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Whats a 3d printer


What is 3D printing? How does a 3D printer work? Learn 3D printing

3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital file.

The creation of a 3D printed object is achieved using additive processes. In an additive process an object is created by laying down successive layers of material until the object is created. Each of these layers can be seen as a thinly sliced cross-section of the object.

3D printing is the opposite of subtractive manufacturing which is cutting out / hollowing out a piece of metal or plastic with for instance a milling machine.

3D printing enables you to produce complex shapes using less material than traditional manufacturing methods.

Table of Contents

  • How Does 3D Printing Work?
  • 3D Printing Industry
  • Examples of 3D Printing
  • 3D Printing Technologies & Processes
  • Materials
  • Services

Jump to your field of interest:

  • Rapid Prototyping & Manufacturing
  • Automotive
  • Aviation
  • Construction
  • Consumer Products
  • Healthcare
  • Food
  • Education

Jump to process:

  • All Technologies & Processes
  • Vat Photopolymerisation
  • Material Jetting
  • Binder Jetting
  • Material Extrusion
  • Powder Bed Fusion
  • Sheet Lamination
  • Directed Energy Deposition

How Does 3D Printing Work?

It all starts with a 3D model. You can opt to create one from the ground up or download it from a 3D library.

3D Software

There are many different software tools available. From industrial grade to open source. We’ve created an overview on our 3D software page.

We often recommend beginners to start with Tinkercad. Tinkercad is free and works in your browser, you don’t have to install it on your computer. Tinkercad offers beginner lessons and has a built-in feature to export your model as a printable file e.g .STL or .OBJ.

Now that you have a printable file, the next step is to prepare it for your 3D printer. This is called slicing.

Slicing: From printable file to 3D Printer

Slicing basically means slicing up a 3D model into hundreds or thousands of layers and is done with slicing software.

When your file is sliced, it’s ready for your 3D printer. Feeding the file to your printer can be done via USB, SD or Wi-Fi. Your sliced file is now ready to be 3D printed layer by layer.

3D Printing Industry

Adoption of 3D printing has reached critical mass as those who have yet to integrate additive manufacturing somewhere in their supply chain are now part of an ever-shrinking minority. Where 3D printing was only suitable for prototyping and one-off manufacturing in the early stages, it is now rapidly transforming into a production technology.

Most of the current demand for 3D printing is industrial in nature. Acumen Research and Consulting forecasts the global 3D printing market to reach $41 billion by 2026.

As it evolves, 3D printing technology is destined to transform almost every major industry and change the way we live, work, and play in the future.

Examples of 3D Printing

3D printing encompasses many forms of technologies and materials as 3D printing is being used in almost all industries you could think of. It’s important to see it as a cluster of diverse industries with a myriad of different applications.

A few examples:

  • – consumer products (eyewear, footwear, design, furniture)
  • – industrial products (manufacturing tools, prototypes, functional end-use parts)
  • – dental products
  • – prosthetics
  • – architectural scale models & maquettes
  • – reconstructing fossils
  • – replicating ancient artefacts
  • – reconstructing evidence in forensic pathology
  • – movie props

Rapid Prototyping & Rapid Manufacturing

Companies have used 3D printers in their design process to create prototypes since the late seventies. Using 3D printers for these purposes is called rapid prototyping.

Why use 3D Printers for Rapid Prototyping?
In short: it’s fast and relatively cheap. From idea, to 3D model to holding a prototype in your hands is a matter of days instead of weeks. Iterations are easier and cheaper to make and you don’t need expensive molds or tools.

Besides rapid prototyping, 3D printing is also used for rapid manufacturing. Rapid manufacturing is a new method of manufacturing where businesses use 3D printers for short run / small batch custom manufacturing.

Automotive

Car manufacturers have been utilizing 3D printing for a long time. Automotive companies are printing spare parts, tools, jigs and fixtures but also end-use parts. 3D printing has enabled on-demand manufacturing which has lead to lower stock levels and has shortened design and production cycles.

Automotive enthusiasts all over the world are using 3D printed parts to restore old cars. One such example is when Australian engineers printed parts to bring a Delage Type-C back to life. In doing so, they had to print parts that were out of production for decades.

Aviation

The aviation industry uses 3D printing in many different ways. The following example marks a significant 3D printing manufacturing milestone: GE Aviation has 3D printed 30,000 Cobalt-chrome fuel nozzles for its LEAP aircraft engines. They achieved that milestone in October of 2018, and considering that they produce 600 per week on forty 3D printers, it’s likely much higher than that now.

Around twenty individual parts that previously had to be welded together were consolidated into one 3D printed component that weighs 25% less and is five times stronger. The LEAP engine is the best selling engine in the aerospace industry due to its high level of efficiency and GE saves $3 million per aircraft by 3D printing the fuel nozzles, so this single 3D printed part generates hundreds of millions of dollars of financial benefit.

GE’s fuel nozzles also made their way into the Boeing 787 Dreamliner, but it’s not the only 3D printed part in the 787. The 33-centimeter-long structural fittings that hold the aft kitchen galley to the airframe are 3D printed by a company called Norsk Titanium. Norsk chose to specialize in titanium because it has a very high strength-to-weight ratio and is rather expensive, meaning the reduction in waste enabled by 3D printing has a more significant financial impact than compared to cheaper metals where the costs of material waste are easier to absorb. Rather than sintering metal powder with a laser like most metal 3D printers, the Norsk Merke 4 uses a plasma arc to melt a metal wire in a process called Rapid Plasma Deposition (a form of Directed Energy Deposition) that can deposit up to 10kg of titanium per hour. A 2kg titanium part would generally require a 30kg block of titanium to machine it from, generating 28kg of waste, but 3D printing the same part requires only 6kg of titanium wire.

Construction

Is it possible to print a building? – yes it is. 3D printed houses are already commercially available. Some companies print parts prefab and others do it on-site.

Most of the concrete printing stories we look at on this website are focused on large scale concrete printing systems with fairly large nozzles for a large flow rate. It’s great for laying down concrete layers in a fairly quick and repeatable manner. But for truly intricate concrete work that makes full use of the capabilities of 3D printing requires something a little more nimble, and with a finer touch.

Consumer Products

When we first started blogging about 3D printing back in 2011, 3D printing wasn’t ready to be used as a production method for large volumes. Nowadays there are numerous examples of end-use 3D printed consumer products.

Footwear

Adidas’ 4D range has a fully 3D printed midsole and is being printed in large volumes. We did an article back then, explaining how Adidas were initially releasing just 5,000 pairs of the shoes to the public, and had aimed to sell 100,000 pairs of the AM-infused designs by 2018.

With their latest iterations of the shoe, it seems that they have surpassed that goal, or are on their way to surpassing it. The shoes are available all around the world from local Adidas stores and also from various 3rd party online outlets.

Eyewear

The market of 3D printed eyewear is forecasted to reach $3.4 billion by 2028. A rapidly increasing section is that of end-use frames. 3D printing is a particularly suitable production method for eyewear frames because the measurements of an individual are easy to process in the end product.

But did you know it’s also possible to 3D print lenses? Traditional glass lenses don’t start out thin and light; they’re cut from a much larger block of material called a blank, about 80% of which goes to waste. When we consider how many people wear glasses and how often they need to get a new pair, 80% of those numbers is a lot of waste. On top of that, labs have to keep huge inventories of blanks to meet the custom vision needs of their clients. Finally, however, 3D printing technology has advanced enough to provide high-quality, custom ophthalmic lenses, doing away with the waste and inventory costs of the past. The Luxexcel VisionEngine 3D printer uses a UV-curable acrylate monomer to print two pairs of lenses per hour that require no polishing or post-processing of any kind. The focal areas can also be completely customized so that a certain area of the lens can provide better clarity at a distance while a different area of the lens provides better vision up close.

Jewelry

There are two ways of producing jewelry with a 3D printer. You can either use a direct or indirect production process. Direct refers to the creation of an object straight from the 3D design while indirect manufacturing means that the object (pattern) that is 3D printed eventually is used to create a mold for investment casting.

Healthcare

It’s not uncommon these days to see headlines about 3D printed implants. Often, those cases are experimental, which can make it seem like 3D printing is still a fringe technology in the medical and healthcare sectors, but that’s not the case anymore. Over the last decade, more than 100,000 hip replacements have been 3D printed by GE Additive.

The Delta-TT Cup designed by Dr. Guido Grappiolo and LimaCorporate is made of Trabecular Titanium, which is characterized by a regular, three-dimensional, hexagonal cell structure that imitates trabecular bone morphology. The trabecular structure increases the biocompatibility of the titanium by encouraging bone growth into the implant. Some of the first Delta-TT implants are still running strong over a decade later.

Another 3D printed healthcare component that does a good job of being undetectable is the hearing aid. Nearly every hearing aid in the last 17 years has been 3D printed thanks to a collaboration between Materialise and Phonak. Phonak developed Rapid Shell Modeling (RSM) in 2001. Prior to RSM, making one hearing aid required nine laborious steps involving hand sculpting and mold making, and the results were often ill-fitting. With RSM, a technician uses silicone to take an impression of the ear canal, that impression is 3D scanned, and after some minor tweaking the model is 3D printed with a resin 3D printer. The electronics are added and then it’s shipped to the user. Using this process, hundreds of thousands of hearing aids are 3D printed each year.

Dental

In the dental industry, we see molds for clear aligners being possibly the most 3D printed objects in the world. Currently, the molds are 3D printed with both resin and powder based 3D printing processes, but also via material jetting. Crowns and dentures are already directly 3D printed, along with surgical guides.

Bio-printing

As of the early two-thousands 3D printing technology has been studied by biotech firms and academia for possible use in tissue engineering applications where organs and body parts are built using inkjet techniques. Layers of living cells are deposited onto a gel medium and slowly built up to form three dimensional structures. We refer to this field of research with the term: bio-printing.

Food

Additive manufacturing invaded the food industry long time ago. Restaurants like Food Ink and Melisse use this as a unique selling point to attract customers from across the world.

Education

Educators and students have long been using 3D printers in the classroom. 3D printing enables students to materialize their ideas in a fast and affordable way.

While additive manufacturing-specific degrees are fairly new, universities have long been using 3D printers in other disciplines. There are many educational courses one can take to engage with 3D printing. Universities offer courses on things that are adjacent to 3D printing like CAD and 3D design, which can be applied to 3D printing at a certain stage.

In terms of prototyping, many university programs are turning to printers. There are specializations in additive manufacturing one can attain through architecture or industrial design degrees. Printed prototypes are also very common in the arts, animation and fashion studies as well.

Types of 3D Printing Technologies and Processes

The American Society for Testing and Materials (ASTM), developed a set of standards that classify additive manufacturing processes into 7 categories. These are:

  1. Vat Photopolymerisation
    1. Stereolithography (SLA)
    2. Digital Light Processing (DLP)
    3. Continuous Liquid Interface Production (CLIP)
  2. Material Jetting
  3. Binder Jetting
  4. Material Extrusion
    1. Fused Deposition Modeling (FDM)
    2. Fused Filament Fabrication (FFF)
  5. Powder Bed Fusion
    1. Multi Jet Fusion (MJF)
    2. Selective Laser Sintering (SLS)
    3. Direct Metal Laser Sintering (DMLS)
  6. Sheet Lamination
  7. Directed Energy Deposition

Vat Photopolymerisation

A 3D printer based on the Vat Photopolymerisation method has a container filled with photopolymer resin. The resin is hardened with a UV light source.

Vat photopolymerisation schematics. Image source: lboro.ac.uk

Stereolithography (SLA)

SLA was invented in 1986 by Charles Hull, who also at the time founded the company, 3D Systems. Stereolithography employs a vat of liquid curable photopolymer resin and an ultraviolet laser to build the object’s layers one at a time. For each layer, the laser beam traces a cross-section of the part pattern on the surface of the liquid resin. Exposure to the ultraviolet laser light cures and solidifies the pattern traced on the resin and fuses it to the layer below.

After the pattern has been traced, the SLA’s elevator platform descends by a distance equal to the thickness of a single layer, typically 0.05 mm to 0.15 mm (0.002″ to 0.006″). Then, a resin-filled blade sweeps across the cross section of the part, re-coating it with fresh material. On this new liquid surface, the subsequent layer pattern is traced, joining the previous layer. Depending on the object & print orientation, SLA often requires the use of support structures.

Digital Light Processing (DLP)

DLP or Digital Light Processing refers to a method of printing that makes use of light and photosensitive polymers. While it is very similar to SLA, the key difference is the light source. DLP utilizes other light sources like arc lamps. DLP is relatively quick compared to other 3D printing technologies.

Continuous Liquid Interface Production (CLIP)

One of the fastest processes using Vat Photopolymerisation is called CLIP, short for Continuous Liquid Interface Production, developed by Carbon.

Digital Light Synthesis

The heart of the CLIP process is Digital Light Synthesis technology. In this technology, light from a custom high performance LED light engine projects a sequence of UV images exposing a cross section of the 3D printed part causing the UV curable resin to partially cure in a precisely controlled way. Oxygen passes through the oxygen permeable window creating a thin liquid interface of uncured resin between the window and the printed part known as the dead zone. The dead zone is as thin as ten of microns. Inside the dead zone, oxygen prohibits light from curing the resin situated closest to the window therefore allowing the continuous flow of liquid beneath the printed part. Just above the dead zone the UV projected light upwards causes a cascade like curing of the part.

Simply printing with Carbon’s hardware alone does not allow for end use properties with real world applications. Once the light has shaped the part, a second programmable curing process achieves the desired mechanical properties by baking the 3d printed part in a thermal bath or oven. Programmed thermal curing sets the mechanical properties by triggering a secondary chemical reaction causing the material to strengthen achieving the desired final properties.

Components printed with Carbon’s technology are on par with injection molded parts. Digital Light Synthesis produces consistent and predictable mechanical properties, creating parts that are truly isotropic.

Material Jetting

In this process, material is applied in droplets through a small diameter nozzle, similar to the way a common inkjet paper printer works, but it is applied layer-by-layer to a build platform and then hardened by UV light.

Material Jetting schematics. Image source: custompartnet.com

Binder Jetting

With binder jetting two materials are used: powder base material and a liquid binder. In the build chamber, powder is spread in equal layers and binder is applied through jet nozzles that “glue” the powder particles in the required shape. After the print is finished, the remaining powder is cleaned off which often can be re-used printing the next object. This technology was first developed at the Massachusetts Institute of Technology in 1993.

Binder Jetting schematics

Material Extrusion

Fused Deposition Modeling (FDM)

FDM schematics (Image credit: Wikipedia, made by user Zureks)

FDM works using a plastic filament which is unwound from a spool and is supplied to an extrusion nozzle which can turn the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism. The object is produced by extruding melted material to form layers as the material hardens immediately after extrusion from the nozzle.

FDM was invented by Scott Crump in the late 80’s. After patenting this technology he started the company Stratasys in 1988. The term Fused Deposition Modeling and its abbreviation to FDM are trademarked by Stratasys Inc.

Fused Filament Fabrication (FFF)

The exactly equivalent term, Fused Filament Fabrication (FFF), was coined by the members of the RepRap project to give a phrase that would be legally unconstrained in its use.

Powder Bed Fusion

Selective Laser Sintering (SLS)

SLS uses a high power laser to fuse small particles of powder into a mass that has the desired three dimensional shape. The laser selectively fuses powder by first scanning the cross-sections (or layers) on the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one layer thickness. Then a new layer of material is applied on top and the process is repeated until the object is completed.

SLS schematics (Image credit: Wikipedia from user Materialgeeza)

Multi Jet Fusion (MJF)

Multi Jet Fusion technology was developed by Hewlett Packard and works with a sweeping arm which deposits a layer of powder and then another arm equipped with inkjets which selectively applies a binder agent over the material. The inkjets also deposit a detailing agent around the binder to ensure precise dimensionality and smooth surfaces. Finally, the layer is exposed to a burst of thermal energy that causes the agents to react.

Direct Metal Laser Sintering (DMLS)

DMLS is basically the same as SLS, but uses metal powder instead. All unused powder remains as it is and becomes a support structure for the object. Unused powder can be re-used for the next print.

Due to of increased laser power, DMLS has evolved into a laser melting process. Read more about that and other metal technologies on our metal technologies overview page.

Sheet Lamination

Sheet lamination involves material in sheets which is bound together with external force. Sheets can be metal, paper or a form of polymer. Metal sheets are welded together by ultrasonic welding in layers and then CNC milled into a proper shape. Paper sheets can be used also, but they are glued by adhesive glue and cut in shape by precise blades.

Simplified schematics of ultrasonic sheet metal process (Image credit: Wikipedia from user Mmrjf3)

Directed Energy Deposition

This process is mostly used in the metal industry and in rapid manufacturing applications. The 3D printing apparatus is usually attached to a multi-axis robotic arm and consists of a nozzle that deposits metal powder or wire on a surface and an energy source (laser, electron beam or plasma arc) that melts it, forming a solid object.

Directed Energy Deposition with metal powder and laser melting (Image credit: Merlin project)

Materials

Multiple materials can be used in additive manufacturing: plastics, metals, concrete, ceramics, paper and certain edibles (e.g. chocolate). Materials are often produced in wire feedstock a.k.a. filament, powder form or liquid resin. Learn more about our featured materials on our materials page.

Services

Looking to implement 3D printing in your production process? Get a quote for a custom part or order samples on our 3D print service page.

What is 3D printing?

David Roberson3 May 2021

Guide

3D printing is a manufacturing process that creates a physical object from a digital model file. The technology works by adding layer upon layer of material to build up a complete object.

Introduction to 3D printing

The 3D printing process was devised in the 1980s and originally known as ‘rapid prototyping’. It enabled companies to develop prototypes quickly and more accurately than with other methods. After over 30 years of innovation, its uses are far more diverse today.

Manufacturers, engineers, designers, educators, medics, and hobbyists alike use the technology for a huge range of applications.

3D printing is an 'additive’ manufacturing process which builds up an object in layers

A 3D printed part in use in the automotive industry

The development of more compact ‘desktop’ 3D printers and their affordable cost have also made the technology increasingly accessible over time.

How does 3D printing work?

As we saw earlier, the 3D printing process involves building up layer upon layer of molten plastic to create an object. As each layer sets, the next layer is printed on top and the object is built up.

To make a 3D print, a digital file is needed that tells the 3D printer where to print the material. The most common file format for this is the G-code files. This file essentially contains ‘coordinates’ to guide the printer’s movements, both horizontally and vertically – also known as the X, Y, and Z axes.

3D printers can print these layers at different thicknesses, known as layer height. A bit like pixels on a screen, more layers in a print will give a higher ‘resolution’. This will give a better-looking result, but take longer to print.

3D printing vs. additive manufacturing?

This adding up of layers gives 3D printing its alternative name – ‘additive manufacturing’.

You will often see the terms used to refer to the same manufacturing process. Additive manufacturing is the opposite of ‘subtractive’ processes where material is removed (or subtracted) from a larger block to create the final object, for example CNC machining.

FDM vs FFF 3D printing – explained

Another thing that may confuse newcomers to 3D printing is seeing references to FDM (fused deposition modeling) and FFF (fused filament fabrication) processes. Again, these are essentially different names for the same thing as they both refer to a specific type of 3D printer.

There are different types of 3D printer? Yes! But no need to be confused – we’ll take a quick look at these next.

What are the different 3D printing technologies?

Plastics are a versatile type of material, and as a result there are many ways of manufacturing with it. 3D printing is no exception, so let’s explore the different methods.

The most widely used technologies are FFF 3D printing, SLA (stereolithography), and SLS (selective laser sintering).

What is FFF 3D printing?

An FFF printer extrudes a thick string of material, commonly referred to as filament, through a heated nozzle. The nozzle is mounted on a motion system that moves it around a build area, where melted filament is deposited onto a build plate. As the material cools and solidifies, the build plate moves down by a fraction of a millimeter layer by layer until the object is complete.

The FFF 3D printing process

What is SLA 3D printing?

SLA 3D printing uses a UV-curable resin as raw material. The resin is poured into a glass-bottomed container, into which a build platform is submerged. A laser shines UV light on the resin to selectively harden a cross-section of the required shape. The platform gradually raises out of the container to build up the print.

What is SLS 3D printing?

SLS 3D printing uses a powdered raw material, typically a polymer. The powder sits in a container, where a blade distributes a thin layer of material onto the build area. A laser fuses the small particles of material together to form a single horizontal layer of the part, then the container then moves a fraction of a millimeter to start a new layer, and the blade swipes across the build area to deposit a new layer of raw material. This process repeats to create the finished object.

A model printed in resin on an SLA printer

Removing a finished SLS 3D printed part

This is by no means an exhaustive list, and you may also come across the following:

  • DLP (direct light processing) – A resin-based process similar to SLA. Instead of a laser curing an individual point of resin at a time, DLP uses light to project an image of the entire layer into the resin

  • Binder jetting – A powder-based process similar to SLS, except that the powder is fused by a binding agent rather than a laser

  • Material jetting – A variation on ‘2D’ inkjet printing that can create 3D parts by depositing wax or plastic material then curing it with UV light

  • SLM (selective laser melting) – One of a few similar variations of SLS technology for metal 3D printing

Want to understand the pros and cons of each technology? Read our in-depth guide comparing 3D printing processes.

What materials are used in 3D printing?

Plastic polymers are the most common material used in 3D printing. Using other materials is possible. For example, there are dedicated metal 3D printers, but these are niche compared to polymer printers. And super-sized machines based on 3D printing technology are starting to be developed for construction materials like concrete.

Mainstream 3D printer types such as FFF and SLS can print blends of polymers and other materials (such as metal, glass, or wood). These are known as composites and offer some of the properties of the blended material.

In the context of FFF 3D printing, you may see the terms ‘3D printing material’ and ‘3D printing filament’ used interchangeably. This is because the raw material comes on spools of thin filament.

In the following sections, we will look at some 3D printing filaments in more detail by category.

Starter 3D printing materials

PLA

Derived from organic, renewable resources and easy to print with, PLA is the go-to beginner’s filament. PLA also has great visual properties. But its low temperature resistance and the fact that mechanical properties can degrade over time mean PLA is often overlooked for functional and mechanical applications.

PETG

A well-balanced mix of properties has seen PETG grow to become one of the most widely used 3D printing materials. It could easily be classed as an 'engineering material', but it's also a good option for beginners thanks to good printability. Combining impact and chemical resistance with good thermal properties, while also being cheaper than many other engineering materials, it’s the go-to filament for engineering applications for many users.

Engineering 3D printing materials

Nylon

Possessing chemical resistance and able to withstand significant mechanical stress, nylon is a versatile option for end-use parts.

ABS

Offering superior mechanical and heat resistance properties compared to PLA, ABS is a material for more demanding applications. However, it can be difficult to print with, especially on a cheaper, open-frame 3D printer. An enclosed build chamber and controlled temperature give a much more reliable experience.

Visual prototypes should have good aesthetic and tactile characteristics

End-use parts need material properties to suit their application, such as wear resistance or flame retardancy

Flexible 3D printing materials

TPU

With its rubber-like properties, TPU can be twisted, stretched, and withstand impacts without problems.

PP

Semi-flexible and fatigue resistant, PP (or polypropylene as you may know it) is ideal for applications that need some flexibility, such as hinges or liquid containers.

Specialist 3D printing materials

Composite materials

These filaments combine a polymer with fibers of another material to give enhanced properties. There are two main categories. Engineering composites including glass, carbon, or metal fibers offer enhanced mechanical properties such as strength and stiffness. And for unique visual properties, there are composite options like ceramic or wood filaments for 3D printing, or even glow-in-the-dark. (Note: the fibers in composite filaments can cause abrasion, so check your printer is compatible before using any).

While they sometimes overlap with the categories above, there are many more specialist 3D printing filaments to discover on the market, such as ESD-safe or flame-retardant materials.

Support materials

First, let’s quickly explain what these are.

Each new layer of a 3D print requires the layer underneath to support it. Issues arise when a print’s design requires an overhang, or an element that’s suspended in mid-air. So these materials literally ‘support’ it during the printing process and are removed after. Supports can be printed with the same material as the rest of the print, but their removal can affect its surface quality and dimensional accuracy. To avoid this, specialized support materials have been developed.

Soluble support material

Soluble support materials are dissolvable, so there is no risk of damaging your part during manual removal. PVA support material dissolves in water, while HIPS requires the solvent d-limonene.

Breakaway

Somewhere between the options mentioned so far, a material like Ultimaker Breakaway is a distinct support material that is manually removed. This makes the process faster than waiting for it to dissolve, while retaining the part’s dimensional accuracy.

A 3D printed part with support material (left) and after the support material is removed (right)

Curious to discover more?

Explore the topic of 3D printing further with blogs that answer the following questions:

  • What can you make with a 3D printer?

  • How to use a 3D printer?

  • How much does 3D printing cost?

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? nine0012
  • How does a 3D printer work?
  • What can be printed?

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

What is 3D printing?

3D printing is an additive manufacturing process because, unlike traditional subtractive manufacturing, 3D printing does not remove material, but adds it, layer by layer—that is, it builds or grows. nine0005

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

With limited production of parts, 3D printing will be faster and cheaper. The world of 3D printing does not stand still and therefore there are more and more different technologies competing with each other on the market. The difference lies in the printing process itself. Some technologies create layers by softening or melting the material, then they provide layer-by-layer application of this same material. Other technologies involve the use of liquid materials, which acquire a solid form in the process under the influence of various factors. nine0005

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

Once your design is ready, all you need to do is import it into the Slicer, a program that converts the model into codes and instructions for a 3D printer, most of the programs are open source and free. The slicer will convert your project into a gcode file ready to be printed as a physical object. Simply save the file to the included SD card and insert it into your 3D printer and hit print. nine0005

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

How does a 3D printer work?

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

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

What can be 3D printed? nine0021

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

Custom Models

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

Rapid Prototyping

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

Complex geometry

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

Cost reduction

The cost of 3D printing end-use parts and prototypes is low due to the materials and technology used. Reduced production time and material consumption as you can print models multiple times using only the material you need. nine0005

How to choose and buy a 3D printer? →

What is a 3D printer and why is it needed? / Amperka

Additive technologies have been going to the masses for a long time: institutes and research centers have been closely involved in them since the 80s, and now the moment has come when you can touch high-tech and master 3D printing right at home. You don’t even have to break the bank to do this: the prices of 3D printers have caught up with average smartphones. We understand how it works and what opportunities open up for makers and DIY enthusiasts! nine0005

Everything for 3D printing ❯

Why you need a 3D printer

The printer is very useful for do-it-yourself engineers. You no longer have to look for a universal case for the project, and then drill additional holes in it. 30 minutes of design, a few hours of printing - and you already have a case that is perfect for your device. Assembly of 5 shields does not fit anywhere? Forget about such problems.

The printer is sure to help you repair gizmos around the house. Everyone has had a situation in life when a thing had to be thrown away, although only one plastic part was broken in it. With the help of 3D printing, you can easily replace rare plastic parts in appliances that are difficult to find separately. nine0005

Until you learn how to model plastic parts yourself, you can simply download them on the Internet. There are many sites with millions of ready-made free models that are freely exchanged by users. We devoted a separate article to the search for models.

Types of 3D printers

There are several main types of 3D printers that differ fundamentally in terms of how they work.

FDM (Fused Deposition Modeling)

FDM printers are the most common type. They work due to a movable print head with a heating element. Plastic is fed into it in the form of a rod, which melts and is squeezed out in liquid form onto the printing table. At the same time, the plastic is blown by a fan and instantly freezes, and the head begins to squeeze out a new layer over the frozen one.

SLA technology (Stereolithography Apparatus)

SLA printers work on the basis of stereolithography: instead of plastic, a special photopolymer resin is used, which cures under the influence of ultraviolet rays. For printing, the resin is filled into a tray, below which there is a display with ultraviolet pixels. A drawing of the lower layer of the model is displayed on it for several seconds. In this case, the resin above the display solidifies in the form of a displayed pattern and then sticks to a special movable table from above. After that, the table with the first layer rises, and the next layer polymerizes in the resin. nine0005

SLS (Selective Laser Sintering) Technology

SLS printers use selective laser sintering technology, which uses a special plastic powder. During the printing process, a thin layer of powder is poured, and the printer processes it with a laser so that the layer hardens according to the model. Then the next layer of powder is poured and fused with the previous one - and so on in a circle. At the end, it remains only to clean the finished part from the remnants of the powder, which can then be reused. nine0005

Technology comparison

Each type of 3D printer has its own advantages and disadvantages.

  • SLS printers are large and require expensive raw materials. They are often used in high-tech industries for piece parts.
  • SLA printers are much more widespread. The UV display improves accuracy, but working with toxic photopolymer resin at home is difficult.
  • FDM printers are the most popular among hobbyists. A plastic rod is much cheaper than a special powder or photopolymer resin. However, to print complex geometry on such a printer, you will have to take care of auxiliary support. And the print speed is on average lower than on other technologies. But FDM printers are the easiest and safest to maintain. nine0012

How to prepare a print

The process from the idea to the finished plastic part is simple - a schoolboy can handle it. We've broken it down in a 3D printing guide using the Flying Bear Ghost 5 printer as an example, but here we'll show you the general principle.

Initial model

First you need to create or download a 3D model of the future part. As a rule, sources are stored in the STL format, which describes the polygonal structure of the model as a set of triangles. But it will not be possible to immediately send such a file to the printer: for successful printing, you first need to break a detailed 3D model into layers that the printer can handle. nine0005

Slicing

The program for cutting models (slicer) will require you to enter the model of your printer and set the print settings: layer thickness, percentage of internal filling of the part, auxiliary supports and the like. Based on this data, the slicer will automatically prepare a special code for the printer - G-Code, which describes how to move the print head, to what temperature it should be heated, and at what speed to extrude plastic in order to get the desired model layer by layer. Then it remains to load this code into a 3D printer and be patient until the end of printing. nine0005

The whole process of model preparation is clearly illustrated by the program and provided with intuitive tips for novice users. In general, slicing is not as scary as it is painted!

Finishing

After the model is ready, it can be further processed with sandpaper or a chemical solution. This will smooth out the unevenness between the layers, and the part will look just like the factory. There are a lot of life hacks on the Internet that will help minimize the flaws of the model and give it an improved look. nine0005

Printing consumables

The properties of the printed item largely depend on the raw material. As we said before, FDM 3D printers use plastic filament as a consumable, and you have a lot of room to experiment with different types of plastic.