What is 3d-printing?

3D printing, also known as additive manufacturing, is a process in which material is added layer by layer to create a finished product, rather than removing material from a block to shape it like in traditional manufacturing methods such as CNC machining. This method is more efficient as there is less waste material, and it does not require the energy-intensive process of smelting and reusing waste as in metal manufacturing.

Process of a 3d-printed object

The Process of Printing an object compared to other low volume production methods is also way simpler. The steps a model must go through are pretty much the same, but the individual steps are usually way simpler with a 3D printer.

1. For both methods you first have to create a 3d-model in a Cad-software.
2. The next step is preparing the model for the manufacturing process. For 3D-printing you you’re your model in a Software called a slicer that is than slicing you model in hundreds of layers. These layers are than converted into lines that the printer can follow and finally these lines are converted into g-code which is basically a set of instructions that the printer can follow. For a CNC-machine it’s not that simple. The model is also loaded in a software that assists you with making the g-code but using this software is way more complicated that just typing in a few numbers. You need a lot of experience to properly use a software like this and depending on the model it can take hours preparing a model for machining.
3. The next step is the actual manufacturing, for a 3D-printer it’s as simple as loading the material and pressing play. For a CNC you now have to load tools and materials which can also be a time-consuming process because everything has to be fixed in place with a lot of force.
4. The last step the model must go through is post processing here it really depends on the surface finish and the model. Sometimes there is no need at all for post processing sometimes it can be a process taking hours. So here you can’t really say which method is the fastest or best.

Types of 3d-printer

If you think about 3D-Printing you probably have a printer in mind, that melts a plastic filament which is that pressed through a nozzle. This process is called extrusion but that is only one of many methods used in 3D-Printing.

Extrusion

The extrusion method is the most common process when it comes to desktop machines because they are relatively easy to build and therefore cheap. Another advantage is the wide variety of materials that can be used with these machines. The disadvantages are of course the lack of high accuracy ore a high-grade surface finish and the poor strength along the z-axis.

SLA

SLA machines use a laser to cure a UV reactive resin layer by layer. The advantages here are a good surface finish and good heat resistance because the material does not have to be heated in order to be printed. Another advantage is the high accuracy. But of course, this technology doesn’t come without its disadvantages one of them being the slow speed of the printer because the layers are very thin.

DLP

A close relative to SLA printers are DLP machines, they also cure a resin layer by layer but instead of using a laser they use a projector that displays exrusionlayer after layer.

SLS

SLS printer use a similar approach as SLA printer. They also use a laser the hardens a material layer by layer but instead of a resin they melt plastic ore sometime even metal grains together. That allows for great accuracy and very strong parts but the probably biggest advantage you get with one of these machines is that there is no need for support material because the un melted powder acts like a support structure.

There are other processes but these are the most common.

Industrial usecases

Since 3D-Printing has advanced to a stage where a 3d-printer can actually can produce usable, high-quality parts many industries adapted 3D-Printing so they can be more flexible, more cost efficient and faster when it comes to designing a product or even producing it in low quantitys. Now days 3D-Prining has been adapted in the Automotive and aerospace industry, architecture, construction, Healthcare and even in the Food industry. And for small businesses and startups It is possible to produce their products in lower quantities which lowers the risk of bankruptcy dramatically. And because a 3d-printer can create very complex parts some companies could make new kinds of products which were not possible before.

4d-printing

4d-printing describes a very exiting new concept in wich products are 3d-printed in special materials wich allow them to react to external stimuli. This technology allows for some really cool products like self-assembling furniture or smart clothing. But since the technology is still in the research stage we wont se any comercialy available 4d-printed products in the near future.