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How 3d printing works


How a 3D Printer Works and What It Is Used for

3D printing, also known as additive manufacturing, is defined as a process in which a digital file is used to create a three-dimensional solid object. In the 3D printing process, sequential layers of material are laid down by the ‘printer’ until object creation is completed. This article covers the working, software, and applications of 3D printing.

Table of Contents

  • What Is 3D Printing?
  • How Does 3D Printing Work?
  • Top 7 3D Printing Software
  • 3D Printing Applications

What Is 3D Printing?

3D printing, also known as additive manufacturing, is a process in which a digital file is used to create a three-dimensional solid object. In the 3D printing process, sequential layers of material are laid down by the ‘3D printer’ until object creation is completed.

3D-printed objects are created through an additive process, where the printer places layer after layer of material until the desired thing is ‘printed’. Each layer can be considered a finely sliced cross-section of the printed item. With 3D printing, users can produce complicated shapes without consuming as much material as traditional manufacturing methods require.

The operation style of 3D printing is the opposite of ‘subtractive manufacturing’, where the material is cut out or hollowed using equipment such as a milling machine. Conversely, additive manufacturing does not need a mold or material block to create physical objects. Instead, it stacks layers of material and fuses them together.

3D printing offers swift product creation, low expenses for the initial fixed infrastructure, and the ability to create complicated geometries using several material types, something traditional manufacturing solutions might not be capable of as efficiently.

Timeline of 3D printing

Generally associated with the Do It Yourself (DIY) culture of amateurs and hobbyists, 3D printing has grown to include commercial and industrial applications. For instance, engineers today often use 3D printers for prototyping and creating lightweight geometric objects.

The origins of 3D printing lie in ‘rapid prototyping’. When the base technology was first invented in the 1980s, the term was used to describe it because, at the time, 3D printing was only suitable for creating prototypes rather than production components. In fact, the original intent of its creation was simply to accelerate the development of new products through swift prototyping.

Interestingly, the technology did not garner much interest when it was first introduced. In 1981, Japan’s Hideo Kodama filed the first patent for a machine that leveraged UV light for curing photopolymers. Three years later, French inventors Olivier de Witte, Jean Claude André, and Alain Le Mehaute jointly filed a patent for a similar technology. Both patents were abandoned, with General Electric saying the ‘latter lacked notable business potential’.

It was in 1984 that American inventor Charles Hull filed a patent for an ‘Apparatus for Production of Three-Dimensional Objects by Stereolithography’. He invented the STL file and founded 3D Systems three years later, in 1987.

Within the same decade, significant strides were made in the US 3D printing space, with patents filed for selective laser sintering (SLS) and fused deposition modeling (FDM). Desktop Manufacturing (DTM) Corp. and Stratasys were pioneering companies in the 3D printing space, founded around the same time.

After that, the industry transformed as rapid commercialization took hold of it. The first ‘3D printers’ were large and cost-intensive, with their makers competing to land contracts for industrial prototyping with large-scale automotive, consumer goods, health products, and aerospace manufacturers.

By 1987, 3D Systems had introduced the first commercial-grade SLA printer; in 1992, Stratasys and DTM released the first commercial FDM and SLS printers, respectively. The first metal 3D printer was introduced in 1994 by Electro Optical Systems (EOS), a German enterprise.

By the dawn of the new millennium, companies in the 3D printing space were competing fiercely for profits. Progress in materials science and the lapse of numerous patents increased the affordability of 3D printing.

Soon, thanks to the strides made in the 3D printing space, manufacturing processes were not exclusively owned by enterprises backed by heavy machinery and capital. Today, 3D printing has transformed into a cutting-edge solution for creating many different types of production components.

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How Does 3D Printing Work?

The ISO/ASTM 52900, related to the general principles and terminologies in additive manufacturing, categorizes 3D printing processes into seven distinct groups. Each type of 3D printing works a little differently.

The time taken to print a 3D object depends on the type of printing, the output size, the type of material, the desired quality, and the setup configuration. 3D printing can take anywhere from a few minutes to a few days.

The different types of 3D printing are:

1.

Powder bed fusion

In powder bed fusion (PBF), thermal energy, in the form of an electron beam or laser, selectively fuses specific areas of a powder bed to create layers. These layers are built on one another until a part is made.

PBF may include sintering or melting processes; however, the primary operation method remains the same. First, a recoating roller or blade places a fine layer of powder on the build platform. Next, the surface of the powder bed is scanned using a heat source. This source selectively increases particle temperature to bind specific areas.

Once the heat source scans a cross-section or layer, the platform descends to let the process be repeated for the next layer. The final output is a volume with fused parts, with the surrounding powder remaining unaffected. The platform then ascends to allow retrieval of the completed build. Powder bed fusion includes several standard printing methods, such as selective laser sintering (SLS) and direct metal laser sintering (DMLS).

SLS is regularly leveraged for manufacturing polymer parts for prototypes and functional components. SLS printing takes place with the powder bed as the sole support structure. The lack of additional support structures allows for the creation of complex geometries. However, produced parts often feature inner porosity and a grainy surface and generally require post-processing.

SLS is similar to selective laser melting (SLM), electron beam powder bed fusion (EBPBF), and direct metal laser sintering (DMLS). However, these processes are used for creating metal parts and rely on a laser for fusing powder particles, one layer at a time.

DMLS increases the temperature of the particles only up to the point of fusion, whereby they combine at a molecular level. On the other hand, SLM completely melts metal particles. Both these techniques are heat-intensive and thus require support structures. Once the process ends, the support structures are removed using CNC machining or manually. Parts are then thermally treated to address residual stresses during post-processing.

These metal 3D printing techniques create components with high-quality physical properties, sometimes even more robust than the base metal used. The surface finish is often excellent as well. In terms of material, these techniques can process metal superalloys and ceramics that can be hard to use in other processes. However, both DMLS and SLM are cost-intensive, and the system’s volume constrains the output size.

2. VAT photopolymerization

VAT photopolymerization can be split into two methodologies: digital light processing (DLP) and stereolithography (SLA). Both these processes create components one layer at a time by using a light source to selectively cure liquid material (usually resin) stored in a vat.

DLP works by ‘flashing’ an image of each complete layer onto the surface of the liquid in the vat. On the other hand, SLA relies on a single-point UV source or laser to cure the liquid. Excess resin has to be cleaned off the output once printing is completed, after which the item must be exposed to light to improve its strength further. Support structures, if any, will need to be removed post-processing, and one can further process the part to create a higher quality finish.

These methods are best-suited for output that requires high-level dimensional accuracy, as they can create intricately detailed items with an excellent finish. DLP and SLA are, therefore, well-suited for the production of prototypes.

However, these methods’ output is often brittle, making them less suited for functional prototypes. These parts’ color and mechanical properties are also likely to degrade in the sun’s UV light, making them unsuitable for outdoor use. Finally, support structures are often required and might leave blemishes, which one can remove through post-processing.

3. Binder jetting

Binder jetting works by depositing a fine layer of powdered material, such as polymer sand, ceramic, or metal, onto the build platform. After this, a print head deposits adhesive drops to bind these particles. The part is hence built layer by layer.

Metal parts must be thermally sintered or infiltrated with a metal that has a low melting point, such as bronze. Parts made of ceramic or full-color polymer can be saturated using a cyanoacrylate adhesive. Post-processing is generally required to finish the output.

Binder jetting has numerous applications, including large-scale ceramic molds, full-color prototypes, and 3D metal printing.

4. Material jetting

Material jetting is conceptually similar to inkjet printing. However, instead of inserting ink on paper, it uses one or more print heads to deposit layers of liquid material. Each layer is cured before the next layer is produced. While material jetting relies on support structures, they can be created using a water-soluble substance that is washable after the building is completed.

This highly precise process is well-suited for creating full-color parts using different material types. However, it is cost-intensive, and the output tends to be brittle and degradable.

5. Fused deposition modeling

In fused deposition modeling (FDM), a heated nozzle is used to feed a filament spool to an extrusion head. The extrusion head increases the temperature of the material, softening it before placing it in predetermined areas to cool. Once a material layer is created, the build platform descends and prepares for the next layer to be placed.

This process, also known as material extrusion, features low lead times and is cost-effective. However, its dimensional accuracy is low, and a smooth finish often requires post-processing. The output is also not well-suited for critical applications as it tends to be anisotropic, i.e., weaker in one direction.

6. Sheet lamination

Sheet lamination can be further classified into two technologies: ultrasonic additive manufacturing (UAM) and laminated object manufacturing (LOM). UAM has a low energy and temperature requirement and works by joining thin metal sheets using ultrasonic welding. It works with several metals, including stainless steel, titanium, and aluminum. On the other hand, LOM places layers of material and adhesive alternatively to create the final output.

7. Direct energy deposition

This technique uses a laser, electric arc, electron beam, or another form of focused thermal energy to fuse powder or wire feedstock as it is placed. The process takes place horizontally to create layers, which are then stacked vertically for part creation. It is suited for different material types, including ceramics, polymers, and metals.

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Top 7 3D Printing Software

The 3D printing space is heavily software-dependent, with programs required for everything from designing the output and slicing it into G-code to controlling the 3D printer. Let’s check out the top 3D printing software across applications.

1. MatterControl 2.0

This solution by MatterHackers is an all-in-one printer host, slicer, and CAD software for desktops. Users can create new models in the CAD section and slice them. Once the model is ready to print, MatterControl 2.0 can be used to directly monitor and control printing via a USB connection or over a Wi-Fi module.

The software features an intuitive interface and allows users to explore a collection of geometric primitives that users can import into the print. These primitives can be dragged into position on the standard triangle language (STL) file to be printed and designated as support structures.

MatterControl also gives users access to advanced print configurations, making it ideal for end-to-end design, support preparation, slicing, and control. Enterprise users can upgrade to MatterControl Pro for even more valuable features.

2. Tinkercad

This free, browser-based solution allows users to design printable 3D models and provides a starting place for practicing solid modeling. Its easy-to-use block-building feature enables users to form models using basic shapes.

Tinkercad has numerous guides and tutorials to help users create the desired designs, which can then be exported or shared easily. Its library gives users access to millions of files, allowing them to find and modify the required shape. Finally, it features direct integration with third-party printing services.

3. Blender

This free, open-source tool is well-suited for both newbies and advanced users. It is feature-rich and can be used for 3D modeling and sculpting, as well as for animation, rendering, simulation, video editing, and motion tracking. However, it has a steep learning curve.

4. UVTools

This open-source solution is a comprehensive resin printing suite, an excellent file viewer, and optimized for layer repair and manipulation for masked SLA. It is compatible with PrusaSlicer, giving users access to numerous third-party MSLA printer profiles.

Twin-stage motor control (TSMC) is a crucial feature of UVTools, enabling tiered print speeds for different movement parts for each layer. This reduces print time and boosts the likelihood of print success.

Finally, UVTools allows users to create a custom resin layer cure time calibration print for testing new resins and setting the appropriate configuration for different layer heights.

5. WebPrinter

This browser-based solution can be used to preview G-code without having to open the file in a full-capability slicer. Users simply need to upload the G-code file, and WebPrinter will show the tool pathing that the file will transmit to the 3D printer. It is a fast and simple method to view a potential 3D print output.

6. Ultimaker Cura

This open-source slicer is compatible with most modern 3D printers. Cura is well-suited for beginners as it is easy to use, swift, and intuitive. On the other hand, advanced users can leverage it to access 200 settings for refining prints.

7. Simplify3D

Simplify3D is a powerful slicing tool for enhancing 3D print quality. It slices CAD into layers, corrects model issues, and showcases a user preview of the final output. Its premium features are handy for enterprise heavy-use 3D printers.

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3D Printing Applications

Although 3D printing is not a recent invention, it has gained immense popularity in recent times across industries due to its newfound simplicity, efficiency, and cost-effectiveness.

The top applications of 3D printing are:

1. Construction

Construction is one of the significant applications of 3D printing. Concrete 3D printing has been explored since the 1990s as researchers sought a faster and cheaper way to construct structures. Specific applications of 3D printing in construction include additive welding, powder bonding (reactive bond, polymer bond, sintering), and extrusion (foam, wax, cement/concrete, polymers).

Today, large-scale 3D printers designed to print concrete are used to pour foundations and erect site walls. They are also capable of printing modular concrete sections for onsite assembly. These solutions allow for higher accuracy, more complexity, faster construction, and improved functional integration while lowering labor costs and minimizing waste.

In 2016, the first pedestrian bridge (12 meters long, 1.75 meters wide) was 3D printed in Spain using micro-reinforced concrete. A year later, the first fully 3D-printed residence was built in Russia. 600 wall elements were 3D-printed and assembled, after which, the roof and interiors were created for a total area of nearly 300 sq meters.

3D printing is also helpful in producing architectural-scale models. It is even being explored as a solution for constructing extraterrestrial habitats on the Moon or Mars, should the need ever arise.

2. Prototyping and manufacturing

In the case of traditional injection-molded prototyping, it can take weeks to produce a single mold that would cost up to hundreds of thousands of dollars. As established earlier in the article, the original purpose of 3D printing was faster and more efficient prototyping.

3D printing technology minimizes lead times in manufacturing, enabling prototyping to be completed within a few hours and at a small percentage of traditional costs. This makes it especially ideal for projects where users must upgrade the design with every iteration.

3D printing is also suitable for manufacturing products that do not need to be mass-produced or are usually customized. SLS and DMLS are used in the rapid manufacturing of final products, not just prototypes.

3. Healthcare

In healthcare, 3D printing creates prototypes for new product development in the medical and dental fields. In dentistry, 3D printing is also helpful in creating patterns for casting metal dental crowns and manufacturing tools for creating dental aligners.

The solution is also helpful for directly manufacturing knee and hip implants and other stock items and creating patient-specific items such as personalized prosthetics, hearing aids, and orthotic insoles. The possibility of 3D-printed surgical guides for particular operations and 3D-printed bone, skin, tissue, organs, and pharmaceuticals is being explored.

4. Aerospace

In aerospace, 3D printing is used for prototyping and product development. The solution is also critically helpful in aircraft development, as it helps researchers keep up with the strenuous requirements of R&D without compromising on the high industry standards. Certain non-critical or older aircraft components are 3D-printed for the flight!

5. Automotive

Automotive enterprises, especially those specializing in racing automobiles, such as those used in F1, leverage 3D printing for prototyping and manufacturing specific components. Organizations in this space are also exploring the possibility of using 3D printing to fulfill aftermarket demand by producing spare parts as customers require rather than stocking them up.

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Takeaway

The term ‘3D printing’ encompasses numerous technologies and processes that collectively offer a wide range of capabilities for producing components using various materials. The key similarity across 3D printing types is the additive layer-by-layer production process where no subtractive methodology, molding, or casting is required. Applications of 3D printing are rapidly emerging across industry verticals as the solution becomes more effective and affordable and penetrates deeply and widely across sectors.

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3D Printing: What It Is, How It Works and Examples

3D printers might seem like they're right out of a science fiction movie, but they're proving to be useful in a variety of industries. | Image: Shutterstock

How Do 3D Printers Work?

3D printing is part of the additive manufacturing family and uses similar methods to a traditional inkjet printer — albeit in 3D. Additive manufacturing describes the process of creating something in layers, adding material continuously until the final design is complete. This term most often refers to molding and 3D printing. 

It takes a combination of top-of-the-line software, powder-like materials and precision tools to create a three-dimensional object from scratch. Below are a few of the main steps 3D printers take to bring ideas to life.

How Does a 3D Printer Work?

3D printers are related to additive manufacturing. 3D printers use computer-aided design to understand a design. When a design is ready, a material that can be dispensed through a hot nozzle or precision tool is printed layer by layer to create a three-dimensional object from scratch.

 

3D Modeling Software

The first step of any 3D printing process is 3D modeling. To maximize precision — and because 3D printers can’t magically guess what you want to print — all objects have to be designed in a 3D modeling software. Some designs are too intricate and detailed for traditional manufacturing methods. That’s where CAD software comes in. 

Modeling allows printers to customize their product down to the tiniest detail. The 3D modeling software’s ability to allow for precision designs is why 3D printing is being hailed as a true game changer in many industries. This modeling software is especially important to an industry, like dentistry, where labs are using 3D software to design teeth aligners that precisely fit to the individual. It’s also vital to the space industry, where they use the software to design some of the most intricate parts of a rocketship.

 

3D PRINTERS USE MODELING AND SLICING SOFTWARE TO GUIDE THE PRINTER IN CREATING EACH OBJECT. Video: Digital Trends

 

Slicing the Model

Once a model is created, it’s time to “slice” it. Since 3D printers cannot conceptualize the concept of three dimensions, like humans, engineers need to slice the model into layers in order for the printer to create the final product. 

Slicing software takes scans of each layer of a model and will tell the printer how to move in order to recreate that layer. Slicers also tell 3D printers where to “fill” a model. This fill gives a 3D printed object internal lattices and columns that help shape and strengthen the object. Once the model is sliced, it’s sent off to the 3D printer for the actual printing process.

 

The 3D Printing Process

When the modeling and slicing of a 3D object is completed, it’s time for the 3D printer to finally take over. The printer acts generally the same as a traditional inkjet printer in the direct 3D printing process, where a nozzle moves back and forth while dispensing a wax or plastic-like polymer layer-by-layer, waiting for that layer to dry, then adding the next level. It essentially adds hundreds or thousands of 2D prints on top of one another to make a three-dimensional object.

3D Printing Materials

There are a variety of different materials that a printer uses in order to recreate an object to the best of its abilities. Here are some examples:

Acrylonitrile Butadiene Styrene (ABS)

Plastic material that is easy to shape and tough to break. The same material that LEGOs are made out of.

Carbon Fiber Filaments

Carbon fiber is used to create objects that need to be strong, but also extremely lightweight.

Conductive Filaments

These printable materials are still in the experimental stage and can be used for printing electric circuits without the need for wires. This is a useful material for wearable technology.

Flexible Filaments

Flexible filaments produce prints that are bendable, yet tough. These materials can be used to print anything from wristwatches to phone covers.

Metal Filament

Metal filaments are made of finely ground metals and polymer glue. They can come in steel, brass, bronze and copper in order to get the true look and feel of a metal object.

Wood Filament

These filaments contain finely ground wood powder mixed with polymer glue. These are obviously used to print wooden-looking objects and can look like a lighter or darker wood depending on the temperature of the printer.

The 3D printing process takes anywhere from a few hours for really simple prints, like a box or a ball, to days or weeks for much larger detailed projects, like a full-sized home.

How Much Do 3D Printers Cost?

The cost of 3D printers vary based on the size, specialty and use. The cheapest 3D printers, for entry level hobbyists, typically range from $100 to $500. More advanced models can range between $300 and $5,000. Industrial 3D printers can cost up to $100,000.

 

3D Printing Processes and Techniques

here are also different types of 3D printers depending on the size, detail and scope of a project. Each different type of printer will vary slightly on how an object gets printed.

Fused Deposition Modeling (FDM)

FDM is probably the most widely used form of 3D printing. It’s incredibly useful for manufacturing prototypes and models with plastic.

Stereolithography (SLA) Technology 

SLA is a fast prototyping printing type that is best suited for printing in intricate detail. The printer uses an ultraviolet laser to craft the objects within hours.

Digital Light Processing (DLP) 

DLP is one of the oldest forms of 3D printing. DLP uses lamps to produce prints at higher speeds than SLA printing because the layers dry in seconds.

Continuous Liquid Interface Production (CLIP) 

CLIP is amongst the faster processes that use Vat Photopolymerisation. The CLIP process utilizes Digital Light Synthesis technology to project a sequence of UV images across a cross-section of a 3D printed part, resulting in a precisely controlled curing process. The part is then baked in a thermal bath or oven, causing several chemical reactions that allow the part to harden.

Material Jetting 

Material Jetting applies droplets of material through a small diameter nozzle layer-by-layer to build a platform, which becomes hardened by UV light.

Binder Jetting 

Binder Jetting utilizes a powder base material layered evenly along with a liquid binder, which is applied through jet nozzles to act as an adhesive for the powder particles.

Fused Deposition Modeling (FDM)

FDM, also known as Fused Filament Fabrication (FFF), works by unwinding a plastic filament from a spool and flowing through a heated nozzle in horizontal and vertical directions, forming the object immediately as the melted material hardens.

Selective Laser Sintering (SLS) 

A form of Powder Bed Fusion, SLS fuses small particles of powder together by use of a high-power laser to create a three-dimensional shape. The laser scans each layer on a powder bed and selectively fuses them, then lowering the powder bed by one thickness and repeating the process through completion.

Multi-Jet Fusion (MJF) 

Another form of Powder Bed Fusion, MJF uses a sweeping arm to deposit powder and an inkjet-equipped arm to apply binder selectively on top. Next, a detailing agent is applied around the detailing agent for precision. Finally, thermal energy is applied to cause a chemical reaction. Direct Metal Laser Sintering (DMLS) also utilizes this same process but with metal powder specifically.

Sheet Lamination

Sheet Lamination binds material in sheets through external force and welds them together through layered ultrasonic welding. The sheets are then milled in a CNC machine to form the object’s shape.

Directed Energy Deposition

Directed Energy Deposition is common in the metal industry and operates by a 3D printing apparatus attached to a multi-axis robotic arm with a nozzle for applying metal powder. The powder is applied to a surface and energy source, which then melts the material to form a solid object.

How a 3D printer works, what can be printed on a 3D printer

The 3D printer is a technology that allows you to create real objects from a digital model. It all started in the 80s under the name "rapid prototyping", which was the goal of the technology: to create a prototype faster and cheaper. A lot has changed since then, and today 3D printers allow you to create anything you can imagine.

Contents:

  • What is 3D printing?
  • How does a 3D printer work?
  • What can be printed?

The 3D printer allows you to create objects that are almost identical to their virtual models. That is why the scope of these technologies is so wide.

What is 3D printing?

3D printing is an additive manufacturing process because, unlike traditional subtractive manufacturing, 3D printing does not remove material, but adds it, layer by layer—that is, it builds or grows.

  1. In the first step of printing, the data from the drawing or 3D model is read by the printer.
  2. Next is the sequential overlay of layers.
  3. These layers, consisting of sheet material, liquid or powder, are combined with each other, turning into the final form.

With limited production of parts, 3D printing will be faster and cheaper. The world of 3D printing does not stand still and therefore there are more and more different technologies competing with each other on the market. The difference lies in the printing process itself. Some technologies create layers by softening or melting the material, then they provide layer-by-layer application of this same material. Other technologies involve the use of liquid materials, which acquire a solid form in the process under the influence of various factors.

In order to print something , you first need a 3D model of the object, which you can create in a 3D modeling program (CAD - Computer Aided Design), or use a 3D scanner to scan the object you want print. There are also easier options, such as looking for models on the internet that have been created and made available to other people.

Once your design is ready, all you need to do is import it into the Slicer, a program that converts the model into codes and instructions for a 3D printer, most of the programs are open source and free. The slicer will convert your project into a gcode file ready to be printed as a physical object. Simply save the file to the included SD card and insert it into your 3D printer and hit print.

The whole process can take several hours and sometimes several days. It all depends on the size, material and complexity of the model. Some 3D printers use two different materials. One of them is part of the model itself, the other acts as a prop that supports parts of the model hanging in the air. The second material is subsequently removed.

How does a 3D printer work?

Although there are several 3D printing technologies, most create an object by building up many successive thin layers of material. Typically desktop 3D printers use plastic filaments (1) which are fed into the printer by the feeder (2) . The filament melts in the print head (3) which extrudes the material onto the platform (4) creating the object layer by layer. Once the printer starts printing, all you have to do is wait - it's easy.

Of course, as you become an advanced user, playing with the settings and tweaking your printer can lead to even better results.

What can be 3D printed?

The possibilities of 3D printers are endless and they are now becoming a common tool in fields such as engineering, industrial design, manufacturing and architecture. Here are some typical usage examples:

Custom Models

Create custom products that perfectly match your needs in terms of size and shape. Do something that would be impossible with any other technology.

Rapid Prototyping

3D printing allows you to quickly create a model or prototype, helping engineers, designers and companies get feedback on their projects in a short time.

Complex geometry

Models that are hard to imagine can be easily created with a 3D printer. These models are good for teaching others about complex geometry in a fun and useful way.

Cost reduction

The cost of 3D printing end-use parts and prototypes is low due to the materials and technology used. Reduced production time and material consumption as you can print models multiple times using only the material you need.

How to choose and buy a 3D printer? →

How does a 3D printer work and what is it for - Code magazine

Over the past couple of years, there has been a lot of news about someone printing something on a 3D printer:

  • hearing aid,
  • milk products,
  • residential building,
  • robotic fingers,
  • brain implants,
  • 1mm statue of David,
  • prefabricated electronic devices.

Let's figure out how this technology works, what its limitations are and whether it has a future.

What a 3D printer is for

3D printers print three-dimensional things from plastic or other materials. They can be used at home or in production. For example, here is what you can 3D print:

Battery case. Hinged LED lamp. Minecraft style lamp. Model of an old castle.

How it works

Usually a 3D printer uses special plastic to print. It comes in the form of powder, liquid resin or plastic wire in coils. It is from this material that the printed part will consist.

Further, roughly speaking, the process looks like this:

  • this plastic is either applied using a moving nozzle;
  • or "baked" with a laser;
  • or the excess is cut out of the mass of the finished material using a movable cutter (but this is more like turning and is often not classified as 3D printing).

The material takes on the shape you want, layer by layer. When all layers are passed, the detail turns out.

Fast 3D Printing with Moving Nozzle:

Due to the fact that the printer needs to constantly heat the plastic, 3D printers do not print very quickly: a part the size of a phone can take 15-20 minutes. The speed also depends on the thickness of the layer: the thicker the layer, the faster the print. But with a large layer thickness, the part may turn out to be sloppy: layers will be visible:

The thinner the layer, the more even the surface is when printed.

Printing Technologies

3D printing is very much needed in industry and industrial design, so there is a whole zoo of printing technologies, each with its own advantages and disadvantages.

Stereolithography . Instead of plastic, a special resin is used here, which hardens in the light. The detail is also formed in layers, but the layers themselves are almost invisible - the resin fills the relief and the detail seems to be a single whole even from a very close distance.

Polymer synthesis (SLS) . This type of printing uses powder, which is then baked with a laser beam. Since the laser beam can be focused anywhere with the desired accuracy, very complex models with high detail can be obtained in this way of printing:

Polyjet. The peculiarity of this technology is that it can print objects simultaneously from different materials. This allows you to create almost any thing of the most complex shape, which immediately have the desired properties. You can even print sneakers that you can wear on this printer:

What can be printed

Anything can be printed on a 3D printer if you have the right material for printing, a finished model and a large enough printer.

Prototypes. Often, before starting production, a company needs to understand how comfortable a thing will turn out to be in use. In order not to launch a line for the sake of one product, it is printed on a 3D printer and they look at what needs to be changed or finalized. On such prototypes, you can notice, for example, that the buttons turned out to be too small and it would be inconvenient to press them, or that the buttons turned out to be very far from the fingers and you will need to reach them specially.

Parts and parts. Sometimes it is difficult or almost impossible to find a spare part for a tool: the manufacturer does not produce them or the model has been out of production for a long time. In this case, you can find a three-dimensional model of the desired part on the Internet or draw it yourself in the editor, so that you can then send it to print.

Medicine. 3D printing is actively used in medicine to create new joints, tissues and treat patients. The difference from traditional printing is that instead of plastic, they print with special “living” solutions that interact with each other and behave like real organs and tissues. Thanks to this technology, it is now easy to print a joint that a surgeon can put on a person instead of a damaged one.

Hobbies and modeling. It is easy to print various miniatures, collectible figurines and models with a 3D printer.

Manufacture of other robots. 3D printers do not yet know how to produce servos and microprocessors, but they already know how to print bodies and frames of robots.

Houses and buildings. We take hefty rails with motors and controllers. We install a movable nozzle, on which you can supply a building mixture (concrete or polymers). You can print the walls of buildings. Unlike traditional brick, panel and block construction technologies, the shape of the walls and the building as a whole can be any. The foundation, floors and roof are not yet printed, but this is for now.

Imagine: we send fifty 3D printers on a mobile basis to Mars. For a year, each of them prints another 100 printers. Then all these 5,000 printers disperse around Mars and begin to build the first colony. While they are building, we order furniture from Ikea, arrange delivery, and just in time for delivery, our robots will finish printing everything. Apple trees on Mars are unlikely to bloom, but five-story buildings can.

Criticisms and issues

❌ Slow and no guarantees: printing is quite slow, not accurate enough. A huge problem in amateur printers is marriage. For example, a part can peel off the substrate right during printing, and hell will happen. Or the motors will decalibrate, and the nozzle will begin to miss the right places.

❌ Low efficiency: to print a 10 x 10 cm part, you need a printer that is at least 50 x 50 cm, which will cost several hundred dollars.

❌ Not the strongest materials: 3D printing is currently limited to plastics and resins. There are separate printing technologies based on metal powder, but if you need a steel part, you don’t need a 3D printer, but a normal turner and machine tool. But not every detail can be made on the machine.

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