. Almost all parts were connected by printed parts. The extruder and table were driven by stepper motors. The source code was open. Of course, visually, it looked like a homemade “made from improvised materials”, but it worked. The printer uses about 50% of printed parts.

Since the term FDM was patented by Stratasys, 3D printing enthusiasts and RepRap project contributors have coined their own term - FFF. Literally stands for - fused filament fabrication (production by fusing threads). The meaning remained the same, but it helped to avoid legal problems.

As RepRap has developed, projects based on OpenSource (open source code) have developed. The most prominent representative of the OpenSource movement was MakerBot. In addition to developing their 3D printer, MakerBot is actively developing the Thingiverse website. On Thingiverse you can find a huge number of free 3D printable models.

MakerBot founders Zack Smith and Bre Pettis with the final MakerBot Cupcake prototypes.

Separately, it is worth highlighting the company Ultimaker. If in the ideology of RepRap the printer was supposed to reproduce itself, then Ultimaker went the other way. They designed their printer from laser-cut plywood parts. This was much faster and more affordable than the manufacture of printed parts. In 2013, the first Ultimaker Original was released. It was sold as a KIT - a set (assemble it yourself).

All the drawings and developments were posted on the network. This made it possible for anyone who wanted to purchase all the necessary components and electronics, order cutting of the case and some components anywhere and assemble their printer. And after assembly, it was possible to print upgrades on the same printer and replace plywood parts with plastic ones.

Quite quickly, Ultimaker had a large and friendly community. Many free 3D models of various Ultimaker Original nodes have been posted online. A lot of upgrades appeared, many unpleasant “sores” of the design were removed.

Plywood Ultimaker Original

In addition to Ultimaker 3D printers, based on the Replicator-G, they developed their own CURA slicer. Due to its versatility and affordability, CURA has become a favorite among 3D maker slicers. In addition to Ultimaker printers, a bunch of ready-made profiles for other 3D printers have been added there. It is easy to set up CURA for a self-assembly printer.

Modern CURA

There were many more different projects - large and small, but it was the RepRap and OpenSource projects that made FDM 3D printing more accessible. Due to the mass character, not only 3D printers themselves, but also consumables for them, have become cheaper and more affordable.

Of course, there are several differences between FDM and FFF technology. The main thing is the presence of a heated chamber for more stable printing. FFF abandoned it in order to make 3D printers cheaper and more affordable. Later, a closed case appeared in some printers. Together with the heated table, a passive heating chamber is obtained.

FDM pros and cons

The most important advantage of FDM printing is affordability. The cost of a home printer is comparable to the cost of a smartphone. With a very limited budget, you can find OpenSource projects and build a printer yourself.

Large variety of models.

You can easily choose a printer for a specific task. For example, Flashforge Adventurer 3, due to the closed case and the absence of a heating table, will be a great gift for a child. Anycubic Mega is suitable as a home assistant for a person who loves upgrades and experiments. And Raise3D Pro2 is suitable for production tasks.

Variety of materials for 3D printing.

Due to the mass application, in addition to the standard ABS and PLA, a variety of plastics began to appear. For example, decorative plastics with imitation of various materials.

Decorative laminates imitating copper and bronze.

Engineering - with improved physical and mechanical properties. These materials can be used to create functional products and prototypes.

Printing example for functional products

Or special. plastics for specific tasks. For example, burnable with low ash content or melted wax.

Blank cast from 3D burnout model

But there are also disadvantages.

Poor accuracy compared to other printing technologies.

The discrepancy with the 3D model is usually no more than 0.1mm. This value depends on the mechanics of the printer and the characteristics of the material. For ordinary gears and domestic needs, such accuracy is quite enough. But in some industries (for example, jewelry), the accuracy of the finished model should be higher.

Layered surface.

It is impossible to get a perfectly smooth surface on an FDM 3D printer. Layers on the model can be smoothed out by sanding, puttying, or by treating with a solvent.

On the left is a printed model on an FDM 3D printer, and on the right is the same model after processing.

Applications

With a wide variety of printers and materials, FDM 3D printing has a very wide range of applications.

Prototyping

The most popular is prototyping. FDM printing has made it much faster and easier to create test models and mechanisms.

From 3D printed model to finished product

FDM printing allows you to quickly prototype anything and quickly make changes.

Medicine

In medicine, using 3D printers, they began to create comfortable, breathable orthoses for fixing fractures.

3D printed orthosis.

Printed orthoses can be fixed much faster than a classic plaster cast. And the process itself is less time-consuming and dirty.

Creation of simple traction mechanical prostheses. This is especially true for children. After all, children grow quickly and they need to change the prosthesis often. Thanks to FDM printing, the process of creating a prosthesis has been made cheaper and faster.

Child traction prosthesis

Dentures are lighter and more comfortable than those made by the classical method.

Film industry

In the film industry, FDM printing is used to print props and costume elements, masks, mechanisms, and other items.

Geisha robot from the movie "Ghost in the Shell"

Sometimes 3D printing is used to create small prototypes of models on a reduced scale, for more accurate calculation of proportions, staging scenes, lighting and further rendering.

Hobby

FDM printers have helped to simplify the creation of RC models of boats, cars, aircraft and spare parts for them.

3D printed RC aircraft

Websites have even appeared with models of radio-controlled aircraft, machines adapted for 3D printing.

Cosplayers have also fallen in love with 3D printing due to the variety of materials and the faster and easier production of masks, functional elements, and some pieces of armor.

Cosplay from the movie "Pacific Rim 2"

Previously, it was necessary to select material for a long time and painstakingly, prepare patterns, carefully prepare the surface for priming and painting. Now it is enough to model a 3D model of the desired costume, it can even be adjusted to the figure of the cosplayer and printed. Simplified manufacturing of complex, moving elements and parts of mechanisms.

Modeling

In breadboarding, the 3D printer made it possible to speed up the creation of complex models of buildings and landscapes by several times. Previously, many elements had to be painstakingly made by hand.

Block layout

A three-dimensional physical model helps the customer to see the future object more fully, compared to the digital environment. You can quickly change the layout if necessary.

Short run

If you need a small batch, for example, key rings with a company logo or a piece product, it will be faster and cheaper to print it on a 3D printer.

Small batch of spare parts

Making a master model with subsequent casting is a laborious and expensive process. If the part is of a complex shape with various protrusions and undercuts, then casting may not be possible, and a 3D printer can easily cope with this task.

Education

The use of 3D printers in the educational process allows students to develop imaginative thinking, to make the learning process more visual. On paper, it is difficult to notice the flaws of the part, and by creating a test part, you can clearly see all the flaws.

Children assemble 3D printer

In robotics, a 3D printer allows you to quickly create various mechanisms and simple robots.

A child assembles a robot in a robotics circle

3D printing is becoming popular for creating visual aids. For example, for visually impaired or blind children. They “see” with their hands, and thanks to 3D printed models, they can perceive information more fully.

Home

At home, a 3D printer can turn out to be not just a toy, but a useful tool. For example, for the repair of household appliances. In some household appliances, plastic gears are erased or broken from the load. With the help of 3D printing, a replacement can be easily made.

Printed and original gears

Or print interior items: coasters, vases, lamps, boxes for small things. Everything is limited only by 3D modeling skills and imagination.

Totals

FDM printing technology, thanks to a wide variety of 3D printers and materials, is very versatile. The main thing is to choose the right tool - a printer suitable for the given tasks.

Despite its youth and active development, FDM has already found many areas for application. From year to year, mechanics are being improved - printers are becoming faster and more accurate. The software is constantly updated so that the novice user is comfortable and does not have to read long instructions before starting the printer, as well as understand millions of settings.

Various plastics appear, helping to obtain more accurate and durable products. Or imitating a different texture and material. This allows you to expand the scope of 3D printers using FDM technology.

3D printing technologies - FDM, FFF, SLA, DLP, PolyJet, CJP, SLS, SLM

FUSED DEPOSITION MODELING PRINT TECHNOLOGY – + FDM

One of the most popular, simple and cheap 3D printing technologies is Fused Depsition Modeling. The technology was invented more than 20 years ago and implemented by Stratasys, and still it remains the most popular. The principle of building a prototype using this method is simple and clear. The simulated 3D object in STL format is transferred to the 3D printer software. After placing the model in a virtual working chamber (automatically or manually), cutting the model into horizontal layers, the 3D printing process begins. The extruder print head melts the filament, laying down layer by layer according to the model data. If necessary, before starting printing, auxiliary structures (supports) are automatically or manually placed on a virtual 3D model, which, after printing, can be removed with a special solution or manually.
There are many types of equipment that print using this technology. They differ in terms of accuracy, the number of print heads, the size of the working platform, the presence or absence of a closed working chamber, consumable options, etc. There are models that support the ability to use different materials when printing. There are also industrial FDM 3D printers and personal ones.
The following materials can be used in FDM 3D printing:

ABS
PLA
SBS plastic
Nylon
Polycarbonate
HIPS support material
PVA support material
PETG plastic
FLEX rubbery plastic
RUBBER plastic with rubber properties

The most popular materials are ABS and PLA. Products printed using FDM technology are characterized by elasticity, strength and stable physical characteristics, depending on the selected material. The construction accuracy varies from 0.027mm to 1mm. As a rule, the printed object has a layered (ribbed) surface, the severity of which depends on the thickness of one layer. This effect can be eliminated by post-processing with chemicals or grinding.
The advantages of FDM 3D printing technology include sufficient speed and ease of manufacturing products, safety, high accuracy, a wide choice of materials, as well as ease of use and maintenance of equipment. In addition, consumables for printing in this way are affordable. All this together makes this technology the most highly competitive and affordable in economic terms.
FDM 3D printing technology can be used for rapid prototyping and even small series production. Depending on the selected consumable material, this technology can be used to create parts of mechanisms, toys, interior items, jewelry, souvenirs and much more. The use of high-strength engineering thermoplastics makes it possible to apply this 3D printing method to products used in the aerospace industry.
Our company has several 3D printers working on this technology. You can order high-quality 3D printing using FDM technology from us with any of the available materials and in any available color option. We guarantee you the quality and efficiency of order execution of any degree of complexity.
To order 3D printing using FDM technology, you need to send us a file in STL format. Trust our professionalism and take advantage of the most affordable 3D printing.

STEREOLITHOGRAPHY PRINT TECHNOLOGY – + SLA

SLA 3D printing technology or laser stereolithography is based on the layer-by-layer curing of a liquid photopolymer under the action of a laser beam. The technology was invented in 1986 by Charles W. Hull, who founded 3D Systems, which manufactures 3D printers that print using this technique.
Photopolymer, which in this case acts as a consumable, is a resinous substance that changes its properties under the influence of ultraviolet radiation - it polymerizes and hardens. In this case, the wavelength and time of exposure to radiation will depend on the environmental conditions and the specific material.
The principle of building a model using laser stereolithography technology at the initial level is similar to any other - a modeled object in STL format is loaded into the 3D printer software, placed in a virtual working chamber and cut into layers. Photopolymer resin is poured into a special container. It contains a working platform on which the part will be built. Initially, the working platform is set so that it is covered with the thinnest layer of photopolymer (0.05-0.13 mm). This will be the size of the layer when printed. Then the laser is turned on, it irradiates the areas that will later become parts of the finished product. As a result of irradiation, the material hardens and the working platform sinks to the extent of the layer. The algorithm repeats again until all programmed layers are exhausted. Then the finished product is immersed in a special bath, into which a composition is poured to remove excess elements. And at the end, the product is again irradiated so that it gains maximum strength.
Stereolithography, like most other 3D printing technologies, requires support. After printing is completed, they are removed manually.
The main advantages of stereolithography technology are the highest precision and the ability to create the smallest and thin-walled objects. The technique is distinguished by easy post-processing of products and their almost perfect surface. The disadvantage of this technology is the impossibility of using several materials at once. Color printing is also not possible. The properties of the model and its color will determine the initial characteristics of one photopolymer. In addition, the cost of such printing and equipment is not cheap.
Due to the fact that stereolithography allows you to get a model of almost any degree of complexity, the main scope of this 3D printing is research. And due to the highest accuracy and detail, this technique is used in medicine, in particular in dentistry. Also, printed models are in demand in art, jewelry, museum work and restoration. There are photopolymers that can be used to print molded models. The model printed on a 3D printer, in this case, is poured with molding sand and placed in an oven for annealing at a temperature of 1000 degrees. As a result, the polymer burns out without leaving a trace, and the resulting form can be used for pouring metal under vacuum. As the metal cools, the mold breaks and the metal part is removed.
In our company you can order 3D printing using SLA technology. We have in our arsenal professional 3D printers using this technology and a wide range of photopolymer resins with various characteristics for 3D printing. We guarantee you high quality and prompt execution of the order. To order 3D printing using the laser stereolithography method, you need to provide us with a file in STL format.
Get the most out of high-precision and highly detailed stereolithographic 3D printing.

DIGITAL LIGHT PROCESSING PRINT TECHNOLOGY – + DLP

DLP 3D printing is one of the most accurate and fastest 3D printing methods. It is based on the technology that Larry Hornbeck invented for multimedia projectors. The peculiarity lies in the use of a special mirror matrix. Each individual pixel of this matrix is a microscopic mirror.
DLP stands for Digital Light Processing, which means "Digital Light Processing". Thus, this technology is one of the varieties of photopolymer 3D printing and photopolymer resin is used as a consumable. This resin is irradiated with projected light from the LEDs and hardens. The technology is very similar to stereolithography. However, with SLA 3D printing, each layer is, as it were, loomed with laser beams. And in DLP technology, the layer is completely projected onto a photopolymer using the same matrix with micromirrors, that is, this method is more like stamping. Thus, while maintaining the highest accuracy of 3D printing, it was possible to significantly increase its speed. At the moment, the speed of DLP printing is several times higher than FDM, SLM and SLA printing. For this reason, the DLP 3D printing technique is one of the most promising.
The thickness of one layer when printing using DLP technology is 10-15 microns, which is basically similar to the indicators for SLA 3D printing technology. For comparison, the FDM method implies a minimum thickness of at least 50 microns.
Since DLP printers are the main competitors of SLA printing, their application is about the same. They can print products for dentistry, jewelry, complex designs and even souvenirs. The technology is also in demand in the research area.
Photopolymers used in 3D printing with this method are diverse, and you can choose a material with the desired characteristics. For example, there are materials that mimic the properties of ABS plastic, hard engineering plastics, and even rubber. However, it is important to know that in some cases, under the influence of light, photopolymer products can crack and become brittle. This technology implies the impossibility of using several materials at once. Color printing is also not possible. The properties of the model and its color will determine the initial characteristics of one photopolymer.
However, there is also a drawback to DLP technology - as in the case of SLA 3D printers, the cost of equipment is very high, as in principle the price of photopolymers. Not every, even a large company, can afford such a 3D printer.
But this does not mean at all that you will not be able to take advantage of the speed and advantages of DLP printing, because you have the opportunity to order 3D printing on such a 3D printer in our company. To do this, you just need to provide us with an STL file with the desired model. We guarantee you prompt execution of the order and high quality.
Take advantage of high-quality, fast, high-precision DLP printing.

PRINT TECHNOLOGY LED DISPLAY – + LED

One of the varieties of DLP 3D printing technology is LED 3D printing. That is, this method is based on the same digital light processing (as Digital Light Processing stands for). However, in devices for LED 3D printing, instead of a mirror chipped matrix, there is an LED display that immediately highlights a whole layer on the material, like a kind of light stamp. Using an LED display allows you to increase the speed of 3D printing. So it takes about 10-15 minutes to 3D print 2.5 cm along the Z-axis, and it's really fast. Although the print speed in any case will directly depend on the thickness of one layer.
As a consumable material, a photopolymer resin is used, which polymerizes under the action of ultraviolet light, that is, it changes its qualities, passing from a semi-liquid state to a solid one. There are many options for photopolymers, among which there are materials that, after the polymerization process, imitate the characteristics of solid, including engineering plastics. There are also those that are very similar to classic rubber after hardening, that is, they have the same strength and elasticity indicators. You can also choose biocompatible photopolymers. When choosing a material for printing, you should be guided by the technical characteristics and scope of a particular photopolymer.
Like any other photopolymer 3D printing, LED technology is characterized by the highest precision and detail. The thickness of one layer is only 10-15 microns. With its help, you can print thin-walled products, objects with complex geometry. Photopolymers practically do not shrink and do not change their geometry after hardening, and this is also an advantage, especially when it is necessary to print anatomically accurate models. The DLP LED 3D printing technology itself, although it provides for a layer-by-layer method for creating a model, still does not differ in pronounced layering of the finished model. The surface is almost perfectly smooth, requiring no additional processing.
If complex objects are printed, support must be used. They can be set in automatic or manual mode immediately before printing during the positioning of the model in the virtual working chamber. These supports are subsequently removed manually.
LED technology implies the impossibility of using several materials at once. Color 3D printing is also not possible. The properties of the finished prototype and its color will determine the initial characteristics of the photopolymer used.
The scope of LED 3D printing does not differ in principle from the scope of DLP printing, since this technology is, in fact, its improvement. The technology is in demand in the production of hearing aids and earmolds, in dentistry and orthodontics, as well as in jewelry. Due to the high accuracy and detail of 3D objects printed using this technology, products will also be in demand in the field of research and engineering activities.
LED 3D printer is very expensive. However, this does not mean that its benefits are not available to you. You can order 3D printing using LED technology in our company. We offer you a large selection of photopolymer resins for printing and guarantee the high quality of models, in full compliance with the provided STL-file, and the prompt execution of the order.
Take full advantage of LED technology with our help.

POLYJET PRINT TECHNOLOGY – + PJ

PolyJet is a revolutionary 3D printing technology that is a powerful tool for high performance additive manufacturing. The technique was invented and patented by Stratasys. The operation of a PolyJet 3D printer is very similar to a conventional, well-known inkjet printer, but printing is carried out not on paper and not with simple ink, but on a special substrate in the chamber, and an acrylic-based liquid photopolymer acts as a material.
The PolyJet-enabled 3D printer is equipped with a special print head with nozzles. There can be several printheads, which allows you to print faster and even prototyping several objects at once. The printing process is carried out by dosed deposition of a photopolymer. One layer of 16 microns is sprayed at a time. Then this layer is exposed to an ultraviolet lamp and the photopolymer turns into a hard plastic. After that, the working platform with the substrate is lowered, and the algorithm is repeated again. When printing complex geometric shapes, a support material is used. For this technology, a special gel-like material has been created, which is easily removed with plain water or hands.
A key feature of PolyJet 3D printing technology is the ability to use multiple materials in one print run. At the same time, there are models of 3D printers that can mix photopolymers in various proportions, obtaining a variety of composite materials with certain characteristics. Also, this technology is characterized by the possibility of complex color reproduction. That is, it is possible to use color printing, the palette of which includes about 1000 colors and shades. In fact, it is the only additive manufacturing technology that supports these capabilities.
Other advantages of the method include: high printing speed, high accuracy and detail, perfect surface and generally excellent quality of printed objects. In addition, a wide range of materials allows you to create objects of almost any kind. More than 100 different photopolymer resins can be used as a base, mixing of which allows obtaining materials from transparent to completely opaque, from hard to elastic and rubbery. This is truly a new standard for realism in the most complex prints. PolyJet technology allows you to achieve perfect surface smoothness and imitate any even the most subtle texture. The camera of the PolyJet 3D printer is quite large, but if you need to print a large object, then it can be broken into parts, which are then simply glued together.
The only disadvantage of the technology is its high cost. The equipment is very expensive, and photopolymer resins are not cheap. But this does not mean that you cannot use this technology, because you have the opportunity to order 3D printing using PolyJet technology in our company. In a short time, we will implement your project on our own 3D printer. All you need is to provide us with the STL file.
PolyJet 3D printing technology is truly limitless.

COLOR JET PRINTING TECHNOLOGY – + CJP

Color inkjet 3D printing - CJP (ColorJet Printing) technology - a patented technique invented by 3D Systems. It consists in layer-by-layer gluing and coloring of the powder gypsum composite. 3D printing of this type is based on a technique called 3DP, which is its improvement.
3D printing by this method is based on the use of two materials: base and binder. To create the base layer, a consumable of the main type is used. It consists of gypsum mixed with a polymer. And the binder is used for gluing and staining the layers.
ColorJet Printing 3D printer has two cameras. A gypsum composite is poured into one of them, and the second chamber is used to remove excess material. The model is "grown" in layers. A special roller distributes a thin layer of material on the working platform. The print head applies the adhesive and colors the main consumable particles. All this is carried out in accordance with the loaded mathematical 3D model. The working surface is lowered by the amount of the layer (0.1016 mm), and the roller again applies a layer of gypsum composite powder, and so on until the model is printed to the end.
ColorJet Printing technology has a relatively low cost of printed models. Its advantage is the absence of the need for supports, since the non-glued material will act as supporting structures. In addition, the material that was not used during printing can be reused. It turns out that this method of additive manufacturing is waste-free.
The CJP technology is the only one that uses the CMYK printing color palette. This palette includes 390 thousand colors and shades. The material is dyed during the gluing of the layer, resulting in details with excellent color reproduction.
The accuracy of building a model by this method is very high, the minimum printed element has dimensions of 0.1-0.4 mm. The thickness of the walls of the prototype, which will not collapse under their own weight, is 0.102-0.089 mm.
Models printed using ColorJet Printing technology have a typical gypsum rough surface, characterized by a high degree of hygroscopicity. The strength of the models is average. However, finished models are easy to sand, paint and glue. To improve the characteristics of the model and protect them from moisture, you can cover the surface with varnishes, waxes, resins, as well as all kinds of fixatives.
The technology can be used for 3D printing of architectural models, product presentations, souvenirs, miniatures, etc. Despite the fact that the products are of low strength, they allow you to visually evaluate the prototypes.
CJP 3D printer has impressive dimensions and is quite expensive, despite the fact that the cost of printed prototypes is low, not everyone can afford such pleasure. In our company, you can order 3D printing using ColorJet Printing technology. We guarantee you prompt execution of the order and full compliance of the prototype with the modeled object. All you need is to provide us with an STL file with a 3D model.
Take advantage of CJP 3D printing technology with our help and appreciate all its advantages in practice.

SELECTIVE LASER SINTERING PRINT TECHNOLOGY – + SLS

Selective, that is, selective, laser sintering is a 3D printing technology that was created back in 1979. However, for a long time it was not available to the market until DTM was created in 1996. In 2001, 3D Systems bought this company, and in 2014 the patent expired, and now this technology is available to a wide range of consumers.
The SLS 3D printing technique is that the material is heated by a laser beam until the particles are sintered, that is, not completely. As a result, the model turns out not to be solid, but as if “sintered” from individual tiny particles. If we consider the structure under magnification, then individual particles of the material will be visible, as if glued to each other.
The operation of a 3D printer that prints using SLS technology is as follows. Powder material is poured into the chamber. A 3D model in STL format is loaded into the software. The working platform is exposed and a thin layer of material (thickness about 120 microns) is applied to it, leveled with a roller. The laser sinters the powder particles according to the loaded model. After the layer is completed, the platform is lowered and a new layer of material is applied. The procedure will be repeated until the very last layer is completed.
Since there is unused material in the working chamber, the need for supports simply disappears, because complex and overhanging parts will be supported by unused material. This allows you to get models of any, even very complex geometry.
Powder polymers, metals and their alloys, ceramics, glass, composite materials can be used as consumables. But in any case, the material must be in powder form. Due to the fact that the power of laser radiation can be adjusted, the degree of melting of the material can change, and, accordingly, the strength and uniformity of the structure of the resulting model. Currently, the most popular material for 3D printing using SLS technology is polyamide. This is a versatile powder material that can be used in almost any field. If powdered metal is used for printing, it is preheated to make printing faster and easier.
As a result of 3D printing, models are obtained with a surface that requires processing, in particular grinding. Models made of polyamide are sensitive to moisture, so they must be coated with a protective compound, such as moisture-resistant paint, if outdoor use is planned.
Selective laser sintering shows excellent results in small batch production as well as for making master models. This 3D printing technology is in demand in the aerospace industry, in manufacturing, etc.
The disadvantages of SLS 3D printing technology are the high cost of equipment. In addition, the powder material is potentially harmful to the human body, so a separate room with air conditioning and an air filter is equipped for such 3D printers. All this imposes difficulties for additive manufacturing using this technique. But this does not mean that you cannot take advantage of the possibilities of selective laser sintering technology, because our company provides professional 3D printing services on such equipment. You can order 3D printing using SLS technology from us. All you need is to provide us with a file with a 3D model in STL format. We guarantee you high quality printing in full accordance with the provided 3D model.

SELECTIVE LASER MELTING PRINT TECHNOLOGY – + SLM

Selective (selective) laser melting - SLM is a 3D printing method from a mathematical CAD model, which is used to create 3D objects by melting metal powders. For this, high-power lasers are used.
Using this technology, it is possible to create precise metal parts that will later be used in various units and assemblies, including non-separable structures that change their geometry during use. This type of printing is becoming more and more widespread, because the parts created by this method are in many ways superior in their mechanical and physical characteristics to products produced by traditional methods.
The advantages of 3D printing using SLM technology are: the ability to solve the most complex production tasks, including in the aerospace industry, where parts and assemblies have a hard load and serious requirements are imposed. Also, SLM printing is used in experimental and scientific and technical activities, where it is possible to significantly reduce the R&D cycle, because the most complex mechanisms and products can be created without serious equipment.
The technology also allows you to print objects with internal cavities, which can significantly reduce the weight of products.
The essence of the method lies in the layer-by-layer application of metal powder on a special heated platform and its subsequent processing with a high-power laser, in accordance with the CAD model. The working chamber of the 3D printer, where the melting process itself takes place, is filled with argon or nitrogen. The choice of gas will depend on which consumable is selected for printing. Inert gas will be mainly consumed in preparation for printing, when the chamber is purged, because it is necessary to achieve conditions so that the percentage of oxygen in the chamber is no more than 0.15%. This is a necessary condition in order to avoid the oxidation of metals. Consumables can be: powdered metals and alloys. It can be tool or stainless steel, titanium and its alloys, aluminum, platinum, gold, as well as cobalt-chromium alloys.
The model is fused layer by layer. After the printing of the prototype is completed, it is removed from the chamber with the working platform and separated from it mechanically. In the future, it may require processing, because the surface of the product may not be ideal. However, the product will be very strong and uniform in structure, similar to cast.
One of the advantages of the technology is its economy and non-waste. After all, unsintered material can be reused. The thickness of one layer is 20-100 microns. Thus, SLM 3D printing is a very precise and highly detailed additive manufacturing technique.
The cost of 3D printers using this method is very high. And in general, their operation is by no means a simple matter, requiring special conditions. But you have a great opportunity to use 3D printing using selective laser fusion technology with the help of our company. All you need is just to order 3D printing using this technique in our company. To do this, you need to provide us with an STL file with a CAD model for printing.
Take advantage of the innovative method of creating high-precision metal products - SLM printing.

ELECTRON BEAM MELTING PRINT TECHNOLOGY – + EBM

One of the most reliable metal 3D printing methods is EBM printing or electron beam melting. This is an additive manufacturing technology that is used to create high-strength, comparable to cast, metal products. Pure (without impurities) metal powder acts as a consumable. Printing is carried out in a vacuum chamber, which minimizes the oxidation of the material, such as pure titanium.
Electron beam melting is very similar to SLS 3D printing technology, that is, selective laser melting. However, it does not use powerful lasers, but electron emitters, which serve as sources of powerful energy used to melt metal. So-called electron guns fire high power electron beams that fuse metal powder. The method is similar to other 3D printing methods - the layering of consumables. A layer of metal powder is applied, and electron beams, following the contour of the model, fuse the material. Then the algorithm is repeated again until all layers are created and a finished three-dimensional object is obtained in accordance with the mathematical 3D model.
As a result of such 3D printing, a high-density metal model is obtained, and the porosity of the structure is absent. This means that additional processing by the method of firing for a strong fusion of the material in the model is not required. And the model itself will have high strength characteristics initially, that is, it will not differ in any way from cast products.
Electron beam melting is printed at high background temperatures of 700-1000 degrees Celsius. This avoids a strong temperature difference between the already cooled printed layer and the fresh hot layer. Therefore, printed parts will not suffer from residual mechanical stress. This is how the highest possible strength of EBM-printed products is achieved.
This 3D printing technology is used to create high-precision titanium prostheses and implants, such as hip and knee implants, skull parts, etc. Titanium combines strength and biocompatibility.
EBM printing is also used in the aerospace industry. With the help of this technology, load-bearing structural elements of various devices (aircraft, rockets), as well as parts of their engines, are printed.