Uses for 3d printer

25 (Unexpected) 3D Printing Use Cases

For years, hype around 3D printing captured audiences in the mainstream press. With visions of a future including a 3D printer in every home, these predictions were light on details and ultimately most did not come to fruition. However, the possibilities of 3D printing were undeniable, despite the youth of the technology and the relatively low number of use cases that were viable in the past.

The initial hype masked legitimate and growing business applications for 3D printing. With a proliferation of high-performance desktop and benchtop machines being introduced into the market, we are now seeing a broader variety of businesses expanding their product offerings and delivering better results to customers.

What can you do with a 3D printer? Read on to discover 25 (often unexpected) 3D printing use cases that show the broad scope of possible applications for the technology.

Report

A new industry report that compares how recent and early adopters are using 3D printing for their business, and explores future trends of the technology.

3D printing can add enormous value to supply chains, unlocking a broad spectrum of production applications. The technology is growing more workable and affordable, with companies able to bring additive manufacturing in-house to support processes on the factory floor. New, resilient 3D printing materials are opening opportunities for the production of high precision, functional 3D prints that can stand in for final parts, offering customization opportunities that help designers radically push the boundaries of high-performance cars. Industrial design studio Vital Auto has put all of this technology to work creating high-fidelity prototypes and concept cars, rapidly working through iterations using a variety of advanced tools, including a large fleet of in-house 3D printers.

“We've used 3D printing from day one. We wanted to introduce it to our manufacturing processes, not only to reduce costs, but to give the customer more diversity with their designs and their ideas,” said Design Engineer Anthony Barnicott.

The automotive industry has seen the value additive manufacturing can add to multiple touch points in the creation of automobiles. This means going well beyond rapid prototyping to include:

Creating custom, complex, and high-performance parts
Producing tooling and manufacturing aids
Manufacturing replacement parts and spare parts on demand
Cutting costs and lead times by up to 90% compared to outsourcing

See How Concept Cars Are Created

Recent advancements in 3D printing technology have started to fundamentally change the audio industry, meaning that digital printing of custom fit ear devices for the audiology, noise protection, and consumer audiology industries has never been so affordable. In recent years, 3D printing manufacturers have brought skin-safe biocompatible materials to market, allowing for in-house production of ear models and headphone tips.

Custom fit offers a unique individual listening experience built around the earphone fitting exactly in the customers ear. This gives a secure fit that removes any possibility of earphones falling out of the ear, in addition to improved comfort and noise isolation.

“We are very excited about the concept of custom fit to deliver a custom experience to further enhance immersive listening. Formlabs shares Sennheiser’s drive for innovation – and improving the customer experience through this prototype is a testament to that mindset.”
Sennheiser Director AMBEO Immersive Audio, Veronique Larcher

The challenges that come with customized manufacturing can be overcome through the combination of Formlabs' disruptive printing technology and mobile scanning coupled with machine learning. This means customers can have easy access to custom fit earphones, with lead times reduced from four days to next day delivery or even same day.

Learn More About 3D Printing in Audiology

restor3D tools being printed, along side their final form.

Ten years ago, few people were talking about the huge impact 3D printing would have on the medical industry, from helping create advanced medical devices to patient-specific surgical guides. One company no one saw coming was restor3d, who leverages 3D printing capabilities to drastically improve surgical care by printing procedure-specific polymer instrumentation tailored to cervical spine implants.

With a fleet of over 25 Formlabs 3D printers in its production line, restor3D is already printing the next generation of surgical tools. For surgeons using these tools, this procedure-specific, single packed sterile instrumentation system results in:

Replacement of large, expensive surgical trays.
Ability to iterate designs and quickly introduce new tools or features based on surgeon preferences.
Dramatic reduction of supply chain and sterilization costs for hospitals.

Read How restor3d Is Creating Next Generation Tools

As much as 3D printing technology has developed in the past few years, there are even more high-impact, use cases currently in development. 3D printed organs is one of them.

Being able to easily create new organs has for decades been a dream for scientists working in regenerative medicine. While it remains in its early stages, the use of the 3D workflow to produce organic tissue eligible for transplant is bearing early fruit.

Dr. Sam Pashneh-Tala from the University of Sheffield is leading the way. His research uses high-precision desktop stereolithography (SLA) 3D printing to enable the production of tissue-engineered blood vessels with a variety of geometries. This will allow for patient-specific vascular graft designs, improved surgical options, and provides a unique testing platform for new vascular medical devices for those suffering from cardiovascular disease—which is currently the number one cause of death worldwide.

“My differentiator is that I’m able to create blood vessels with geometries that are more closely matched to those found in the body. This offers the potential for improved surgical options and even patient-matched blood vessel designs. Without access to high-precision, affordable 3D printing, creating these shapes would not be possible, ” said Dr. Pashneh-Tal.

Read About Tissue Engineering

The reconstruction of the three cities in the two different time periods consisted of over 650 segments, which were printed using Formlabs White Resin, each measuring 12x12cm.

As an industry already based on geometric design, prototyping, and modeling, architecture stands to gain enormously from advances in 3D printing technology.

On top of saving time during model production, the 3D printed models allow architects to anticipate the effects of certain design features with much greater certainty, e.g., by seeing a model produced with a fuller complement of materials, an architect can measure aspects such a light flow through the structure with higher precision.

But 3D printing’s use case goes beyond a single model: some firms are recreating entire towns. Institute of Architecture at the Hochschule Mainz - University of Applied Sciences. The result is an extraordinary exhibition that showcases six large-scale models of the cities, in the years 800 and 1250 AD. The models consist of over 650 parts, all of which were created using SLA 3D printing technology.

Learn About the Reconstruction of Medieval German Cities

The 990S TripleCell and the FuelCell Echo Triple.

The sport-footwear industry has long relied on technology to optimize the performance of their products, and with the digital workflow they have more options than ever in customization.

Large brands like New Balance, Adidas, and Nike, having recognized the power of additive manufacture, intend to mass produce custom midsoles made from 3D printed materials. As in other industries, the digital workflow will augment traditional methods of manufacture here—critical, highly-customized components of each product will be entrusted to the 3D printing, and the rest left to traditional means.

Given the unique properties required for footwear, New Balance worked with Formlabs to create a custom printing material which could resist the daily wear and tear faced by an athletic shoe. Shoe materials experience a variety of environments, with the additional need to withstand various levels of pressure thousands of times per day. Designed to create springy, resilient lattice structures, Rebound Resin has a much higher energy return, tear strength, and elongation than any other Formlabs material. Rebound Resin is strong enough to be used in gaskets, seals, and automotive interiors, but light and flexible enough for the sole of a shoe.

“One of the things that’s really exciting for us is that it provides a very different experience for the runner.”
Katherine Petrecca, General Manager of Footwear at the Innovation Design Studio, New Balance

See the 3D Printed New Balance Shoe

3D printing has already been integrated into the production of Hollywood films and is widely used for practical visual effects and costuming.

Whereas the creation of film's most fantastic creatures once required meticulous handcraft, the increased deadline pressure and time demands of modern moviemaking have made a quicker method of creating practical effects vital. Effects studios like Aaron Sims Creative now use a hybridized approach, practical effect-making enhanced by the digital workflow, to create new opportunities for collaboration and cut lead times on bringing ideas to life.

“The Demogorgon was one of the first prints that we did using our Formlabs 3D printers, and we were amazed. Before that, we had always outsourced printing. So to be able to grow it in-house, and see a design that we helped create from the very beginning printed right in front of us, was kind of an amazing thing. It was like going back to the days when we used to sculpt with clay,” said Aaron Sims.

Read About How Aaron Sims Creative Builds Their Worlds

3D printing's artistic potential is not limited to physical artwork. It also has the power to bring entirely new dimensions to forms like dance and music. Given the design freedom inherent in 3D printing, even the most complex or unique instruments can be modified or created from scratch, at a fraction of the price of traditionally made instruments.

Having been around for centuries and barely changing, the violin’s form is recognizable to all. Violin music has evolved to such a high level that the instrument has attained an almost legendary status in our culture. But Formlabs engineer Brian Chan challenged himself to create a fully-functional acoustic violin, using a 3D printer and Formlabs White Resin.

Get an Inside Look at Design Process

3D scanning, CAD, and 3D printing have been used to restore the works of some of history's most famous artists, returning works by the likes of Michelangelo and da Vinci to their former glory.

Art restoration projects can be enhanced by combining 3D printing and 3D scanning, two powerful technologies that allow builders to take physical objects, turn them into three dimensional shapes, make changes or restorations, and re-print the parts.

Mattia Mercante uses 3D replication to replace lost pieces of sculptures and fine artworks at the world-renowned Opificio institute in Florence, allowing museum visitors to experience the art as the artists intended.

For one 17th-century reliquary, Mercante scanned intricate frame details from elsewhere on the piece using an HP 3D Structured Light Scanner, and then replicated the missing pieces on a Formlabs 3D printer. The prints were painted to appear identical to the original decorations. Best of all, the restoration required minimum CAD modeling, and was fast and affordable compared to hand craft.

Learn More About Art Restoration

3D printing has as much potential utility in reconstruction as it does in production. The work of a forensic artist is often made difficult by incomplete evidence. Digital technologies can be of tremendous use in legal investigations and can augment the abilities of forensic artists to reconstruct accurate models of persons of interest or victims.

The digital workflow here involves turning CT scans into 3D prints to aid in identification. For instance, when investigators find just part of a skull as evidence, a printer can model and replicate the complete sample.

Reconstructions of the appearance of crime victims have already played a key role in attaining justice, proving once again the utility of 3D printing beyond considerations of design and productive efficiency.

Just like 3D printing can be used for preoperative planning, CT scans of crime victims can help detectives get up-close to bones. Digital CT scan and X-ray data of remains can be used to produce 3D-printed replicas of various body parts. Then, the pathologist can determine the full circumstances of a crime, from the number of participants to the nature of the weapon used.

Learn More About Solving Crime

3D printing's impact is not limited to improving workflows or enabling rapid prototyping. It can also change lives directly. With 30 million people worldwide in need of artificial limbs and braces, there is hope that 3D printing can provide new solutions where cost and specification have traditionally been hurdles.

3D printing can provide an affordable alternative that, like many related advances in medicine, can provide therapy that is much more closely tailored to a patient's needs. The affordability and customizability of 3D printing techniques can profoundly alter the quality of life for the better for those suffering from injury or disability, as we saw in this story of a father and son.

We saw this type of innovation first hand with Matej’s and Mateja’s son Nik, who was suffering from cerebral palsy. Matej set out with a simple goal: to enable Nik to walk. Months of research and development followed, resulting in a custom-made, 3D printed orthosis that provides support and correction exactly where Nik needs them, which finally helped him take his first steps independently. Watch the full video above and read their story.

Beyond prosthetics which return lost function to a user’s body, it is possible to 3D print devices which are, in some ways, even better than the limbs they are replacing. With 3D printing, this is no longer a future possibility about bionetic, robo-cop like body parts, but part of the latest in cutting-edge prosthetic production. Some firms, such as Psyonic, are already delivering advanced prosthetics.

Arm Wrestling With A Bionic Hand

Maybe people think of 3D printing as producing smaller items which you can hold. In recent years, firms have been exploring manufacture-scale additive workflows that can produce much larger functional components. In the last few years, various initiatives have gotten underway to create houses and larger structures that are entirely the product of 3D printing, opening new frontiers in sustainable living and construction.

3D printing technique gives freedom of form to architects, even with previously less malleable building materials like concrete. More broadly speaking, it allows fully sustainable and energy-efficient homes to be built that also meet modern comfort standards. Construction by this means could be entirely waste-free, as well as less expensive and environmentally costly as traditional methods.

While you will not be moving into a 3D printed house on the near horizon, you can experience 3D printed construction projects today. The MX3D Bridge in Amsterdam is currently open to foot traffic. According to dezzen.com, the “structure used 4,500 kilograms of stainless steel, which was 3D-printed by robots in a factory over a period of six months before being craned into position over the canal this year.”

Source: www.dezeen.com

12 Uses for 3D Printers at Home

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Martin

Martin has a M.Sc. in physics and has gained many years of experience in industry as a lab manager and quality assurance manager. He has now tested dozens of 3D printers and is happy to share the collected experience with each new article.

Having Fun

Whether you’re printing miniatures for your tabletop, toys for your kids, your own action figures, or just decorative items for your home, the many uses for 3D printers at home give you plenty of room to express your creativity!

The endless possibilities of 3D printing offer you always new things you can learn and try. For inspiration, you have your own creativity as well as that of many other hobbyists. On websites like Thingiverse you can find numerous objects that you can print.

There are also countless filaments you can try:

TPU: An elastic filament that can be used to print many interesting objects.
Wood*: Filaments with wood fibers are especially popular for decorative items.
transparent filaments: some filaments, like PETG, are available in transparent form.
ABS: After PLA, the most popular filament for 3D printing. It is very tough and well suited for functional objects.

Especially when you venture into unknown territories and try new things, a sense of achievement is not long in coming. Of course, a certain amount of frustration is also pre-programmed, as there are many minor problems in 3D printing.

But for these problems, there is always at least one simple solution. And especially the overcoming of such problems brings you a sense of achievement and therefore a lot of fun.

As you can see, you probably won’t get bored with this hobby. The endless creativity of the community always provides you with new 3D objects that you can try out. There will also always be new interesting 3D printers that raise your interest.

A very interesting aspect of the 3D printing hobby is upgrading your own 3D printer. For example, the extremely popular Ender-3 from Creality* offers countless upgrade options, allowing you to transform it from an extremely affordable entry-level model into a capable 3D printer for your own use.

It’s also a lot of fun to get friends and family involved in your hobby. The enthusiasm for 3D printing is highly contagious and you can have a lot of fun with gifts or joint projects.

3D Printed Practical Things

Stackable Battery Holders by adoniram made by iceekb

As already mentioned, there is an almost infinite number of 3D printing templates that you can find online. Among them are not only toys or fan articles, but also many practical objects.

These include, for example, tea dispensers, stylish shelves, speakers, sanding blocks or mini purses. Self-created decorative objects are also very popular. There are numerous templates for plant pots, lamps and other stylish objects for your home.

Many things you need in your household can be 3D printed. This saves you the trip to the hardware store or the purchase on the Internet. This saves you time and money and you even have fun making the object.

Often you need to repair small things in the household and do not have the right part at hand. The resulting improvisation usually looks suboptimal and is in need of repair after a short time. If you 3D print the part to fit exactly, you won’t have these problems.

For many projects, it can be practical to design the objects yourself. This way you have full control over how the object will look and what function it will perform. But you don’t have to worry about needing half an engineering degree or having to deal with complicated CAD programs. There are now very simple online services like TinkerCAD that make designing objects very easy.

An example of a successful DIY project is printing a replacement part for my dishwasher. One of the wheels for the lower basket of my dishwasher was broken. I simply measured an intact wheel and replicated it in TinkerCAD. Then all I had to do was print it out with my 3D printer and mount it (I used ABS* as filament so it could withstand the temperatures in the dishwasher).

3D Printed Toys and Fan Articles

Cute Mini Octopus by McGybeer made by m0g0d0n

Of course, it is exciting to produce practical things with a 3D printer to create real added value. But more often, 3D printers are used in the private sector for fun things like fan articles or toys. Often there are also combinations of practical things and fan items like a Minecraft lamp or a Baby Groot planter.

Other examples of popular fan articles:

Iron Man Mask
Link Sword and Shield
Baby Yoda (Grogu)
Lightsaber
Draft Punk Planter
Hand of the King pin from GoT

If you buy official fan merchandise, it’s usually quite expensive due to its license. 3D printed items can look similarly good and cost only a fraction.

Attention: You are not allowed to sell the fan articles printed at home, otherwise you will get into copyright trouble. But they are very good for decoration or as a gift.

Besides fan merchandise, actual toys are also very popular. And this doesn’t just mean toys for kids, but also for adults. Here are a few examples of popular toys for kids that you can 3D print:

Flexi Rex (T-Rex made of several, movable links)
Spinning Top
Penny Balista

But there are also things for adults like tabletop terrain or figures. Here are a few examples:

3D Settlers of Catan
Fantasy Figures
Watchtower
Dice Tower

3D Printed Gifts

Curved honeycomb vase by eggnot made by Oscar_Perales

Finding the right gift for someone is often not easy. Many options are boring or impersonal. The search for an individual gift is often stressful and unsatisfying. To find a good gift you have to invest a lot of time in the search.

With a 3D printer, however, you have the choice to create anything your creativity can come up with in no time. There are many possibilities to create a personalized gift for friends or family members through 3D printing.

A gift from the 3D printer is always unique and the recipient is usually very happy about it. With a self-made gift, it is obvious that you have dealt with the person and thought about how you can make him or her happy with a gift.

The search for a suitable gift is also very simple. Everyone has a special area of interest or things that they love. If you search for these things on the online databases for 3D print templates, you will find a lot that fits into this niche.

Is your friend or relative interested in a particular movie series, such as Star Wars? Does he or she like to build remote control cars? Or maybe a nice decorative object is just the thing?

For every field of interest or hobby, there are creative ideas that you can 3D print. And even your own creativity limits you here only limited because you can fall back on the creativity of many other hobbyists.

Save Time

With 3D printers, you can produce any geometry in a very short time. This is one of the great strengths of this technology that makes it interesting not only for hobbyists but also for industry and science.

If you need to make a quick repair at home and you’re missing a spare part, you can simply 3D print it. You don’t have to wait for long delivery times and can solve the problem directly.

I mentioned above that this is how I fixed my dishwasher. Had I not printed the broken wheel myself, I would have either had to live with the defect or wait weeks for the replacement part, if it had been available at all.

Depending on what kind of 3D printer you have, smaller parts are ready within 20 to 30 minutes and even complex and large objects after a few hours. I have often saved myself a trip to the hardware store by simply printing the part myself.

Even in the hobby area, you can save a lot of time with your 3D printer and save yourself eternal waiting times. Are you missing a part in a board game? Just print it. Did your kid break a toy? Just print a new one. Want to upgrade your 3D printer but don’t want to wait 4 weeks for a power supply cover? Just print it yourself.

Even with 3D printing itself, you will save more and more time as the process becomes more efficient. With time you will know exactly which settings you need to pay attention to. You will be able to create or find new objects faster and faster and print them with the right settings.

Save Money

We spend far too much money on the little everyday things. Here a new doorstop, there a new plant pot and a kitchen roll holder is also missing.

Especially such small household items add up to a big pile of money over time. But the price of such items in the store or online consists mainly of logistics and profit margin. The actual manufacturing costs are usually only pennies!

If you print such things from a cheap filament, you will save a lot of money in the long run, which you can invest in other, more useful things.

The trend to make your own objects will increase more and more in the future. At some point, it could be that everyone makes their own everyday objects at home.

At the moment it is only possible to print with plastics in the hobby area. But this material alone offers millions of items you can make yourself. This doesn’t mean that the big factories in East Asia will disappear anytime soon, but more and more will happen at home.

Need a new cover for your smartphone? You can print countless designs yourself and not only save delivery times and their costs – you also do something good for the environment because this small plastic item no longer has to be shipped halfway around the world but is produced directly at your home.

Earn Money

3D Printed Products on etsy.com

The production of objects exactly to customer dimensions is a specialty of 3D printing. Few manufacturing methods can deliver similar results so cost-effectively and quickly.

Injection molding, for example, is only worthwhile for objects that you want to produce thousands or even millions of times. But if someone only needs a prototype, injection molding is much too expensive and much too slow. To produce a suitable tool for this alone costs several $1000, engineers and a lot of time. Making a CAD model of the prototype and printing it within a few minutes or hours is much faster and cheaper.

But not only in this professional context, you can earn money with 3D printing, also private persons can earn some money on the side or even start their own business.

There are many startups that make themselves independent with self-designed objects. On Kickstarter, for example, there are regularly new projects that support the launch of tabletop figures. Mostly they are very successful and offer the startup a possibility to make their ideas come true.

You can also offer your self-designed and manufactured products on platforms like ebay or Etsy and sell them directly to customers.

But you don’t only have to have profit in mind. You can continue to feed your hobby with the money you earn from it. If you sell a few items online in between, you can eventually buy a better printer with the profit. This opens up a whole new world of possibilities.

Also, the whole process around the topic of making money with 3D printing can be turned into money. There are now many online portals like udemy where you can offer self-created online courses.

Educate Children

Children learn best when they can try things out for themselves and enjoy the activity. 3D printers are a perfect example of how hands-on technology can support learning new skills.

Building a 3D printer yourself and holding a self-printed object in your hand promotes the technical competence of children enormously. Also, the sense of achievement to hold something self-made in your hands contributes strongly to the development of the child. To get only dry theory through monotonous lectures or boring books is not very effective. Many schools and universities have noticed this by now.

There are now many educational institutions that use 3D printers in their teaching. Especially DIY 3D printers are advantageous because they promote problem-solving. The learning effect is even greater when you have solved a problem while printing in a team and can hold the perfect result in your hand at the end.

In today’s world, it is increasingly important that children learn how to use technology. Once they lag behind, they can hardly catch up with the others.

3D printers cover many areas of modern technology that should be learned. The perfect combination of touchable technology, entering settings in the 3D printer program and operating the 3D printer via touch screen, is the perfect mix of digital and analog technology.

If you are looking for a 3D printer for children, you have to make sure that it is safe to use. Also, children should only use filaments that do not release toxic gases.

Experience the Future

Large-Scale 3D Printer (source: forcetechnology)

3D printing is still in its infancy. The technology will continue to evolve over time and take over more and more areas of our lives. The technology will not only spread in the industry, but it will also influence our everyday life immensely.

While 3D printing is still a gimmick or an interesting hobby for many at the moment, it will be indispensable in the future. With many technical gadgets, we have justified doubt before buying whether it is worthwhile to invest in this technology at all or whether it is just an entertaining fashion and quickly becomes boring.

With 3D printing, however, you are actively participating in a future technology that will continue to develop over time. This is not only exciting but also practical, as you are one of the first to benefit from the advantages of 3D printing.

It is also very exciting for children to learn about this technology as it will have even more importance in their future. In 20-30 years, when every household is printing its own everyday items, these children will be able to say that they were there at the beginning.

Just as it sounds inconceivable to kids today when you tell them you’re older than Google, this will eventually be the case with 3D printing. When it is taken for granted that you can print a new coffee mug or a new chair, it will be unimaginable for many that they had to have these objects sent to their homes from manufacturers around the world.

So when you invest in a 3D printer, you make sure that you don’t get stuck in the past and join a conversation when it comes to future technologies. The ever-growing topic will continue to develop and thus remain endlessly exciting.

Boost Your Creativity

3D printing is like magic! And just like magic, 3D printing is only limited by your creativity.

And it’s not just about what you should print next but also how you solve problems. Like so many things in life, the journey itself is the destination. While 3D printing is all about holding a specific object in your hand at the end, it’s also about getting to grips with the 3D printer, its settings and the associated software, especially when it comes to the hobby.

Depending on which aspect of this hobby you want to focus on, you can either buy a 3D printer kit or a ready-made high-end 3D printer.

With a kit, you have to do a lot more tinkering on your own. With a ready-made 3D printer of high quality, it is actually only necessary to download the appropriate 3D object and press a few buttons in the 3D printing software and on the 3D printer itself.

But you don’t need to be afraid of such DIY kits – there are now countless tutorials in video and text form that explain everything about such kits. In addition, there are many specialized forums where you can address problems and think about solutions together.

Indulging in a creative hobby can bring you a lot of joy and be a meaningful pastime. There are far too many distractions to get lost in these days that don’t add value in the end. Social media is depressing, but a creative hobby makes for lasting happiness as long as it doesn’t get boring. And with the endless possibilities of 3D printing, this hobby can’t get boring!

Protect the Environment

PolyTerra*, the Environmentally Friendly 3D Printing Filament (source: 3dnatives)

The environmental footprint of 3D printers can be much smaller than that of conventional manufacturing processes.

For 3D printing, you need filament which is manufactured and shipped in one spool. All the objects you make from this one spool do not need to be shipped or made.

Most manufacturing processes require a lot of energy and several steps to produce the final product. With 3D printing, this is only one step and only some electricity. And even this electricity you can get from sustainable sources.

It is unbelievable how many items ordered online are transported across our oceans. It’s a seemingly endless series of massive container ships blowing their exhaust fumes into our environment. Some of this could be saved if we made more items at home. Besides, it could save you a lot of time!

It is now even possible to recycle and reuse filaments. This way you could reduce the impact on our environment even more. There are also a variety of eco-friendly materials available for 3D printing.

The most popular filament for 3D printing is PLA. This plastic is biodegradable and can be produced in an environmentally friendly way. So if it’s important to you to protect the environment, you should use materials that don’t harm our planet even more.

Learn New Skills

From the idea to the finished 3D printed object, you have to go through a few processes. All these processes are very different and require different skills.

Not only do you need to be comfortable with digital media, but you also need some dexterity and technical understanding. And if any of these aren’t your strengths, 3D printing is a perfect way to turn that weakness into a strength!

3D printer assembly: right at the beginning you train your technical understanding when you assemble the 3D printer. Some 3D printers, especially those in the lower price segment, are delivered in a half-assembled state. Here you have to do it yourself and make sure that everything is connected correctly.

Upgrading a 3D printer: Many 3D printers can be upgraded. There are many purchasable upgrades that you just need to install. But there are also many printable upgrades, such as a more efficient housing for the hot end or a filament holder.

Create 3D models: If you want to create your own CAD models, you’ll learn a lot of skills that can be useful in other fields. The intuitive handling of new software is also extremely important for almost every career or job.

Solving problems: A variety of problems can arise during 3D printing. Sometimes the filament throws bubbles (“blobs“), small threads appear on the print object (“stringing“) or the first layers curl up (“warping“). For all these problems there are solutions that have to be found and applied. You will not only learn a lot about 3D printing – your ability to solve problems, in general, will be promoted.

Conclusion: 3D Printers Are Worth It!

3D printing has successfully found the home user. Entry-level 3D printers are more affordable than ever, and usability is improving all the time.

The entry hurdle is getting lower and lower and it is no longer a big investment to dedicate yourself to this hobby. The only requirements you need to bring for the hobby are curiosity, a PC and internet access. If you have all this, you will very quickly find pleasure in being able to hold your own creations in your hands.

As you’ve seen in this article, there’s almost no limit to the things you can print. You’ll also save time and money in the process.

If you are interested, these articles are the next step:

Best 3D Printers for Beginners
Best 3D Printer DIY Kits
Best 3D Printers under $300, $500 and $1000

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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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

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

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.

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.

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.

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.

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.

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!

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.

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.

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

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, builds or grows.

In the first step of printing, the data from the drawing or 3D model is read by the printer.
Next is the sequential overlay of layers.
These layers, consisting of sheet material, liquid or powder, are joined together to form the final shape.

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 have to do is import it into the Slicer, a program that adapts the model into codes and instructions for a 3D printer, most of the programs are open source and distributed free of charge. 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 even 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 into 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 use cases:

Custom Models

Create custom products that perfectly fit 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.