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Types of 3D Printers, 3D Printing Materials, and Applications

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3D printing or additive manufacturing (AM) technologies create three-dimensional parts from computer-aided design (CAD) models by successively adding material layer by layer until physical part is created.

While 3D printing technologies have been around since the 1980s, recent advances in machinery, materials, and software have made 3D printing accessible to a wider range of businesses, enabling more and more companies to use tools previously limited to a few high-tech industries.

Today, professional, low-cost desktop and benchtop 3D printers accelerate innovation and support businesses in various industries including engineering, manufacturing, dentistry, healthcare, education, entertainment, jewelry, and audiology.

All 3D printing processes start with a CAD model that is sent to software to prepare the design. Depending on the technology, the 3D printer might produce the part layer by layer by solidifying resin or sintering powder. The parts are then removed from the printer and post-processed for the specific application.

See how to go from design to 3D print with the Form 3 SLA 3D printer. This 5-minute video covers the basics of how to use the Form 3, from the software and materials to printing and post-processing.

3D printers create parts from three-dimensional models, the mathematical representations of any three-dimensional surface created using computer-aided design (CAD) software or developed from 3D scan data. The design is then exported as an STL or OBJ file readable by print preparation software.

3D printers include software to specify print settings and slice the digital model into layers that represent horizontal cross-sections of the part. Adjustable printing settings include orientation, support structures (if needed), layer height, and material. Once setup is complete, the software sends the instructions to the printer via a wireless or cable connection.

Some 3D printers use a laser to cure liquid resin into hardened plastic, others fuse small particles of polymer powder at high temperatures to build parts. Most 3D printers can run unattended until the print is complete, and modern systems automatically refill the material required for the parts from cartridges.

With Formlabs 3D printers, an online Dashboard allows you to remotely manage printers, materials, and teams.

 

Depending on the technology and the material, the printed parts may require rinsing in isopropyl alcohol (IPA) to remove any uncured resin from their surface, post-curing to stabilize mechanical properties, manual work to remove support structures, or cleaning with compressed air or a media blaster to remove excess powder. Some of these processes can be automated with accessories.

3D printed parts can be used directly or post-processed for specific applications and the required finish by machining, priming, painting, fastening or joining. Often, 3D printing also serves as an intermediate step alongside conventional manufacturing methods, such as positives for investment casting jewelry and dental appliances, or molds for custom parts.

The three most established types of 3D printers for plastics parts are stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM). Formlabs offers two professional 3D printing technologies, SLA and SLS, bringing these powerful and accessible industrial fabrication tools into the creative hands of professionals around the world.

Stereolithography was the world’s first 3D printing technology, invented in the 1980s, and is still one of the most popular technologies for professionals. SLA 3D printers use a laser to cure liquid resin into hardened plastic in a process called photopolymerization.

SLA resin 3D printers have become vastly popular for their ability to produce high-accuracy, isotropic, and watertight prototypes and parts in a range of advanced materials with fine features and smooth surface finish. SLA resin formulations offer a wide range of optical, mechanical, and thermal properties to match those of standard, engineering, and industrial thermoplastics.

Resin 3D printing a great option for highly detailed prototypes requiring tight tolerances and smooth surfaces, such as molds, patterns, and functional parts. SLA 3D printers are widely used in a range of industries from engineering and product design to manufacturing, dentistry, jewelry, model making, and education.

  • Rapid prototyping
  • Functional prototyping
  • Concept modeling
  • Short-run production
  • Dental applications
  • Jewelry prototyping and casting

Learn More About SLA 3D Printers

Stereolithography (SLA) 3D printing uses a laser to cure liquid photopolymer resin into solid isotropic parts.

SLA parts have sharp edges, a smooth surface finish, and minimal visible layer lines.

Selective laser sintering (SLS) 3D printers use a high-power laser to sinter small particles of polymer powder into a solid structure. The unfused powder supports the part during printing and eliminates the need for dedicated support structures. This makes SLS ideal for complex geometries, including interior features, undercuts, thin walls, and negative features. Parts produced with SLS printing have excellent mechanical characteristics, with strength resembling that of injection-molded parts.

The most common material for selective laser sintering is nylon, a popular engineering thermoplastic with excellent mechanical properties. Nylon is lightweight, strong, and flexible, as well as stable against impact, chemicals, heat, UV light, water, and dirt.

The combination of low cost per part, high productivity, and established materials make SLS a popular choice among engineers for functional prototyping, and a cost-effective alternative to injection molding for limited-run or bridge manufacturing.

  • Functional prototyping
  • End-use parts
  • Short-run, bridge, or custom manufacturing

Learn More About SLS 3D Printers

SLS 3D printers use a high-powered laser to fuse small particles of polymer powder.  

SLS parts have a slightly rough surface finish, but almost no visible layer lines.

Fused deposition modeling (FDM), also known as fused filament fabrication (FFF), is the most widely used type of 3D printing at the consumer level. FDM 3D printers work by extruding thermoplastic filaments, such as ABS (Acrylonitrile Butadiene Styrene), PLA (Polylactic Acid), through a heated nozzle, melting the material and applying the plastic layer by layer to a build platform. Each layer is laid down one at a time until the part is complete.

FDM 3D printers are well-suited for basic proof-of-concept models, as well as quick and low-cost prototyping of simple parts, such as parts that might typically be machined. However, FDM has the lowest resolution and accuracy when compared to SLA or SLS and is not the best option for printing complex designs or parts with intricate features. Higher-quality finishes may be obtained through chemical and mechanical polishing processes. Industrial FDM 3D printers use soluble supports to mitigate some of these issues and offer a wider range of engineering thermoplastics, but they also come at a steep price.

  • Basic proof-of-concept models
  • Simple prototyping

Learn More About FDM 3D Printers

FDM 3D printers build parts by melting and extruding thermoplastic filament, which a printer nozzle deposits layer by layer in the build area.

FDM parts tend to have visible layer lines and might show inaccuracies around complex features. 

Having trouble finding the best 3D printing process for your needs? In this video guide, we compare FDM, SLA, and SLS technologies, the most popular types of 3D printers, across the most important buying considerations.

Each 3D printing process has its own benefits and limitations that make them more suitable for certain applications. This video compares the functional and visual characteristics of FDM, SLA, and SLS printers 3D printers to help you identify the solution that best matches your requirements.

Do you need custom parts or prototypes fast? Compared to outsourcing to service providers or using traditional tools like machining, having a 3D printer in-house can save weeks of lead time. In this video, we compare the speed of FDM, SLA, and SLS 3D printing processes.

Comparing the cost of different 3D printers goes beyond sticker prices—these won’t tell you the full story of how much a 3D printed part will cost. Learn the three factors you need to consider for cost and how they compare across FDM, SLA, and SLS 3D printing technologies.

As additive manufacturing processes build objects by adding material layer by layer, they offer a  unique set of advantages over traditional subtractive and formative manufacturing processes.

With traditional manufacturing processes, it can take weeks or months to receive a part. 3D printing turns CAD models into physical parts within a few hours, producing parts and assemblies from one-off concept models to functional prototypes and even small production runs for testing. This allows designers and engineers to develop ideas faster, and helps companies to bring products more quickly to the market.

Engineers at the AMRC turned to 3D printing to rapidly produce 500 high-precision drilling caps used in drilling trials for Airbus, cutting the lead time from weeks to only three days.

With 3D printing, there’s no need for the costly tooling and setup associated with injection molding or machining; the same equipment can be used from prototyping to production to create parts with different geometries. As 3D printing becomes increasingly capable of producing functional end-use parts, it can complement or replace traditional manufacturing methods for a growing range of applications in low- to mid-volumes.

Pankl Racing Systems substituted machined jigs and fixtures with 3D printed parts, decreasing costs by 80-90 percent that resulted in $150,000 in savings.

From shoes to clothes and bicycles, we’re surrounded by products made in limited, uniform sizes as businesses strive to standardize products to make them economical to manufacture. With 3D printing, only the digital design needs to be changed to tailor each product to the customer without additional tooling costs. This transformation first started to gain a foothold in industries where custom fit is essential, such medicine and dentistry, but as 3D printing becomes more affordable, it’s increasingly being used to mass customize consumer products.

Gillette's Razor Maker™ gives consumers the power to create and order customized 3D printed razor handles, with the choice of 48 different designs (and counting), a variety of colors, and the option to add custom text.

3D printing can create complex shapes and parts, such as overhangs, microchannels, and organic shapes, that would be costly or even impossible to produce with traditional manufacturing methods. This provides the opportunity to consolidate assemblies into less individual parts to reduce weight, alleviate weak joints, and cut down on assembly time, unleashing new possibilities for design and engineering.

Nervous System launched the first-ever 3D printed ceramic jewelry line, consisting of intricate designs that would be impossible to manufacture using any other ceramic technique.

Product development is an iterative process that requires multiple rounds of testing, evaluation, and refinement. Finding and fixing design flaws early can help companies avoid costly revisions and tooling changes down the road. With 3D printing, engineers can thoroughly test prototypes that look and perform like final products, reducing the risks of usability and manufacturability issues before moving into production.

The developers of Plaato, an optically clear airlock for homebrewing, 3D printed 1,000 prototypes to fine tune their design before investing in expensive tooling.

3D printing accelerates innovation and supports businesses across a wide range of industries, including engineering, manufacturing, dentistry, healthcare, education, entertainment, jewelry, audiology, and more.
 

Rapid prototyping with 3D printing empowers engineers and product designers to turn ideas into realistic proofs of concept, advance these concepts to high-fidelity prototypes that look and work like final products, and guide products through a series of validation stages toward mass production.

Applications:

  • Rapid prototyping
  • Communication models
  • Manufacturing validation

Learn More

Manufacturers automate production processes and streamline workflows by prototyping tooling and directly 3D printing custom tools, molds, and manufacturing aids at far lower costs and lead times than with traditional manufacturing. This reduces manufacturing costs and defects, increases quality, speeds up assembly, and maximizes labor effectiveness.

Applications:

  • Jig and fixtures
  • Tooling
  • Molding (injection molding, thermoforming, silicone molding, overmolding)
  • Metal casting
  • Short run production
  • Mass customization

Learn More

3D printers are multifunctional tools for immersive learning and advanced research. They can encourage creativity and expose students to professional-level technology while supporting STEAM curricula across science, engineering, art, and design.

Applications:

  • Models for STEAM curricula
  • Fab labs and makerspaces
  • Custom research setups

Learn More

Affordable, professional-grade desktop 3D printing helps doctors deliver treatments and devices customized to better serve each unique individual, opening the door to high-impact medical applications while saving organizations significant time and costs from the lab to the operating room.

Applications:

  • Anatomical models for surgical planning
  • Medical devices and surgical instruments
  • Insoles and orthotics

Learn More

High definition physical models are widely used in sculpting, character modeling, and prop making. 3D printed parts have starred in stop-motion films, video games, bespoke costumes, and even special effects for blockbuster movies.

Applications:

  • Hyper-realistic sculptures
  • Character models
  • Props

Learn More

Jewelry professionals use CAD and 3D printing to rapidly prototype designs, fit clients, and produce large batches of ready-to-cast pieces. Digital tools allow for the creation of consistent, sharply detailed pieces without the tediousness and variability of wax carving.

Applications:

  • Lost-wax casting (investment casting)
  • Fitting pieces
  • Master patterns for rubber molding

Learn More

Hearing specialists and ear mold labs use digital workflows and 3D printing to manufacture higher quality custom ear products more consistently, and at higher volumes for applications like behind-the-ear hearing aids, hearing protection, and custom earplugs and earbuds.

Applications:

  • Soft silicone ear molds
  • Custom earbuds

Learn More

The market for 3D printing materials is wide and ever-growing, with printers for everything from plastics to metals, and even food and live tissue in development. Formlabs offers the following range of photopolymer materials for the desktop.

 

Standard 3D printing materials provide high resolution, fine features, and a smooth surface finish ideal for rapid prototyping, product development, and general modeling applications.

These materials are available in Black, White, and Grey with a matte finish and opaque appearance, Clear for any parts requiring translucency, and as a Color Kit to match almost any custom color.

Explore Standard Materials

3D printing materials for engineering, manufacturing, and product design are formulated to provide advanced functionality, withstand extensive testing, perform under stress, and remain stable over time.

Engineering materials are ideal for 3D printing strong, precise concept models and prototypes to rapidly iterating through designs, assess form and fit, and optimize manufacturing processes.

Explore Engineering Materials

Medical resins empower hospitals to create patient-specific parts in a day at the point of care and support R&D for medical devices. These resins are formulated for 3D printing anatomical models, medical device and device components, and surgical planning and implant sizing tools.

Explore Jewelry Materials

Jewelry resins are formulated to capture breathtaking detail and create custom jewelry cost-effectively. These resins are ideal for jewelry prototyping and casting jewelry, as well as vulcanized rubber and RTV molding.

Explore Jewelry Materials

Specialty Resins push the limits of 3D printing, featuring advanced materials with unique mechanical properties that expand what’s possible with in-house fabrication on our stereolithography 3D printers.  

Explore Specialty Materials

In recent years, high-resolution industrial 3D printers have become more affordable, intuitive, and reliable. As a result, the technology is now accessible to more businesses. Read our in-depth guide about 3D printer costs, or try our interactive tool to see if this technology makes economic sense your business.

Calculate Your Savings

New to 3D printing? Explore our guides to learn about the key terms and specific characteristics of 3D printing to find the best solution for your business.

For further questions, 

Explore 3D Printing Resources

With This 3-D Printer, Objects Emerge From a Plastic Soup

It might be the future of manufacturing, but 3-D printing is built on a 2-D foundation: A MakerBot is essentially an inkjet printer that spits out plastic instead of ink. Keep printing in the same spot, over and over, and the layers will eventually form a 3-D object from the bottom up. But an outfit called Carbon3D is taking the opposite tack: Its new rig creates objects from the top down, in one continuous motion. It’s faster and eliminates the layering that can result in weak, jagged objects.

Inspired by the mercurial T-1000 bot from Terminator 2, University of North Carolina professor Joseph DeSimone wanted to make objects emerge from liquid. The process is based on a 30-year-old printing technology called stereo­lithography. It starts with a bath of liquid resin that hardens when exposed to UV light. A projector underneath deliv­ers targeted blasts of UV to shape the form from below as the overhead platform lifts, drawing the object out of the soup.

The method has some limits. Oxygen inhibits the chemical reaction that solidifies the resin, slowing the process some­what. But rather than fighting that limitation, DeSimone harnessed it. A sheet of glass between the projector and the resin is gas-permeable like a contact lens, and the oxygen keeps the resin from hardening too soon, before the object is com­plete.

1. Object-building platform
2. UV-curable liquid resin
3. Microthin layer of oxygenated resin
4. Oxygen-permeable glass
5. Ultraviolet-light projector
BROWN BIRD DESIGN

Even with this effect, the Carbon3D can print up to 100 times faster than leading 3-D and stereolithographic printers. In a video that ricocheted around the Internet after DeSimone pre­sented it at TED, the device pulls a model of the Eiffel Tower out of the goo, as if it had just been sitting in the liquid all along.

Carbon3D has a team developing new materials for the printer. “We're pioneering new resins for our machine and also working with the chemical industry to evolve what’s already available,” says Rob Schoeben, the com­pany’s chief marketing and strategy officer. “As long as a material is in the polymer family, we should be able to do it.”

The machine has vast potential. Rather than warehousing and shipping car parts, technicians could make components for older models on the spot from designs stored in the cloud. Aeronautical engineers could print high-strength, low-weight lattice structures to replace, for example, components in passenger seats, lightening the payload and increasing fuel efficiency in planes. And Carbon3D could prove invaluable for medical applications: Custom molds could be made onsite at a dentist’s office, and stents or other emergency implants could be custom-printed on-demand in the hospital.

Right now, Carbon3D has prototypes running at auto behemoth Ford in Dearborn, Michigan, at an athletic apparel company, and at a special-effects house in San Fernando, California, with an eye to hitting the market in 2016. But it has no shape-shifting bots that are hell bent on destroying humanity. Yet.

3D printer for liquid testing — Stock Video © Marina1408 #157899656

3D printer for liquid testing — Stock Video © Marina1408 #157899656

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3D printer for fluid testing. 3D printer print pancakes with liquid dough of various shapes close-up. Modern additive technologies 4.0 — Video by Marina1408

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    3D Printer Comparison Guide 2020

    The market for 3D printing and additive manufacturing has changed significantly in recent years. While technology used to be mostly a hobbyist business, high-end desktop machines have turned it into an indispensable tool for businesses. After 3D printing became the main tool for prototyping and product design, it has become widely used in manufacturing, dentistry, jewelry and many other fields. nine0003

    Fused Deposition Modeling (FDM) and Stereolithography (SLA) printers are the two most popular types of 3D printers on the market. Both 3D printing technologies have been adapted and enhanced for desktop use, increasing their accessibility, functionality and usability.

    In this comprehensive buyer's guide, we take a closer look at FDM and SLA 3D printers and compare them in terms of print quality, materials, application, workflow, speed, cost, and more to help you determine which method is the most suitable for your business. nine0003

    VIDEO MANUAL

    Can't find the 3D printing technology that best suits your needs? In this video tutorial, we compare Fused Deposition Modeling (FDM), Stereolithography (SLA), and Selective Laser Sintering (SLS) technologies in terms of the top factors to consider when purchasing.

    Watch Video

    Fused Deposition Modeling (FDM), also known as Fused Filament Manufacturing (FFF), is the most widely used form of 3D printing at the consumer level. The working principle of FDM 3D printers is to extrude thermoplastic filaments such as ABS (Acrylonitrile Butadiene Styrene), PLA (Polylactide) through a heated nozzle, melt the material, and deposit the plastic on the build platform layer by layer. Layers are applied sequentially one after another until the model is ready. nine0003

    See how FDM 3D printing is done.

    FDM 3D printers are well suited for making basic experimental models, as well as for quickly and inexpensively prototyping simple parts, such as parts that are usually machined.

    Invented in the 1980s, stereolithography is the world's first 3D printing technology and is still one of the most popular technologies among professionals today. SLA 3D printers use a process called photopolymerization, which is the conversion of liquid polymers into hardened plastic using a laser. nine0003

    See how SLA 3D printing is done.

    Resin-based SLA 3D printers have become extremely popular due to their ability to produce highly accurate, isotropic and waterproof prototypes and models with excellent detail and smooth surfaces. SLA polymers offer a wide range of optical, mechanical and thermal properties that match those of standard, engineering and industrial thermoplastics.

    Resin 3D printing is an excellent option for producing highly detailed prototypes that require tight tolerances and smooth surfaces such as molds, templates and functional parts. SLA 3D printers are widely used in industries ranging from engineering and design to manufacturing, dentistry, jewelry, modeling, and education.

    White Paper

    Download our white paper to find out how SLA printing works, why thousands of professionals use it today, and how this 3D printing technology can be useful in your work. nine0003

    Download white paper

    When additive manufacturing builds a model layer by layer, each layer contains the potential for inaccuracies. The layering process affects the surface quality, the level of accuracy and correctness of each layer, and therefore the overall print quality.

    FDM 3D printers form layers through the application of lines of molten material. During this process, the resolution of the model is determined by the size of the extrusion nozzle, and when lines are drawn with the nozzle, voids are created between the rounded lines. As a result, the layers may not be completely adjacent to each other, they are usually clearly visible on the surface, and, in addition, there is no ability to reproduce the complex details that other technologies offer. nine0003

    In SLA 3D printing, each layer is formed by curing a liquid polymer with a high-precision laser, which allows you to get models with greater detail and achieve high quality on a consistent basis. As a result, SLA 3D printing is known for excellent detail, smooth surfaces, high precision models and accurate rendering.

    3D Printing Accuracy, Accuracy and Tolerance are terms that are not entirely clear and often misunderstood. Find out what they mean to get a better idea of ​​3D printing quality. nine0190

    Models created using SLA technology have sharp edges, smooth surfaces and almost invisible layer lines. This sample was printed on a Formlabs Form 3 desktop stereolithography 3D printer.

    Using light instead of heat in the printing process is another way to ensure the print quality of SLA printers. Since 3D models are printed at close to room temperature, they do not suffer from the thermal expansion and contraction distortions that can occur during FDM printing. nine0003

    Due to the high-precision laser, SLA 3D printers are better suited for making complex parts (FDM printed part on the left, SLA printed part on the right).

    While FDM printers create a mechanical bond between layers, SLA 3D printers create chemical bonds between photopolymers by cross-linking photopolymers, resulting in dense, waterproof and airtight models. These bonds provide a high degree of shear strength resulting in isotropic parts, which means that the strength of the parts does not change depending on the direction. This makes the use of SLA 3D printing especially useful in the field of engineering and manufacturing, where material properties are important.

    The difference in quality is less noticeable on relatively simple parts. However, SLA parts are dense and isotropic, so they find more use in design and manufacturing (left - FDM printed part on the left, right - SLA printed part on the right). nine0003

    free sample

    Experience Formlabs print quality firsthand. We will send a free 3D printing sample directly to your office.

    Request a Free Sample

    Extrusion 3D printers use a range of standard thermoplastic filaments such as ABS, PLA and various blends thereof. The popularity of FDM 3D printing among hobbyists has led to a large number of colors available. There are also various experimental mixtures of plastic threads designed to create models with a surface that mimics wood or metal. nine0003

    Engineering materials such as nylon, PETG, PA or TPU and high strength thermoplastics such as PEEK or PEI are also available, but in most cases only certain professional FDM printers support them.

    FDM filaments and blends offer various color options. (source: All3DP.com)

    The advantage of SLA polymers lies in the wide range of formulations that offer a variety of characteristics: they can be soft or hard, contain additives such as glass and ceramic, have special mechanical properties, such as high bending temperature under load or shock resistance. The polymers offer a wide range of optical, mechanical and thermal properties that match those of standard, engineering and industrial thermoplastics. nine0003

    SLA 3D printers provide access to a variety of materials for design and production.

    In some cases, it is this combination of versatility and functionality that leads businesses to adopt SLA 3D printing in-house. Once a solution has been found with a particular functional polymer, other applications are usually quickly discovered, and the printer becomes a tool for exploiting the diverse properties of different polymers. nine0003

    Some properties of SLA polymers are unique. Among them:

    SLA is the only 3D printing technology that allows you to create transparent models on a desktop printer. Ideal for enhancing the visibility of complex assemblies, (micro)fluidic elements, mold making, optics, lighting elements and any product requiring transparency.

    Learn more

    Parts printed with this material look and feel like silicone; They are durable enough to be used multiple times. nine0003

    Learn more

    Offers the highest HDT of 238°C at 0.45 MPa, the highest temperature resistance of any desktop 3D printing material.

    Learn more

    Resin with 20% wax for investment casting and pressing of dental and jewellery.

    Learn more

    Specialty resins for dental products such as biocompatible surgical guides, splints, permanent casts and dentures, clear aligner patterns, and complete dentures. nine0003

    Learn more

    Resin for 3D printing of models with a stone-like texture and subsequent production of a ceramic product by firing.

    Learn more

    Material selection

    Our interactive material wizard helps you select the right material from our growing range of polymers based on the future application of the material and the properties that matter most to you.

    Get material recommendations

    Both FDM and SLA 3D printing workflow consists of three steps: design, 3D printing, and post-processing. nine0003

    First, a model is designed using CAD software or 3D scan data and exported to a 3D print file format (STL or OBJ). Then you need to use the software to prepare the 3D model for printing, in particular, set the print parameters and separate the digital model into layers.

    Budget FDM or SLA 3D printers are not very convenient in terms of usability: finding the right print settings for them requires experimentation and often takes hours. Even so, when using a new design or material, the print result may change, and the probability of rejection remains high. This not only causes delays in projects, but can also cause printer failure that will take a long time to resolve. nine0003

    Professional SLA 3D printers such as the Form 3 and some professional FDM printers come with their own proprietary software and presets for each material that have been rigorously tested to ensure the best printing results.

    With advanced print preparation tools such as PreForm, print setup is plug and play. PreForm software is available as a free download and you can try it right now. nine0172 .

    Once the 3D printing process has started, most 3D printers can run it without an operator, even overnight, until the model is finished. Advanced SLA 3D printers such as the Form 3 automatically refill resins from cartridges.

    The last step in the workflow is post-processing. Models produced by SLA require rinsing with isopropyl alcohol (IPA) or alternative solvents to remove uncured polymers from their surface. The standard workflow involves first removing the models from the build platform and then manually soaking them in a solvent bath to remove excess resin. nine0003

    Professional solutions such as Form Wash automate this process. Models from the printer are transferred to the Form Wash station, which cleans the models by stirring the solvent around them and automatically removes the models from the alcohol bath when the process is complete.

    After washed models have dried, some SLA resins require final curing , a process that helps models achieve the highest possible strength and stability. nine0003

    The advantage of the FDM method is that it does not require cleaning; models without supporting structures are ready for use or post-processing immediately after the printing process is completed.

    In both FDM and SLA printing, support structures can be used to facilitate 3D printing of complex shapes, and their removal is the last step in post-processing.

    On FDM models, the supporting structures must be separated manually or dissolved in water, depending on the material of the structure. nine0003

    Obtaining a high quality surface on FDM models with supporting structures requires additional post-processing (source: 3D Hubs).

    Removal of the supporting structures on SLA models consists of cutting off the supporting structures and lightly sanding the models to remove traces of the supports. Formlabs Low Force Stereolithography (LFS) ™ technology offers easy-to-release supports that allow separation of the object from the supporting structure in seconds and with minimal marks, reducing post-processing costs. nine0003

    In additional post-processing, both FDM and SLA models can be machined, primed, painted or assembled depending on the application. However, before priming or painting, FDM models require additional sanding, and for machining or drilling, a higher filling density is required.

    Use our easy-to-use interactive tool to help you calculate model costs and lead times using your Form 2 3D printer and compare time and cost savings with other manufacturing methods. nine0003

    One of the main advantages of FDM 3D printers is the low cost of the device. Entry-level FDM printers are available for as little as a few hundred dollars, giving hobbyists and small businesses a chance to see 3D printing in action and decide whether to add the technology to their toolbox. For novice users, the lower cost of an entry-level FDM printer is often an argument for making a purchase. However, inexpensive FDM printers can be unreliable and often require specialized knowledge for long-term use. nine0003

    Professional desktop FDM printers are easier to use and more suitable for business applications and are priced between $2,000 and $8,000. Such 3D printers typically offer higher reliability, higher print quality, and higher print volumes. Although these devices are suitable for the production of functional models, competition in this price category is strong, since the scope of SLA printers is wider and the print quality is better.

    SLA 3D printers start at $3750 and only Formlabs releases SLA Large Format 3D Printer priced under $11,000.

    In terms of materials, FDM filaments also have a relatively low cost compared to materials used in other 3D printing technologies. Commonly used FDM materials such as ABS, PLA and their various blends typically cost around $50/kg, while specialized FDM filaments for engineering applications can cost $100-150/kg. Soluble support materials for dual extrusion FDM 3D printers sell for $100-200/kg. By comparison, most standard and engineered resins for SLA 3D printers cost $50-$150/L. nine0003

    Labor is the last and often overlooked part of the equation. FDM models of simple form, which do not need support structures when printed, require almost no post-processing. For FDM models with supporting structures and parts where high surface quality is important, lengthy manual post-processing is required.

    SLA models require rinsing and, depending on the material, also final polymerization, but in most cases both processes can be automate with accessories , thus minimizing labor costs. SLA models with support structures require only minimal sanding to remove support marks and achieve a high quality finish.

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    FDM printers can print in thicker layers and typically use lower infill density to speed up the 3D printing process. FDM also has fewer post-processing steps for simple models. Depending on the specific project, this means that the models are ready for use shortly after printing is completed. This is very useful for tasks such as rapid prototyping - users can quickly evaluate the result and move on to printing another model or project. nine0003

    However, the speed advantage of FDM is currently waning due to the introduction of faster SLA resins such as Draft Resin , which prints 40% faster than FDM 3D printers. With a layer thickness of 300 µm, Draft Resin achieves sufficient precision to meet the needs of prototyping while enabling faster design iteration cycles. If the model occupies the entire working volume, it can take up to 20 hours for the SLA printer to produce it using standard resins, which will require printing at night. Printing the same part in 300 micron layers with Draft Resin takes less than six hours. nine0003

    These are six prototype pump housings printed using Draft Resin. It took 3 hours and 7 minutes to print one prototype with standard resins, and 47 minutes with Draft Resin. The final model was printed using Tough Resin and Rigid Resin.

    With the same layer thickness, the print speed of FDM and SLA printers becomes comparable. Please note that due to the way the layers are formed, a part printed with 100 micron layers on an FDM printer is very different from a part printed with 100 micron layers on an SLA printer. Achieving comparable quality on an FDM printer would require a thinner layer—which means two to four times longer print times—or more and longer post-processing to improve surface quality. nine0003

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    In this webinar, two Formlabs experts will teach you when to use Draft Resin and how to incorporate this resin into your 3D printing workflow to speed it up and shorten your product development cycle.

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    Print volume is an area where FDM printers have traditionally dominated. Due to the specifics of the technology, the production of large-format FDM printers is less complicated. There are many large format FDM solutions on the market for applications that require 3D printing of large parts. nine0003

    Inverted stereolithography used in desktop SLA printers reduces printer space and cost, but the intensive layer separation process creates material and print volume limitations, and strong support structures are required to successfully print larger parts.

    The development of Formlabs Low Force Stereolithography (LFS) technology, used in the Form 3 and Form 3L printers, has revolutionized the approach to resin 3D printing and drastically reduced the forces on models during the printing process. Uniform linear illumination and a force-reducing elastic reservoir mean that Low Force Stereolithography technology can be seamlessly scaled to a wider print area using the same powerful print engine. nine0003

    The first affordable large-format stereolithography printer, the Form 3L prints large details quickly using two stepped Light Processing Units (LPUs) that work simultaneously on an optimized print path. Offering up to five times the print volume of current SLA printers, the Form 3L eliminates size constraints that can be found on small desktop devices at a competitive price.

    9The 0002 Form 3L offers five times the print volume of existing SLA printers at a competitive price.

    Each 3D printing technology has its strengths, weaknesses, limitations and applications. The following table summarizes the key characteristics and factors.

    Fused Deposition Modeling (FDM)0400 ★cle ★ opa
    COMPITION ★cle ★ opa ★ opa
    Productivity ★ opa ★★★★★ ★★★★★
    Benefits Speed Inexpensive custom machines and materials High cost efficiency High accuracy Smooth surface Wide range of functional applications
    Disadvantages Low accuracy low detail Limited Design Compliance Long Term UV Sensitivity
    Application Low Cost Rapid Prototyping Functional Prototyping Templates, forms and tools Dental products Prototyping jewelry and molds Model building
    Print Volume Up to ~200 x 200 x 300mm (Desktop 3D Printers) Up to ~200 x 335 x 200mm (Desktop and Workshop 3D Printers) Materials Standard thermoplastics such as ABS, PLA and their various blends. Various polymers (thermosets). Standard, engineering (with properties of ABS plastic, polypropylene, flexible, heat-resistant), molding, dental and medical (biocompatible). nine0410
    Training Minimum training in equipment setup, machine operation and surface treatment; short maintenance training. Plug and play concept. Minimal training in equipment setup, maintenance, machine operation and surface treatment.
    Room requirements Air-conditioned environment or individual ventilation preferred for desktop machines. Desktop machines suitable for office use. nine0410
    Accessories Support removal system for machines with soluble support structures (optionally automated), finishing tools. Finishing station, washing station (optionally automated), finishing tools.

    Comparing the two technologies, we can conclude that FDM and SLA printers have similar, often complementary features. These two types of 3D printers are not always in competition; many companies use both FDM and SLA 3D printers. In this way, you can get the best of both worlds: inexpensive rapid prototyping combined with high-quality functional model production allows you to solve a wide range of problems. nine0003

    Some practical examples: