3D printers convert digital models into three-dimensional parts using a range of printing technologies. They include sintering, melt fusion and stereolithography.

Printing

By building them layer by layer, impression 3D turns digital models – which are mathematical representations of any three-dimensional surfaces created using computer-aided designing (CAD) software, or scanned directly from physical objects – into real parts. The printers vary in size, material, and technique but all share the ability to turn computer-generated data into a tangible object.

Desktop/home 3D Printers can be divided into two categories: resin MSLA and filament FDM. In FDM, a thermoplastic material such as ABS (acrylonitrile butadiene) or PLA (polylactic acid) is melted down and extruded in layers over a printing bed. This technology is used in many printers for consumers and hobbyists.

MSLA printers build models from a vat of liquid photo-sensitive resin that solidifies as the UV laser beam passes over it layer by layer. Different colors and materials are available for printing. These printers typically require a longer process than FDM printers and produce models with smooth surfaces.

Most printers include print preparation software, which slices the digital model horizontally into cross-sections. This allows the user to adjust and select printing settings. The software creates a file containing a series commands that the printer can follow to produce the part. The file can be sent to the print via Wi-Fi, or wired.

3D printing, unlike traditional manufacturing, is done closer to where the product will be used, reducing freight costs and emissions. Printing with sustainable materials like biodegradable polymers such as Polylactic Acid (PLA), gives businesses an edge by reducing the environmental impact.

The speed with which 3D printers can turn digital designs into tangible prototypes reduces product development time by weeks, making them a valuable tool for companies that need to quickly test new products and design. The ability to create customized parts for every customer can increase profitability through a reduction in production time.

Materials

There are a variety of materials that can be printed with a 3D Printer, and each has its own properties and advantages. Plastics and polymers are the most common, followed by metals and composites. Ceramics and other non-traditional material are also popular. The type of material you choose for your print will depend on what kind of part you are trying to create and what it will be used for. A concept model for a new package might not need a very durable materials, but a prototype that will be tested could benefit from a strong and lightweight material.

Most consumer-level 3D Printers use a technique called fused deposition modelling (FDM), in which filaments such as acrylonitrile, butadiene, styrene and nylon are heated, then deposited layer by layered. This is the same technology used by most office printers. It is easy to use and relatively inexpensive. It can produce a variety of colors, including some textures.

Selective laser sintering is a more advanced form of 3D-printing. A powerful laser heats powdered polymer particles to create parts. The process is extremely fast, precise, accurate, and ideal for manufacturing prototypes and manufacturing tools. It can also handle difficult geometries that are too complex for FDM printing, such as undercuts and thin walls.

Selective laser-sintering can also produce parts with high quality finishes, such as smooth surfaces, a variety of colors, or even some translucency. This is especially important for aesthetics, as it can make the difference between a prototype that looks professional and one that looks like a student project.

The field of 3D printing materials is constantly expanding, with new polymers and composites emerging to meet the needs of a growing range of industries. Polyether Ether Ketones (PEEK) or Polyetherimides (ULTEM) are two families that offer excellent thermal resistance and strength. They are therefore ideal for aerospace and automobile applications. Their biocompatibility, optimal strength to weight ratios, and high-performance properties make them ideal for medical implants and engineering components. Aluminum alloys and titanium are also high-performance materials that provide lightweight, corrosion resistant properties. They are ideal for industrial applications.

Supports

Support structures are a crucial part of FDM 3D Printing. They help overcome certain design restrictions, such as overhangs and steep angle. Many slicer programs such as Cura automatically generate supports. This can save a lot of time. To optimize your print quality, you need to know how and when to use them.

The main goal of creating supports is to keep your print stable and in one piece, which can be challenging for overhanging parts or features that extend from the base of a model. The density of your support material will determine how hot and quickly they cool. You need to find the perfect balance between strength, and ease of removal.

Another factor to consider is how your supports attach to the model. If your supports are too thin, or not well attached to the base of the model, it may be difficult to remove without damaging or marking the finished product. You can adjust many settings in your slicer to enhance support attachment and remove.

One of the most common ways to reduce the amount of support material used is by reorienting your model. This involves rotating your design or flipping it so that any bridges or overhangs are supported by flat surface. This technique can drastically decrease the number of supports needed and save on both printing time and materials.

You can reduce the amount required of support material if you use a 3D printer with multiple extruders by activating horizontal growth. This setting produces longer, thinner supports which are more durable and easy to remove from the printed object. Finally, you can increase the thickness of your support infills to make them more resistant to vibrations and heat from your printer.

If you’re printing with resin-based 3D printers, such as SLA and DLP, you can print dissolvable supports that are removed during post processing using water jets or ultrasonic baths. This method eliminates manual pliers, and allows for more accurate support removal without compromising your prints’ quality. It’s important that you remove the support carefully, regardless of which type you choose. This will ensure that your final product is intact.