3D printing also referred to as additive manufacturing is method using digital image file to create 3D solid objects. 3D printing processes are laid out using 3D printers till production of object is completed.
3D printed products are produced using an additive method that involves printing layer upon layer of different materials until they are printed. Each layer is cut into fine section of product being printed. With 3D printing its now possible to print intricate designs and not use same quantity of material traditional production techniques require.
The operation method employed for 3D printing follows in same with “subtractive manufacturing” in which materials are taken out or hollowed out using tools such as milling machines. Contrary to additive manufacturing it doesnt require molds or another blocks of material to create tangible objects. Instead it applies layers of material are fused before being able to create layers.
3D printing allows rapid production with low costs for stationary equipment and also ability to create complex geometries using diverse types of materials which traditional manufacturing processes would not be able to do with similar efficacy.
The timetable to 3D printers
Most commonly related to Do It Yourself (DIY) type of amateurs and hobbyists. 3D printing is now able to cover commercial and industrial applications. Engineers nowadays frequently use 3D printers for prototyping and create lightweight geometric designs.
The beginnings of 3D printing began within “rapid prototyping. technology that was basis of it was created during early 1980s. This term was coined because at time 3D printing could only be used for creating prototypes not for production parts. primary reason for development of 3D printing was speeding creation of novel products with rapid prototype.
Its interesting to note that this technique didnt draw much attention at moment it was announced. In year 1981 Japanese inventor Hideo K. Kodama filed his first patent patenting device that used ultraviolet light for curing photopolymers. few years later French inventors Olivier de Witte Jean Claude Andre and Alain Le Mehaute jointly filed patents for similar technologies. Both patents were rescinded as well as General Electric saying latter patent wasnt good idea for business .
In 1984 American inventor Charles Hull filed patent on an apparatus for production of 3D Objects with Stereolithography. Hull created STL file and then created 3D Systems 3D Systems three years later in 1987.
While doing so important steps were made with regards to advancements in US 3D printing and patents were issued for use of selective laser Sintering (SLS) as well as fused deposition modelling (FDM). Desktop Manufacturing (DTM) Corp. and Stratasys were among pioneering companies that were pioneering in 3D printing that were established around simultaneously.
The market was transformed after rapid commercialization started to rule it. Initial 3D printers were costly as well as large and their makers had to compete for contracts manufacturing massive prototypes for consumer products such as vehicles aerospace and health manufacturers.
In 1987 3D Systems had introduced first commercial grade SLA printer. In 1992 Stratasys and DTM released very first commercial FDM alongside SLS printers as well as SLS printers. first 3D printer made of metal was released in year year 1994 in 1994 by Electro Optical Systems (EOS) German company.
The beginning of millenniums new century firms operating in 3D printing industry were competing in market for profits. advancements in field of material science as well as expiration of many patents boosted price for 3D printing.
With coming of technological advancements in 3D printing manufacturing methods are no longer owned solely by businesses that were funded by huge equipment and capital. Today 3D printing has evolved into revolutionary method for making variety of parts to make products.
How Does 3D Printing Work?
The ISO/ASTM52900 that relates to fundamental ideas and terms in additive manufacturing categorizes three dimensional printing methods in seven different types. Each type of 3D printing works differently.
The amount of time printing process takes for 3D object will depend on what kind of printing is used dimension of print as well as type of material utilized desired quality and setting configurations. 3D printing may take anything from couple of minutes to many days.
The different types of 3D printing comprise:
1. fusion of powder bed
When it comes to the process of powder bed fuse (PBF) it involves the use of heat energy which can be in shape of an electron beam or laser. Lasers are employed to fuse certain areas of bed so that layers can be formed. layers are then stacked on top of one before being fused until final piece forms.
PBF may include sintering or melting processes but fundamental method is similar. Roller or recoating blade places an extremely fine layer powder on top of platform in order to construct. After that top layer of powder is then scan with to create energy sources. heat source is used to increase temperature of particles for bonding specific areas.
After heat source scans sections of surface or section platform will be reduced so that process will continue to next layers. End result is region filled with melting pieces leaving surrounding powder remains unaffected. platform then raises to allow it to be removed from final item. Powder bed fusion is made up of variety of traditional printing techniques such as selective laser intersintering (SLS) and Direct Laser Sintering (DMLS ).
SLS is commonly used in production of polymer components to serve as prototyping and functional parts. SLS printing takes place by using bed of powder as main support structure. As there arent any additional support structures they allow creation of complex geometric forms. However parts produced generally have internal porosity and uneven surfaces and typically require further processing.
SLS can be compared in number of methods to process of selective laser melting (SLM) and EBM powder bed Fusion (EBPBF) together with Direct Metal Laser Sintering (DMLS). However these processes are utilized to produce parts from metal and rely on lasers to fuse powder particles at interval.
DMLS raises temperatures of particles but only until moment particles join in molecular degrees. However SLM totally melts metallic particles. Both methods require sufficient to heat and require support structures. When process is complete support structure is removed using CNC machines or hand. Parts are later treated using use of thermal treatment to lessen tension during post processing.
Metal 3D printing techniques produce parts with superior physical characteristics. At times even stronger than base metal which is utilized. Its surface finish may be impressive as well. In terms of material they could be utilized to treat ceramics and superalloys made out of metal that are not suitable in other processes. Both DMLS and SLM demand significant cash and also size of production capacity.
2. Photopolymerization of VAT
The VAT photopolymerization process can be divided into two different methods: digital light processing (DLP) and stereolithography (SLA). Both methods create layers of components using an illumination source which can precisely cure liquid substances (usually resin) and stored in an ingot.
DLP technique is method for flashing images from every layer of vats of liquid. As opposed to SLA is based on only single points UV source or lasers to curing liquid. excess resin must be removed from item after printing has been completed. product is placed in UV light in order to improve quality of product. Any support structures that are in place is required to be removed following process. after that you are able to use components for better finishing.
They are best suited when it comes to production that requires precision in dimensions as they can produce stunningly detailed items that feature excellent quality finishes. DLP as well as SLA are also excellent for creation of prototypes.
The issue is that this techniques outcome is typically brittle making them incompatible for designs that could be useful. color of these components and mechanical properties of these parts are likely to be damaged by UV radiation from sun making parts incompatible with outdoor use. Support structure in addition is frequently required and can create marks that are cleaned up by post processing process.
3. Binder jetting
Binder jetting involves placing powdered substances like ceramic polymer sand or metal on platform for building. After that print head applies drops of adhesive to join powdered particles. This is reason why parts are constructed layer by layer.
Metal components need to be sintered or infiltrated with metallic materials with melting temperature which is lower for instance bronze. components made of clay or polymer with full color can be coated using cyanoacrylate adhesive. post processing process is usually essential to get final outcome.
Binder jetting can be used to serve variety of functions in large ceramic moulds prototyping in full color and three dimensional metallic printing.
4. Material jetting
Material jetting shares conceptual idea of printing using inkjet. Instead of printing ink on paper it makes use of printing equipment or printer to distribute layer of liquid. Each layer is dried before next layer gets made. Jetting of material is dependent upon supporting structures. They are capable of being made from by water soluble substances that may be rinsed off after completion of construction.
This process that is highly precise allows production of premium quality full color elements that are bonded to various kinds of substances. process is nevertheless costly because products are often delicate and indestructible.
5. modeling of deposition and fusion
In fused deposition modeling (FDM) that heated nozzle is employed to connect filament spool with an extrusion head. Extrusion head increases temperature of material which causes it to soften before placing it into specific areas to cool. After layer of material has been created platform is lowered to create layer to be placed.
The method also known as extrusion of material has very shorter lead times and cost much less. But dimensional accuracy isnt very high and smooth finish typically calls for post processing. Additionally output doesnt work well for critical scenarios since its usually anisotropic. i.e. less durable in direction of one.
6. Sheet lamination
Lamination of sheets is classified in two different types of technologies that comprise Ultrasonic Additive Manufacturing (UAM) in addition to laminated object manufacturing (LOM). UAM has lower requirement for heat and energy as well as joining thin metal sheets using an ultrasonic welding method. It can work using range of metals such as aluminum and titanium stainless steel. But LOM uses layers of material and glues to ensure creation of final product.
7. Direct energy deposition
This method employs lasers or electron beams of electric arc or any other technique of focusing energies to melt steel or wire feedstocks in way that is placed. This process is carried out on horizontal planes to form layers. They are then laid horizontally and stacked to make components. process is used to make various kinds of materials including polymers ceramics and as for metals.
Top 7 3D Printing Software
The industry of 3D printing is highly dependent on software. There are applications that produce output and later convert it to G codes that control 3D printer. Explore best 3D printing programs for different programs.
1. MatterControl 2.0
MatterHackers solution MatterHackers includes complete print host slicer as well as CAD software made specifically for use on desktops. It lets users make models inside an CAD section and slice models. Once model has been set to print MatterControl 2.0 can be used to control and monitor printing by using USB connection as well as Wi Fi modules.
The program comes with an easy to use interface that allows users to explore various geometric primitives that can use for printing. These geometrical primitives may be placed on standard triangle (STL) file which is afterwards printed. These can be classified as structural supports.
MatterControl allows users to gain access to advanced printing settings which make it ideal tool for supporting complete design and preparation slicing as well being control. Enterprise license holders can upgrade into MatterControl Pro with additional features which are better.
2. Tinkercad
This browser based solution allows users to create 3D printable models. program also gives opportunity to practice real world modeling. block building tool is simple to utilize and lets users create models from most basic geometric forms.
Tinkercad offers wealth of instructional videos and instructional videos that help those who want to create best designs and can then be exported and distributed effortlessly. It allows users to open millions of files that permit them to search and modify desired shapes. Also it permits users to integrate directly with printing services from third parties.
3. Blender
The open source and free software is suitable for beginner as well as experienced users. It comes with lot of options and features for 3D modeling and sculpting and as well for rendering animation editing of simulation videos along with motion tracking. It comes with an extremely steep learning process.
4. UVTools
Open source software is among most complete resin printing tools which has superb file viewer and specifically designed to facilitate fixing layers and controlling to create Masked SLA. Its fully integrated with PrusaSlicer and provides users with access to variety of third party MSLA print profiles.
Twin Stage Motor Control (TSMC) is an essential feature that UVTools has. It permits tied print speed that is different for each motion part in layer. It speeds printing speed and boosts chances of printing successfully.
Furthermore UVTools permits users to create individual curing times of resin layer calibration prints to be used to test new resins and also to make appropriate configurations for different layers.
5. WebPrinter
WebPrinter is browser based application that lets users view G codes without need to open files using fully capacity slicer. user just needs to upload G code file into WebPrinter and WebPrinter can provide way that files can be transfer to 3D printer. Its straightforward and simple way to check out possible 3D printing.
6. Ultimaker Cura
The slicer which is open source is compatible in conjunction with modern 3D printers. Cura is great option for those who are new to 3D printing because its simple to use and quick to operate. Advanced users will appreciate capabilities to make use of 200 different configurations to improve prints.
7. Simplify3D
Simplify3D is an efficient and fast slicer that can enhance quality of 3D printing. It breaks down CAD layers to fix model issues and also provides glimpse of printout. top attributes allow it to be used with huge scale heavy use 3D printers.
3D Printing Applications
Although 3D printing isnt new technology which was developed in past but its gained massive popularity in recent years across industries due to its simple efficiency as well as efficiency in terms of cost.
The most well known applications to print 3D objects comprise:
1. Construction
Construction is one of most important applications that 3D printing can be used for. Concrete 3D printing was researched from 1990s when researchers were looking for more efficient and cost effective methods of building structures. Specific applications of 3D printing in construction industry includes welding bonding using powder (reactive bond polymer bond ) and Sintering) and extrusion (foam concrete wax and polymers). ).
Today large scale 3D printers printing concrete are utilized to construct foundations and to build walls on site. These printers can also be utilized to print concrete sections which are modular and can be assembled at site.
This allows for higher precision more complex constructions faster constructions and improved functionality. All and reduces cost of workers and eliminating waste material.
The an initial bridge designed for pedestrians (12 meters in length and 1.75 meters wide) has been built 3D in Spain by using reinforced concrete that is micro porous. following year The first 3 D printed home was built in Russia. 600 walls were printed prior to being assembled. After that interiors as well as roofs were built for area of 300 square meters.
3D printing can also be used to design models that have an architecture scale. technology is currently being researched as way of creating extraterrestrial habitats on Mars as well as Moon or Mars should there need.
2. Prototyping and manufacturing
If youre using traditional method of injection molded prototyping it could take several weeks to design mold which can be valued at hundreds of thousands of dollars. main reason in previous article using 3D printing was expedite and improve prototyping.
3D printing reduces manufacturing times which means prototypes can be created in only few hours and at less than fraction of price. This is particularly beneficial for applications that require users to change design after each successive attempt.
3D printing can be utilized to create items that dont need production in large numbers or have to be modified. SLS and DMLS are employed to make fast production of goods which are just prototypes.
3. Healthcare
for healthcare professionals 3D printing produces prototypes to help develop innovative products in medical and dental sectors. In dental sector 3D printing can be additionally beneficial for dental crowns made of metal as well as in production of instruments to make dental aligners.
It can also be useful for directly manufacturing knee and hip implants and other components that are already readily available and also for creation of products specifically for people with hearing loss like custom made hearing aids prosthetics for hearing aids as well with orthotic insoles. Printing is now possible. 3D surgical guides that aid during specific procedures and 3D printed skin bone organs and pharmaceuticals are also being studied.
4. Aerospace
Within field of aerospace 3D printing is utilized to create prototypes and models. It can be beneficial for developing aircraft because it aids researchers in maintaining rigorous demands of R&D while not compromising top standard in industry.
Some of older or less essential parts of aircrafts can be printed in 3D for flying!
5. Automotive
Automotive manufacturers particularly focused on race cars such as those used in F1 employ 3D printing for prototyping and also to manufacture certain parts.
Businesses in this area are also exploring possibility of combining 3D printing to aid in aiding in satisfying market demand for in aftermarket through manufacturing of spare components to meet needs of customers rather than having them in stock.