Officeworks 3d printing mini me

How To Make 3D Printed Stuff Without Owning A 3D Printer

Eric Ravenscraft

Published 7 years ago: March 18, 2016 at 7:30 am -

3D printing is really friggin’ cool, but promises that we’d all have one in our homes by now have turned out to be less than true. Fortunately, you don’t need one of your own to bring your imaginary creations to life. Photos by Creative Tools and Karen Blakeman.

You may still be wondering why you should care about 3D printing to begin with. It’s a fair question! While 3D printer prices haven’t plummeted like some expected, the community around them has grown considerably. Sites like Thingiverse have huge libraries of ready-to-print models. You can download everything from cool stuff like a miniature Millennium Falcon (a neat gift idea!), to useful things like phone stands or cord protectors. There are a ton of things that you can print that are absolutely worth what they cost to make. They just might not be worth thousands of dollars for the printer, as well. If your hang-up is the hardware, here are some places that will let you print out objects without buying a mini factory.

Things to Consider Before You Print

Before you pick a place that’s going to make your 3D object, you need a 3D model to actually print. There are a few things you need to consider when you’re looking for something to make. Contrary to early adopter opinion, 3D printing isn’t the best solution for everything. When you’re getting started, ask yourself a few questions:

Does what I want already exist somewhere else? When I was browsing 3D printed objects, I found a potentially useful bag carrier that would make bringing in groceries easier. Then I found this thing on Amazon for $US6. 3D printing is cool, but it’s not always necessary. Before you order something, see if a regular mass-produced version exists.
Does the model have any flaws? In case you’ve never worked with 3D models before, let me give you a tip: they’re hard to get right. Before you spend money on an object, read reviews where available, or look for pictures of an item after it’s been printed, rather than just the renders of what an object “should” look like.
Do I need to alter or tweak this model? While you can technically change any 3D model using modelling software, some objects are easier to tweak than others. Thingiverse has an entire collection of customisable items with specific aspects you can tweak to fit your needs, like a Christmas tree stand with an adjustable diameter, so you can make it fit your tree. Before you download and print a model, make sure you check out all the possible ways to customise it that are available.
What materials will this be made of? Wait, aren’t all 3D printed objects just coloured plastic? Nope. You can get 3D printed objects in wax, sandstone, porcelain and even precious metals like gold and silver. That’s super awesome, but it’s also another thing that can affect your object. If you’re going to make something other than plastic, check out material sample kits so you can see how durable your object might be, or how intricately it can be printed.

Even if you do your due diligence, keep in mind that printing isn’t always perfect. You may get an object that you need to sand down to make it look just right, or you may have an intricate object that doesn’t quite line up. Be prepared for the possibility that something might not come out exactly the way you envisioned it.

Option One: Order Through Online Services

Several 3D printing services have popped up in the last few years that allow you to upload your own models and get them printed in whatever material you want. One of our favourites is Shapeways. This site lets you upload your own designs and get an immediate quote on how much a particular object will cost in a variety of materials. You can explore the object in a 3D model viewer.

If you don’t have a ready-made 3D model to work with, services like You3Dit will pair you with designers who can help you create what you want, then print it for you. This can be a little more expensive than just uploading a model and ordering a print, but it also reduces the likelihood that you’re going to get a botched product. Not to mention, most 3D printing services will use industrial-grade equipment that can get a lot more detail than the typical consumer models that you’re used to seeing in stores.

Option Two: Get a Quick Print at Local Stores

I have a confession: I don’t own a printer. And not the 3D kind: I don’t own a regular, 2D paper printer either. I just have so few instances where I need to print something, and unused printers break so much, that it just makes more sense to go down to the local library and print something when I need it. Unsurprisingly, some stores have decided that this concept works just as well for 3D printing and now offer in-store printing of your own models.

This is more common in the US than in Australia, however the Russell St Officeworks in Melbourne is equipped with 3D printers. A quick google search also reveals a few speciality 3D printing stores. They may not be nearby for everyone, but if you do happen to live near one, it’s probably easier to drive to a store for a bit, instead of buying a hulking machine just to make a cool figurine.

Option Three: Check Your Local Library

When you get to your local library, among the many other cool things they have, you may find a 3D printer. That’s right, libraries are cool. You heard it here first. If your library has a 3D printer, you may be able to use it for free (though you may have to buy or bring your own materials).

If you want to really get your hands dirty learning how to 3D print objects, this is one of your two best bets. Most libraries won’t have a clerk behind a desk who takes a USB stick and gives you a printed object. They will let you get hands-on with the software and learn how it works. Not every library will have staff that are experts in 3D modelling, but you can experiment on your own and learn how to do it yourself. Learning in a library. Imagine that.

Option Four: Join a Makerspace Community

So far this year, I’ve visited three different Makerspace communities in Atlanta, and every single one has had at least one 3D printer. If you can find a Maker Faire in your town, or a local maker community, and you’re even slightly interested in 3D printing, take a day and visit. If you’re actually looking to learn how 3D printing works, this will be the most educational and likely the most rewarding.

Not only will most makerspaces have shared resources (like 3D printers!), they also have people who are experienced in using them on site. You probably won’t be able to walk in the front door, ask for a print job, and walk out. Instead, you can join classes, or work directly with someone who knows what they’re doing.

In my experience, this was the best way to get started with 3D printing, as you learn some of the intricacies of what you’re doing, not to mention the problems that can arise. Despite cool demo videos, prints can become improperly aligned, nozzles can get clogged or material can come out unevenly. All of these can quickly ruin a project, especially if you don’t know how to fix your printer.

Owning a 3D Printer Probably Isn’t a Good Idea to Begin With

With all of these options on the table, you might reasonably start to wonder, “Is it ever going to be worth owning a 3D printer?” And the truth is… probably not? It’s easy to imagine a wonderful world where anything you can imagine, you can build. The reality is that 3D printers are still printers. They get clogged, jammed and misaligned, and they can ruin your day when they don’t work right.

3D printing services, on the other hand, are much more consumer friendly. You can use models you find online (or make yourself) and get someone else who knows what they’re doing to make the product itself. If you really want to get one to learn how to make your own stuff, libraries and makerspaces are going to be way better for you than just buying a 3D printer for your house and fiddling with it until something good comes out. For enthusiasts and regular makers, owning a 3D printer might be a great idea, but for the rest of us, contracting that work is likely going to be the best bet for a long time to come.

Want a 3D selfie? 3D printers in Australia are now printing your mini-me

And why stop there? If you have a spare room, you could fill it with hundreds of dolls of yourself churned out by the 3D printer. Who needs to go to China to see the Terracotta Warriors when you could make your own version? Of course, the warriors all have different faces – so maybe just change outfits before every doll you get made.

Preservation of a different kind

If you're getting married maybe you and the future hubby could feature as the figurines on top of the cake. If you're missing your girlfriend, who travels for work a lot, maybe a 3D-printed doll in her likeness will ease your pining.

If you're a busy person who can't make all the events in your diary then perhaps you could send the mini-me instead. Your mini-me doll could go to the school reunion and be in the photos. You'd be the talk of the gathering! And guess what? You'd be in two places at the same time. Freaky!

And what about former Prime Minister Kevin Rudd? Wouldn't he enjoy a Julia Gillard 3D doll so he could stick pins in its eyes between stuffing handfuls of popcorn into his mouth while watching the ABC's The Killing Season?

Imagine, you could have a doll made for each member of your extended family 3D mini me

And if not that option maybe he'd hanker after a bunch of miniature figurines of his political enemies that he could arrange on a chessboard, where they would face off against 16 Kevin figurines.

The options are endless and ridiculous. Retailers and online stores have been offering to 3D-print customers' mini-mes globally, and even a funeral parlour owner in New York State is in on the act.

Yes, Billy La Pierre of Westchester says he's known in the Yorktown community for his caring and comforting funeral home services. However, Billy has created a different buzz around Yorktown with his new 3D-printing business, Mini 3D ME. A buzz indeed if he's intending to make mini-mes of anyone arriving but not leaving his funeral parlour.

Me, me, me!

Officeworks, Westfield and a bunch of online companies are now offering to print up a 3D mini figurine of you.

But before you get too excited and rush out to get one made and gift-wrapped for Christmas (the selfie stick is so 2014), you should be warned. It's not cheap, unlike your average Barbie or Ken doll. But why should it be cheap? It's you! It's unique! It's your selfie in 3D shrunk to the size of either a pen or a ruler!

The prices range from $40 to $580 for a mini-me doll and are determined by the material used, the size and whether it's printed in multiple colours or monochrome.

3D printing, or additive manufacturing as it's properly called, has set the world alight with its possibilities. Last year, an astronaut at the International Space Station used a 3D printer to make a wrench that he needed at the station. Prosthetic limbs are being made by 3D printers, and even pizzas.

Or we could just have fun with such printers in this vain age of ME, ME, ME and make miniature figurines of ourselves. From selfies to Facebook to Instagram there's an ever-growing societal preoccupation with one's own image. So why not add yet another enabler, one with which we can genuflect to shrines of ourselves (or at least wipe the dust off it on the mantelpiece)?

One thing to note, however, is a mini-me will render every flaw and, of course, every perfection of your body into plastic or plaster permanently, whereas images that appear on Instagram or Facebook can be altered and improved. It's worth thinking about.

On the subject of mini-mes, however, the last word should really go to Dr Evil, the villain from the Austin Powers movies who, if you recall, had his own mini-me.

"Mini-Me, you complete me. Hang on Mini-Me! If anything should happen to you I don't know what I would do!" Dr Evil says. He then pauses to think about what he's just said and proceeds to answer his own question.

"I'd probably move on, get another replica, but there would be a 10-minute period there where I would just be inconsolable."

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Twitter: @newsandimages

3D printing for "dummies" or "what is a 3D printer?"

1 3D printing term
2 3D printing methods

2.1 Extrusion printing
2.2 Melting, sintering or gluing
2.3 Stereolithography
2.4 Lamination

3 Fused Deposition Printing (FDM)

3.1 Consumables
3.2 Extruder
3.3 Working platform
3.4 Positioners
3.5 Control
3.6 Varieties of

4 Laser stereolithography (SLA)

4. 1 Lasers and projectors
4.2 Cuvette and resin
4.3 Types of

3D printing term

The term 3D printing has several synonyms, one of which quite briefly and accurately characterizes the essence of the process - "additive manufacturing", that is, production by adding material. The term was not coined by chance, because this is the main difference between multiple 3D printing technologies and the usual methods of industrial production, which in turn received the name "subtractive technologies", that is, "subtractive". If during milling, grinding, cutting and other similar procedures, excess material is removed from the workpiece, then in the case of additive manufacturing, material is gradually added until a solid model is obtained. nine0048

Soon 3D printing will even be tested on the International Space Station

Strictly speaking, many traditional methods could be classified as "additive" in the broad sense of the word - for example, casting or riveting. However, it should be borne in mind that in these cases, either the consumption of materials is required for the manufacture of specific tools used in the production of specific parts (as in the case of casting), or the whole process is reduced to joining ready-made parts (welding, riveting, etc.). In order for the technology to be classified as “3D printing”, the final product must be built from raw materials, not blanks, and the formation of objects must be arbitrary - that is, without the use of forms. The latter means that additive manufacturing requires a software component. Roughly speaking, additive manufacturing requires computer control so that the shape of final products can be determined by building digital models. It was this factor that delayed the widespread adoption of 3D printing until the moment when numerical control and 3D design became widely available and highly productive. nine0048

3D printing techniques

3D printing technologies are numerous, and there are even more names for them due to patent restrictions. However, you can try to divide technologies into main areas:

Extrusion printing

This includes methods such as deposition deposition (FDM) and multi-jet printing (MJM). This method is based on the extrusion (extrusion) of consumables with the sequential formation of the finished product. As a rule, consumables consist of thermoplastics or composite materials based on them. nine0048

Melting, sintering or bonding

This approach is based on bonding powdered material together. Formation is done in different ways. The simplest is gluing, as is the case with 3D inkjet printing (3DP). Such printers deposit thin layers of powder onto the build platform, which are then selectively bonded with a binder. Powders can be made up of virtually any material that can be ground to a powder—plastic, wood, metal. nine0048

This model of James Bond's Aston Martin was successfully printed on Voxeljet's SLS printer and blown up just as successfully during the filming of Skyfall instead of the expensive original

sintering (SLS and DMLS) and smelting (SLM), which allow you to create all-metal parts. As with 3D inkjet printing, these devices apply thin layers of powder, but the material is not glued together, but sintered or melted using a laser. Laser sintering (SLS) is used to work with both plastic and metal powders, although metal pellets usually have a more fusible shell, and after printing they are additionally sintered in special ovens. DMLS is a variant of SLS installations with more powerful lasers that allow sintering metal powders directly without additives. SLM printers provide not just sintering of particles, but their complete melting, which allows you to create monolithic models that do not suffer from the relative fragility caused by the porosity of the structure. As a rule, printers for working with metal powders are equipped with vacuum working chambers, or they replace air with inert gases. Such a complication of the design is caused by the need to work with metals and alloys subject to oxidation - for example, with titanium. nine0048

Stereolithography

How an SLA printer works

Stereolithography printers use special liquid materials called "photopolymer resins". The term "photopolymerization" refers to the ability of a material to harden when exposed to light. As a rule, such materials react to ultraviolet irradiation.

Resin is poured into a special container with a movable platform, which is installed in a position near the surface of the liquid. The layer of resin covering the platform corresponds to one layer of the digital model. Then a thin layer of resin is processed by a laser beam, hardening at the points of contact. At the end of illumination, the platform together with the finished layer is immersed to the thickness of the next layer, and illumination is performed again. nine0048

Lamination

Laminating (LOM) 3D printers workflow

Some 3D printers build models using sheet materials - paper, foil, plastic film.

Layers of material are glued on top of each other and cut to the contours of the digital model using a laser or a blade.

These machines are well suited for prototyping and can use very cheap consumables, including regular office paper. However, the complexity and noise of these printers, coupled with the limitations of the models they produce, limit their popularity. nine0048

Fused Deposition Modeling (FDM) and Laser Stereolithography (SLA) are the most popular 3D printing methods used in the home and office.

Let's take a closer look at these technologies.

Fused Deposition Printing (FDM)

FDM is perhaps the simplest and most affordable 3D construction method, which makes it very popular.
High demand for FDM printers is driving device and consumable prices down rapidly, along with technology advances towards ease of use and improved reliability. nine0048

Consumables

ABS filament spool and finished model

FDM printers are designed to print with thermoplastics, which are usually supplied as thin filaments wound on spools. The range of "clean" plastics is very wide. One of the most popular materials is polylactide or "PLA plastic". This material is made from corn or sugar cane, which makes it non-toxic and environmentally friendly, but makes it relatively short-lived. ABS plastic, on the other hand, is very durable and wear-resistant, although it is susceptible to direct sunlight and can release small amounts of harmful fumes when heated. Many plastic items that we use on a daily basis are made from this material: housings for household appliances, plumbing fixtures, plastic cards, toys, etc. nine0048

In addition to PLA and ABS, printing is possible with nylon, polycarbonate, polyethylene and many other thermoplastics that are widely used in modern industry. More exotic materials are also possible, such as polyvinyl alcohol, known as "PVA plastic". This material dissolves in water, which makes it very useful for printing complex geometric patterns. But more on that below.

Model made from Laywoo-D3. Changing the extrusion temperature allows you to achieve different shades and simulate annual rings

It is not necessary to print with homogeneous plastics. It is also possible to use composite materials imitating wood, metals, stone. Such materials use all the same thermoplastics, but with impurities of non-plastic materials.

So, Laywoo-D3 consists partly of natural wood dust, which allows you to print "wooden" products, including furniture.

The material called BronzeFill is filled with real bronze, and models made from it can be ground and polished, achieving a high similarity to products made from pure bronze. nine0048

One has only to remember that thermoplastics serve as a binding element in composite materials - they determine the thresholds of strength, thermal stability and other physical and chemical properties of finished models.

Extruder

Extruder - FDM print head. Strictly speaking, this is not entirely true, because the head consists of several parts, of which only the feed mechanism is directly "extruder". However, by tradition, the term "extruder" is commonly used as a synonym for the entire print assembly. nine0048

FDM extruder general design

The extruder is designed for melting and applying thermoplastic thread. The first component is the thread feed mechanism, which consists of rollers and gears driven by an electric motor. The mechanism feeds the thread into a special heated metal tube with a small diameter nozzle, called a "hot end" or simply a "nozzle". The same mechanism is used to remove the thread if a change of material is needed. nine0048

The hot end is used to heat and melt the thread fed by the puller. As a rule, nozzles are made from brass or aluminum, although more heat-resistant, but also more expensive materials can be used. For printing with the most popular plastics, a brass nozzle is quite enough. The “nozzle” itself is attached to the end of the tube with a threaded connection and can be replaced with a new one in case of wear or if a change in diameter is necessary. The nozzle diameter determines the thickness of the molten filament and, as a result, affects the print resolution. The heating of the hot end is controlled by a thermistor. Temperature control is very important, because when the material is overheated, pyrolysis can occur, that is, the decomposition of plastic, which contributes both to the loss of the properties of the material itself and to clogging of the nozzle. nine0048

PrintBox3D One FDM Printer Extruder

To prevent the filament from melting too early, the top of the hot end is cooled by heatsinks and fans. This point is of great importance, since thermoplastics that pass the glass transition temperature significantly expand in volume and increase the friction of the material with the walls of the hot end. If the length of such a section is too long, the pulling mechanism may not have enough strength to push the thread. nine0048

The number of extruders may vary depending on the purpose of the 3D printer. The simplest options use a single printhead. The dual extruder greatly expands the capabilities of the device, allowing you to print one model in two different colors, as well as using different materials. The last point is important when building complex models with overhanging structural elements: FDM printers cannot print “over the air”, since the applied layers require support. In the case of hinged elements, temporary support structures have to be printed, which are removed after printing is completed. The removal process is fraught with damage to the model itself and requires accuracy. In addition, if the model has a complex structure with internal cavities that are difficult to access, building conventional supports may not be practical due to the difficulty in removing excess material. nine0048

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

In such cases, the same water-soluble polyvinyl alcohol (PVA) comes in handy. Using a dual extruder, you can build a model from waterproof thermoplastic using PVA to create supports.

After printing, PVA can be simply dissolved in water and a complex product of perfect quality can be obtained.

Some FDM printers can use three or even four extruders. nine0048

Working platform

Heated platform covered with removable glass work table

Models are built on a special platform, often equipped with heating elements. Preheating is required for a wide range of plastics, including the popular ABS, which are subject to a high degree of shrinkage when cooled. The rapid loss of volume by cold coats compared to freshly applied material can lead to model distortion or delamination. The heating of the platform makes it possible to significantly equalize the temperature gradient between the upper and lower layers. nine0048

Heating is not recommended for some materials. A typical example is PLA plastic, which requires a fairly long time to harden. Heating PLA can lead to deformation of the lower layers under the weight of the upper ones. When working with PLA, measures are usually taken not to heat up, but to cool the model. Such printers have characteristic open cases and additional fans blowing fresh layers of the model.

Calibration screw for work platform covered with blue masking tape

The platform needs to be calibrated before printing to ensure that the nozzle does not hit the applied layers and move too far causing air-to-air printing resulting in plastic vermicelli. The calibration process can be either manual or automatic. In manual mode, calibration is performed by positioning the nozzle at different points on the platform and adjusting the platform inclination using the support screws to achieve the optimal distance between the surface and the nozzle.

As a rule, platforms are equipped with an additional element - a removable table. This design simplifies the cleaning of the working surface and facilitates the removal of the finished model. Stages are made from various materials, including aluminum, acrylic, glass, etc. The choice of material for the manufacture of the stage depends on the presence of heating and consumables for which the printer is optimized.

For a better adhesion of the first layer of the model to the surface of the table, additional tools are often used, including polyimide film, glue and even hairspray! But the most popular tool is inexpensive, but effective masking tape. Some manufacturers make perforated tables that hold the model well but are difficult to clean. In general, the expediency of applying additional funds to the table depends on the consumable material and the material of the table itself. nine0048

Positioning mechanisms

Scheme of operation of positioning mechanisms

Of course, the print head must move relative to the working platform, and unlike conventional office printers, positioning must be carried out not in two, but in three planes, including height adjustment.

Positioning pattern may vary. The simplest and most common option involves mounting the print head on perpendicular guides driven by stepper motors and providing positioning along the X and Y axes. nine0048

Vertical positioning is carried out by moving the working platform.

On the other hand, it is possible to move the extruder in one plane and the platforms in two.

SeemeCNC ORION Delta Printer

One option that is gaining popularity is the delta coordinate system.

Such devices are called "delta robots" in the industry.

In delta printers, the print head is suspended on three manipulators, each of which moves along a vertical rail.

The synchronous symmetrical movement of the manipulators allows you to change the height of the extruder above the platform, and the asymmetric movement causes the head to move in the horizontal plane.

A variant of this system is the reverse delta design, where the extruder is fixed to the ceiling of the working chamber, and the platform moves on three support arms. nine0048

Delta printers have a cylindrical build area, and their design makes it easy to increase the height of the working area with minimal design changes by extending the rails.

In the end, everything depends on the decision of the designers, but the fundamental principle does not change.

Control

Typical Arduino-based controller with add-on modules

The operation of the FDM printer, including nozzle and platform temperature, filament feed rate, and stepper motors for positioning the extruder, is controlled by fairly simple electronic controllers. Most controllers are based on the Arduino platform, which has an open architecture. nine0048

The programming language used by the printers is called G-code (G-Code) and consists of a list of commands executed in turn by the 3D printer systems. G-code is compiled by programs called "slicers" - standard 3D printer software that combines some of the features of graphics editors with the ability to set print options through a graphical interface. The choice of slicer depends on the printer model. RepRap printers use open source slicers such as Skeinforge, Replicator G and Repetier-Host. Some companies make printers that require proprietary software. nine0048

Program code for printing is generated using slicers

As an example, we can mention Cube printers from 3D Systems. There are companies that offer proprietary software but allow third-party software, as is the case with the latest generation of MakerBot 3D printers.

Slicers are not intended for 3D design per se. This task is done with CAD editors and requires some 3D design skills. Although beginners should not despair: digital models of a wide variety of designs are offered on many sites, often even for free. Finally, some companies and individuals offer 3D design services for custom printing. nine0048

Finally, 3D printers can be used in conjunction with 3D scanners to automate the process of digitizing objects. Many of these devices are designed specifically to work with 3D printers. Notable examples include the 3D Systems Sense handheld scanner and the MakerBot Digitizer handheld desktop scanner.

MakerBot Replicator 5th Generation FDM Printer with built-in control module on the top of the frame

The user interface of a 3D printer can consist of a simple USB port for connecting to a personal computer. In such cases, the device is actually controlled by the slicer. nine0048

The disadvantage of this simplification is a rather high probability of printing failure when the computer freezes or slows down.

A more advanced option includes an internal memory or memory card interface to make the process standalone.

These models are equipped with control modules that allow you to adjust many print parameters (such as print speed or extrusion temperature). The module may include a small LCD display or even a mini-tablet. nine0048

Varieties of FDM printers

Professional Stratasys Fortus 360mc FDM printer that allows printing with nylon

FDM printers are very, very diverse, ranging from the simplest homemade RepRap printers to industrial installations capable of printing large-sized objects.

Stratasys, founded by Scott Crump, the inventor of FDM technology, is a leader in the production of industrial installations. nine0048

You can build the simplest FDM printers yourself. Such devices are called RepRap, where "Rep" indicates the possibility of "replication", that is, self-reproduction.

RepRap printers can be used to print custom built plastic parts.

Controller, rails, belts, motors and other components can be easily purchased separately.

Of course, assembling such a device on your own requires serious technical and even engineering skills. nine0048

Some manufacturers make it easy by selling DIY kits, but these kits still require a good understanding of the technology. RepRap Printers nine0048

And, despite their "homemade nature", RepRap printers are quite capable of producing models with quality at the level of expensive branded counterparts.

Ordinary users who do not want to delve into the intricacies of the process, but require only a convenient device for household use, can purchase a ready-made FDM printer.

Many companies are focusing on the development of the consumer market segment, offering 3D printers for sale that are ready to print “right out of the box” and do not require serious computer skills. nine0048

3D Systems Cube consumer 3D printer

The most famous example of a consumer 3D printer is the 3D Systems Cube.

While it doesn't boast a huge build area, ultra-fast print speeds, or superb build quality, it's easy to use, affordable, and safe: This printer has received the necessary certification to be used even by children.

Mankati FDM printer demonstration: http://youtu.be/51rypJIK4y0 nine0048

Laser Stereolithography (SLA)

Stereolithographic 3D printers are widely used in dental prosthetics

Stereolithographic printers are the second most popular and widespread after FDM printers.

These units deliver exceptional print quality.

The resolution of some SLA printers is measured in a matter of microns - it is not surprising that these devices quickly won the love of jewelers and dentists. nine0048

The software side of laser stereolithography is almost identical to FDM printing, so we will not repeat ourselves and will only touch on the distinctive features of the technology.

Lasers and projectors

Projector illumination of a photopolymer model using Kudo3D Titan DLP printer as an example

The cost of stereolithography printers is rapidly declining due to growing competition due to high demand and the use of new technologies that reduce the cost of construction. nine0048

Although the technology is generically referred to as "laser" stereolithography, most recent developments use UV LED projectors for the most part.

Projectors are cheaper and more reliable than lasers, do not require the use of delicate mirrors to deflect the laser beam, and have higher performance. The latter is explained by the fact that the contour of the whole layer is illuminated as a whole, and not sequentially, point by point, as is the case with laser options. This variant of the technology is called projection stereolithography, "DLP-SLA" or simply "DLP". However, both options are currently common - both laser and projector versions. nine0048

Cuvette and resin

Photopolymer resin is poured into a cuvette

A photopolymer resin that looks like epoxy is used as consumables for stereolithography printers. Resins can have a variety of characteristics, but they all share one key feature for 3D printing applications: these materials harden when exposed to ultraviolet light. Hence, in fact, the name "photopolymer".

When polymerized, resins can have a wide variety of physical characteristics. Some resins are like rubber, others are hard plastics like ABS. You can choose different colors and degrees of transparency. The main disadvantage of resins and SLA printing in general is the cost of consumables, which significantly exceeds the cost of thermoplastics. nine0048

On the other hand, stereolithography printers are mainly used by jewelers and dentists who do not need to build large parts but appreciate the savings from fast and accurate prototyping. Thus, SLA printers and consumables pay for themselves very quickly.

Example of a model printed on a laser stereolithographic 3D printer

Resin is poured into a cuvette, which can be equipped with a lowering platform. In this case, the printer uses a leveling device to flatten the thin layer of resin covering the platform just prior to irradiation. As the model is being made, the platform, together with the finished layers, is “embedded” in the resin. Upon completion of printing, the model is removed from the cuvette, treated with a special solution to remove liquid resin residues and placed in an ultraviolet oven, where the final illumination of the model is performed. nine0048

Some SLA and DLP printers work in an "inverted" scheme: the model is not immersed in the consumable, but "pulled" out of it, while the laser or projector is placed under the cuvette, and not above it. This approach eliminates the need to level the surface after each exposure, but requires the use of a cuvette made of a material transparent to ultraviolet light, such as quartz glass.

The accuracy of stereolithographic printers is extremely high. For comparison, the standard for vertical resolution for FDM printers is considered to be 100 microns, and some variants of SLA printers allow you to apply layers as thin as 15 microns. But this is not the limit. The problem, rather, is not so much in the accuracy of lasers, but in the speed of the process: the higher the resolution, the lower the print speed. The use of digital projectors allows you to significantly speed up the process, because each layer is illuminated entirely. As a result, some DLP printer manufacturers claim to be able to print with a vertical resolution of one micron! nine0048

Video from CES 2013 showing Formlabs Form1 stereolithography 3D printer in action: http://youtu.be/IjaUasw64VE

Stereolithography Printer Options

Formlabs Form1 Desktop Stereolithography Printer

As with FDM printers, SLA printers come in a wide range in terms of size, features and cost. Professional installations can cost tens if not hundreds of thousands of dollars and weigh a couple of tons, but the rapid development of desktop SLA and DLP printers is gradually reducing the cost of equipment without compromising print quality. nine0048

Models such as the Titan 1 promise to make stereolithographic 3D printing affordable for small businesses and even home use at around $1,000. Formlabs' Form 1 is available now for a factory selling price of $3,299.

The developer of the DLP printer Peachy generally intends to overcome the lower price barrier of $100.

At the same time, the cost of photopolymer resins remains quite high, although the average price has fallen from $150 to $50 per liter over the past couple of years. nine0048

Of course, the growing demand for stereolithographic printers will stimulate the growth in the production of consumables, which will lead to further price reductions.

Go to the main page of the Encyclopedia of 3D printing

what he can do and how to make money on it

Viktor tells how he turned his hobby into a profitable business. And why he no longer has "work time"

Victor tells how he turned his hobby into a profitable business. And why does he no longer have "work time"

Victor

On YouDo
since October 2016

Victor prints everything (almost) on the printer - from a machine gun to dental crowns. And on YouDo he finds couriers who deliver all this. We decided to ask him what kind of business it is - 3D printing, how it works and whether it is profitable to do it.

Victor

On YouDo
since October 2016

How I got hooked

Four years ago I realized that the office is not about me. I try in life to do only what is interesting. Something to create, organize, be creative. My hobbies have always been something like this.

Manufacturers say: "I brought it home, pulled it out of the box - voila, print it!" But this is all marketing

3D printing was in full view then. It seemed to me that it was just about creation and creativity, so I got hooked. I bought a printer, installed it at home, and began to find orders via the Internet. nine0048

Manufacturers say: "I brought it home, pulled it out of the box - voila, print it!" But this is all marketing, you need at least elementary training. You will have to spend at least a day to understand how the printer is refueled and a special slicer program works, which converts a 3D model into a special G-code. By reading this code, the printer understands what and how to print.

Four years ago Victor decided to turn his hobby into a business

What you need to know at the start

A 3D printer is used in the jewelry industry, in the automotive industry, and in instrumentation.

Even rocket parts and photopolymer dental crowns have been printed on it! That's why I love 3D printing so much: you cover a wide range of issues, you can communicate with specialists from completely different fields. It broadens your horizons!

3D printers are different. There are capricious samples, but there are user-friendly ones. These cost from 50,000 ₽. 80,000 ₽ will be enough to start your business. nine0044

Calculation for launch

-printer-50 000 ₽
-plastic (1 kg)-from 800 ₽
-10 000 ₽
-Internet advertising-20 000 ₽

80 000 ₽

starting budget

There are no complex algorithms in the production process itself, I quickly figured it out. But to improve the level of skill, it takes time. Only after working on several printers and performing hundreds of diverse tasks did I understand how, for example, to increase the speed of printing without losing its quality. nine0048

Let me show you how it all happens using the YouDo logo as an example.

Draw a drawing

I do rendering and 3D visualization

I choose plastic

I load the coil to the printer

I put the thread to the extruder

so,

is printed, then the smiley is printed and the smile

Packed in a box

What we left and what we came to

My first product was a prototype of a mouse for a computer. It turned out so badly that I thought they wouldn't accept it - miraculously it worked. At that time, I did everything myself: I posted ads on the Internet, took orders, did modeling - I created a 3D model in a special program and printed it. nine0044

The first order turned out so badly that I thought they wouldn’t accept it - it miraculously worked

The number of orders began to grow over time, I began to hire freelance assistants. Until now, a significant part of our team are freelance modelers who create 3D models.

Two people work in the office:

a full-time modeler,
a project manager responsible for receiving applications and printing parts.

There is also an accountant, but he works remotely. We also do not need a regular courier, because on average we have one delivery per day. We arrange delivery through YouDo. I know that you can find cheaper delivery options, but YouDo is more reliable: you look at the rating, reviews - it’s immediately clear who you are working with. Our main requirement for the courier is to be careful, especially when some unusual things need to be delivered. nine0044

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Submit what is possible and that it is impossible and that

Tasks of our company I divide into creative, engineering, production and scientific:

Creative -Figules of Machines, Working Machines, Work with Jewriers. Most often it is souvenir products, the creative process.
Engineering is the creation of elements of device cases, a copy of parts. The latter is especially relevant. If some part is broken, it is not for sale, or you can only buy it complete with a mechanism - we come to the rescue. nine0004
Scientific - any experimental samples that are used by scientists for research. For example, for graduate students in dentistry, we made dentures, metal crowns, special samples of dental polymer, which they tested for strength.

Souvenirs made of plastic, photopolymers, which are stored in Victor's workshop

The largest order in size is a copy of a two-meter machine gun

Often there is something adjacent. Once they made a souvenir for a large oil company: they printed typewriters that they actually operate at their facilities. They also made hands for robots. The robots themselves are funny: they ride on caterpillars, there is a display on their stomach. We printed their hands, now some of them work as waiters in a cafe. nine0048

The largest order in terms of size is a copy of a Russian-made two-meter machine gun for a military-patriotic camp. On May 9, they attached it to an UAZ with a cut-off roof, drove it to a performance.

What now?

Once upon a time, 3D printing was just my hobby. Gradually, it grew into a profitable business. So far not so profitable that my salary was much more than the office one. But I realized how cool it is when a hobby brings money.

One printer was enough for a hobby, now four is not enough

I don't have to rush between work and free time. I am basically free. I plan my day the way I want. And each of my days can be completely unique and not like the next or the previous one.

In the morning I work on one project, and in the afternoon I discuss another, and so on. And I can generally take it and go for a ride on a scooter in the middle of the day.

I no longer have such a thing as “working time”. Or "non-working". There is just time, and I use it the way I want. nine0044

How do you know when it's time to leave your office and start your own business?

Driven by a hobby, but not enough time for it.
There are several business ideas with at least approximate business plans, and not an abstract desire to "do something of your own."
At the beginning, you are ready to take almost all the work on yourself and do not expect a crowd of professional altruists to run into your startup.
You have grown to a level of responsibility where "quitting office work" means for you to work for two weeks under the contract and close all unfinished tasks. nine0044
You understand that your income may not exceed the average office salary for a long time.

Have you also made your hobby your business? Tell us how it was: blog@youdo.

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