Ultimate Beginners Guide To 3D Printing

3D PRINTING BEGINNERS GUIDE BOOK

3D printing or additive manufacturing technologies have taken the world by storm. This kind of disruption was last seen during the advent of the Internet. 3d printing has gone beyond preparing decorative, and industries are leveraging this technology to simplify their long-haul traditional processes. Online 3d printing offers significant flexibility to businesses regardless of their industries to try and innovate new ideas. Be it creating a prototype or creative figurine, 3d print is a turnkey solution. Here is a beginner’s guide to how and why you should choose 3D printing services for your business today.

What is 3D Printing?
3D Printing History
3D Printing Vs Additive Manufacturing Vs Rapid Prototyping
How it Works?
3D Printing Materials
3D Printing Technology
Benefits of 3D Printing
Types of 3D Printing
How to Select Right 3D Printing Process
3D Printing Design Guidelines
Future of 3D Printing

WHAT IS 3D PRINTING?

First things first. The technique of online 3D printing can be described as one in which a digital 3D model is used to create a physical object. This is done through the successive layering of a chosen material, using specific techniques.

It is also called additive manufacturing, which, as the name suggests, is the opposite of subtractive manufacturing. 3D print services facilitate the production of complex shapes with fewer amounts of materials compared to traditional manufacturing techniques.

It offers a wide range of materials. From attractive miniatures to robust mechanical parts made with metal, plastic 3d printing, you get more customization as compared to the traditional process.

3d printing services is the next paradigm shift that's opening new innovative opportunities for multiple industries. From medical to automotive, aerospace, and consumer-industry; additive manufacturing is the next big thing.

HISTORICAL BACKGROUND OF 3D PRINTING

3D printing technology is not a new technology, and it has been around since the 1980s when Chuck Hull of 3D Systems Corporation developed it. Hull patented the stereolithography apparatus (SLA), which is considered to be the first 3D printer. In the 1990s, 3D printing technology was further developed by Dr. Carl Deckard of the University of Texas at Austin and his graduate student, Joe Beaman. They invented a process called selective laser sintering (SLS), which uses a laser to fuse together small particles of plastic, metal, or ceramic powder into a solid object.

SLS became the basis for commercial 3D printers made by companies such as Stratasys and EOS. In 2001, Dr. Hod Lipson and Dr. Melba Kurman co-wrote the book Fabricated: The New World of 3D Printing, which discusses how additive manufacturing is being used across various industries such as healthcare, aerospace, automotive, and consumer products. Now you can find many different types of 3D printers available on the market that use various technologies such as SLA, SLS, fused deposition modeling (FDM), and polyjetting.

3D PRINTING VS ADDITIVE MANUFACTURING VS RAPID PROTOTYPING

3D printing, additive manufacturing, and rapid prototyping are all terms that are often used interchangeably. There are few key differences between these technologies.

ThreeD printing is a process where layers of material are deposited to create a three-dimensional object. Additive manufacturing refers to create objects from scratch using 3D printing or other similar mechanisms. Rapid prototyping is a term that encompasses both 3D printing and additive manufacturing, but specifically refers to the creation of prototypes or models.

So, while all three mechanisms can be used to create three-dimensional objects, they each have their own specific applications. 3D printing is best suited for low-volume production, additive manufacturing is best for creating complex objects from scratch, and rapid prototyping is best for creating prototypes or models quickly and efficiently.

3D Printing Vs Additive Manufacturing Vs Rapid Prototyping

HOW IT WORKS

Using different 3D scanning software, a digital Three-D CAD model is first created. The digital model is then converted into a file that can be used for 3D printing. Finally, the material selected is laid down in succession, one layer after another to obtain the physical object.

There are many types of 3D printing technologies, such as FDM 3D printing, SLA or SLS, DMLS, material jetting, and variations of these. Along with the variety of techniques, the inventory of 3D print filaments is also expanding.

3D PRINTING MATERIALS

The materials are available in plastics, metals, ceramics, nylon, all meant for rapid prototyping and industrial production. Additionally, the development of bioprinting promises to add to the repertoire of 3D print services.

Specific materials include:

Plastic Nylon, Polyamide, ABS, PLA, Carbon, ULTEM 9085, ULTEM 1010, HP Premium Nylon PA12.
Metal: Aluminium (manufacturing and automobile industries), Cobalt Chrome, Stainless Steel 316L, Stainless Steel 420, Gold, Platinum, and Silver (jewellery creation), Copper, Bronze, Titanium, MS1 Steel (aerospace industry), Nickel alloy, IM 625.
Biocompatible Materials: PC-ISO, MED610.

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3D PRINTING TECHNOLOGY

Many different 3D printing technologies are available, each with its own strengths and weaknesses. The most common technology used Fused deposition modeling (FDM), which extrudes layers of molten plastic. Other popular technologies include stereolithography (SLA), selective laser sintering (SLS), and multi-jet modeling (MJM).

Fused Deposition Modeling (FDM)

FDM is a 3D printing method that uses a continuous filament of thermoplastic material. The filament is fed through a heated extrusion nozzle that melts the material and deposits it in thin layers on a build platform. The layers are then fused together to create the final 3D object. FDM is well suited for prototyping and small-scale production, as it is a relatively low-cost technology. Additionally, FDM can be used to produce parts with complex geometries or features that would be difficult to create using other manufacturing methods.

Stereolithography (SLA)

Stereolithography (SLA) is a 3D printing technology used to create models and prototypes. A laser beam is used to draw the desired image onto a photosensitive resin, curing it and creating a solid layer. This method is repeated until the model is complete. SLA is considered one of the most accurate technologies available, making it ideal for creating prototypes and models with fine details.

Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS) is a type of additive manufacturing technology that uses a laser to selectively fuse together powder particles. The powder is first deposited in layers on a build platform, and the laser selectively fuses the particles together to form the desired 3D shape. SLS is well-suited for producing complex shapes that would be difficult or impossible to produce using traditional manufacturing methods.

Multi-jet Modeling (MJM)

Multi-jet modeling is a statistical technique used to estimate the parameters of multiple regression models. It is similar to ordinary least squares regression but allows for the inclusion of more than one predictor variable. The technique is used when there is evidence that the predictor variables are not independent of each other, and can be used to estimate both linear and nonlinear relationships.

BENEFITS OF USING 3D PRINTING

The demand for 3D printing in Australia has gone up manifold in recent years. To understand this phenomenon, look at these advantages:

Customisation – Mass customization are easier with 3D printed products. Objects can be personalized as per specific consumer and client. This, in turn, can lead to great cost savings for the manufacturer.

Complexity – It is easy to create objects that have complex geometries and cannot be created through conventional techniques. This gives immense design flexibility to engineers who can now take care of defects and make design modifications without investing too much time or money!

Tool-free – One of the most advantageous factors for the popularity of 3D printing is its tool-free capabilities. Earlier, the production of tools would take up a lot of time even before production could begin. Industrial 3D printing can eliminate the need for this production, thereby leading to overall cost reduction.

Sustainable and Eco-friendly – By saving the need for tooling, and by contributing to the creation of energy-efficient parts, 3D printing is emerging as an eco-friendly alternative to conventional industrial manufacturing.

Local Manufacturing – Businesses can cut down on expensive inventory, logistics, and shipping costs by going local with 3D printing. When products are manufactured on demand, companies do not need to worry about sourcing products from anywhere else in the world.

THE DIFFERENT TYPES OF 3D PRINTING

Vat Polymerization : is a process in which liquid photopolymer is cured by light. This process can be used to create parts with very high precision and detail.
Material Extrusion : Material extrusion is a process in which molten thermoplastic is deposited through a heated nozzle. This process can be used to create a variety of objects and shapes from plastic materials.
Powder Bed Fusion : Powder particles are fused together using a high-energy source. The resulting fused object is typically stronger and more durable than the original powder particles. Powder bed fusion is often used to create metal objects, such as engine parts or medical implants.
Material Jetting : Droplets of liquid photosensitive fusing agent are deposited on a powder bed and cured by light. This process is known as material jetting. The method can be used to create complex shapes that would be difficult to produce using other methods.
Binder Jetting : Binder jetting is a 3D printing technology that uses a binding agent to adhere together small particles of granulated materials. The binding agent is deposited in droplets onto the build platform, where it bonds the particles together. Binder jetting is often used for making sand casts and investment casting patterns, as well as for prototyping and low-volume production runs.

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Direct Energy Deposition : Direct Energy Deposition (DED) is a process where molten metal is simultaneously deposited and fused onto a substrate. Generally, the process is used to create 3D objects with complex shapes or to repair damaged parts. DED offers many advantages over traditional manufacturing methods, including faster production times, lower costs, and less waste.
Sheet Lamination : Sheet lamination is a process in which individual sheets of material are cut to shape and laminated together. It can be implemented for various reasons, including strength, durability, and resistance to moisture. Laminated sheets are often used in construction as they can provide a sturdy surface resistant to weathering and wear.

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HOW TO SELECT THE RIGHT 3D PRINTING PROCESSES

3D printing technology has been used in various industries, and there are now multiple processes to choose from. When selecting a 3D printing process, it is essential to consider the specific application and requirements of the project.

The required accuracy
Surface finish
Material properties
Production volume
Lead time

Selecting the right 3D printing technique can be a complex decision, but working with an experienced partner can help ensure that the best possible process is selected for the project.

3d Printing Software

The software is used to slicing the model into layers and generate instructions for the 3D printer. Some popular 3D printing software includes Cura, Simplify3D, and Slic3r.

3D PRINTING DESIGN GUIDELINES

When designing a model for 3D printing, there are a few guidelines to keep in mind in order to ensure a successful print.

Simplicity is key - the simpler your design, the easier it will be to print and the more successful your final print will be.
Avoid small, delicate features - these are more likely to break during the printing process.
Make sure your model is watertight - any holes or gaps will cause problems during printing.
Consider the size limitations of your printer - you'll need to scale down large designs accordingly.
Think about the orientation of your model - how you position it on the build plate will affect the success of your print.

FUTURE OF 3D PRINTING

The future of 3d printing is fascinating. It has the potential to revolutionize manufacturing, and the way products are made. Year by year, the adoption of 3d printers is increasing in a variety of industries, such as healthcare, aerospace, and automotive. Additionally, the falling costs of 3d printers and the increasing availability of 3d printing services are helping this technology more convenient for consumers and small businesses.

Bonus

Buy a printer or use a 3D printing service?

How to decide which 3D printer to buy?

How to use a 3D printing service?

INDUSTRIES AND APPLICATIONS

The following industries are the most ardent users of AM technologies in their businesses.

Automotive

Lightweight aerodynamics parts are desirable in the automobile industry. This contributes to making cars more energy efficient. 3D printing in the automotive industry is used both for rapid prototyping services as well as for some end parts creation.

Manufacturing

The precision and accuracy of 3D print processes are helping the manufacturing industry reduce material wastage, save time, money, and efforts.

R&D

Rapid prototyping has become a crucial component used in R&D departments of leading businesses. It helps save time and money for the manufacturers.

Medical and Healthcare

This is one of the most promising sectors for applications of 3D printing. Some of the applications include prototyping for product development to creating actual patient solutions, such as dental crowns, prosthetics, implants, human tissues, and organs, as well as 3D printed surgical instruments.

Architecture

3D architectural models enable businesses to showcase accurate details of projects. Architects also have greater design flexibility when they use 3D CAD models.

Jewellery

Lightweight aerodynamics parts are desirable in the automobile industry. This contributes to making cars more energy efficient. 3D printing in the automotive industry is used both for rapid prototyping services as well as for some end parts creation.

Aerospace/Defence/Navy

This industry was one of the earliest adopters of additive manufacturing. Rapid prototyping has become a critical component in the development of replacement and end parts in this industry.

Ultimate Beginners Guide To 3D Printing

3D PRINTING BEGINNERS GUIDE BOOK