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EBOOKS BY ZEAL 3D
Source : Zeal 3D
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What Our Customers Say...
Elisa Peterson
30. March, 2023.
This was my first time 3D printing, and I was on a steep learning curve. David the project engineer who helped me always got back to me promptly and answered all my questions as well as giving me feedback on what parts of my design needed to be reworked in order to print. When I submitted my final design using David's feedback, it printed up perfectly! Zeal 3D produced just what I needed, in a timely manner. Many thanks, David, for all your help, and I look forward to working with you again soon!
Nigel Petrie
6. September, 2022.
Great to deal with, fast turn around times and quality CNC finishes
Shufan Yang
1. April, 2022.
Nice customer services, fast response, and beautiful products.
Stephen White
1. March, 2022.
These people do an amazing job. They produced an aluminium shroud for the electric fans on my 1978 Bathurst Cobra Coupe from a Fusion360 model I produced. The end result was flawless.
Awnet Plus
11. August, 2021.
I couldn't be happier with their service and the prototypes they created for me.
Much appreciated!
David Ashby
6. August, 2021.
Working with Zeal was an incredible experience. As someone who is new to 3D printing and modelling, the Zeal team were able to help me troubleshoot and optimise the project, and were incredibly patient with my enquiries. The final product was very affordable, delivered in a timely manner, and the print quality itself surpassed my expectations. Highly recommended and will definitely work with them again in the future.
Sanjayan Subramaniam
1. July, 2021.
Had a fantastic experience working with Zeal on a little hobby project. I've never 3D printed anything in my life and wanted to try creating two little statues for a friend. They were quite intricate models - one was a sword in a stone, with a crown and other difficult details. The other was a mountain range. Mukul gave me clear instructions on how to make sure the CAD file was ready for printing and offered a very reasonable price. I ordered the statues during a lock-down period so I thought they'd be delayed but to my surprise, they delivered the statues to my house much earlier than the ETA we agreed on. Am very happy with the statues and will definitely look to work with Zeal again for future projects.
Christopher Hatton
30. June, 2021.
I fully recommend Zeal 3D printing service. My experience working with Mukul was fantastic because of the attention to detail to ensure the customer gets the best quality printed parts. I see this as value add when developing products and turn around times was quick to NZ.
WEI MU
12. March, 2021.
I ordered several parts from Zeal. The quality of the products are super good. Customer service is always quick and good. A very happy experiance and trusted vendor.
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Also popularly known as additive manufacturing, is a production method where 3D printers create three-dimensional items by depositing filaments in a layer-by-layer fashion as per the object’s digital model. This allows people to easily produce complex items without getting much into a complex manufacturing setup.
Three-dimensional method is in contrast to conventional production methods which use subtractive manufacturing in which an item is made hollowing or cutting out metal or other filament blocks. Additive manufacturing is widely used in various industries and it's primarily used for rapid prototyping. This method allows on-demand design preparation without requiring a heavy manufacturing setup.
There are different types of techniques available, but there are nine fundamental types of techniques that are widely adopted. These methods are Fused Deposition Modeling (FDM), Digital Light Processing (DLP), Material Jetting, Electron Beam Melting (EMB), Stereolithography (SLA), Laminated Object Manufacturing (LOM), Binder Jetting (BJ), Selective Laser Melting (SLM), and Selective Laser Sintering (SLS).
All these methods are generally used for rapid prototyping and many online 3-D print purposes. Every 3-D printing process has its unique 3-D print design features that are suitable for many industrial applications. FDM and SLA are the most famous additive manufacturing methods.
First, the engineer utilizes 3-D software to make the design that will come out as the ultimate product. The CAD software produces an STL file that comprises all data related to the design. Once the STL file is available, 3d printers interpret the data and start the method.
Based on the filament, technology, and 3-D model, the ultimate object starts building in a layer-by-layer practice. The layered production continues till the final object is developed completely. Once the item is ready, it goes into post-production work for final touches.
Rapid prototyping and rapid manufacturing are the same which cover a wide range of fabrication tactics that help manufacturers produce items faster. In these methods, a CAD file is used to create a prototype model or for mass manufacturing. 3d printing is an ideal technology to perform rapid prototyping.
This technology is revolutionizing the complete manufacturing domain and there are various printing benefits to count on. Some of the important benefits of additive manufacturing are:
- It allows the production of intricate objects that are not feasible with conventional manufacturing.
- Rapid prototyping is much more durable and cost-effective with additive manufacturing.
- It's quick to print lightweight and durable parts.
- The lead time is lower than traditional methods.
- Material wastage is minimum.
Industries that are leveraging three dimensional applications for producing bespoke designs are automotive, construction, healthcare, education, aerospace, and more.
There are several methods that offer various purposes and performances. Here are the different types of widely-used methods:
Fused Deposition Modelling (FDM)
It is the most employed and cost-effective method and it utilizes industry-grade thermoplastics to manufacture objects.
Selective Laser Sintering (SLS)
In this modern manufacturing technology, tiny particles of the material are fused by generating heat using a high-power laser beam to create a solid object.
Stereolithography (SLA)
This additive manufacturing method utilizes a high-power laser to solidify liquid resin to create final products.
PolyJet
In this process, the 3-D printer sprinkles drop of photopolymer that gets crystallized when they come in contact with UV rays.
There are various choices available for filaments that are utilized to build objects of different characteristics and surface finishes. Some of the widely-used materials used to produce items are:
- PLA (Polylactic Acid)
- ABS (Acrylonitrile Butadiene Styrene)
- Stainless steel
- Nylon
- Resin
- HIPS (High Impact Polystyrene)
- PET/PETG
- Carbon fiber
- Ceramics and many more
SLA or Stereolithography is the commonly applied additive manufacturing technique that is employed to create objects of high strength and superior smooth finish. SLA is used to create parts with greater details and functional properties.
The most significant utility of this advanced method is in the healthcare domain and some of the popular SLA purposes are producing snap-fit arrangements, molds & casting models, jigs & fixtures, and many more. In the healthcare industry, this additive manufacturing method is used for producing anatomical models. Fundamental advantages of SLA are intricate prototype creation, faster turnaround, smooth surface finishing, and more.
Selective Laser Sintering or SLS utilizes a powder bed fusion process to produce parts. SLS parts are produced from thermoplastic filaments and are ideal for functional testing. Parts made up from this additive manufacturing have rough surface texture and it doesn't need support structures.
SLS's biggest utility is that it can produce multiple parts into a single build hence it is suitable for producing parts in multiple quantities. The SLS process is ideal for small and medium batch parts production with complex geometries.
Fused Deposition Modeling or FDM is among the most popular plastic-based techniques. In this additive manufacturing, the plastic material is ejected from the nozzle and it creates the objects in a layer-by-layer fashion. Fused Deposition Modeling is a broadly applied method in many industries as it's highly affordable and creates objects with a shorter lead time.
This technology can also be utilized for creating certain functional plastic components for testing and presentation purposes. The items created by this additive manufacturing have rugged surface texture and the items are of limited strength. This additive manufacturing process is ideal for personal hands-on as it's easy to use.
PolyJet method produces parts by jetting photopolymer droplets on the bed and the droplets are then crystallized using a powerful UV light. Polyjet is amongst the quickest additive manufacturing methods that produce accurate geometries. This technique also follows a layer-by-layer fabrication process and the layers are photopolymers.
PolyJet is also known as MultiJet, this method offers higher repeatability and greater precision which makes it an excellent pick for small and medium-sized quantity production. This technology can offer precision up to 0.004” on every part. PolyJet is a perfect pick for producing high-quality prototypes.
Metal 3-D manufacturing is the newest and highly capable additive manufacturing method which is utilized to create complex metal parts. With this method, engineers can produce intricate and strong tooling parts that can be used in conventional manufacturing. It aids in decreasing lead times and delivers high-grade quality.
The metal parts created with this method are both functional and non-functional which can be applied in various industries. These techniques used for manufacturing are Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS). This method delivers robust design flexibility along with the functional mechanical characteristics.
There are numerous performance-driven advantages that are transforming the whole manufacturing paradigm. Some of the key advantages of opting for this method are:
Higher customization - Metal additive manufacturing enables engineers to produce intricate design geometrics without reducing the durability of the item.
Faster turnaround - As compared to the traditional production, it can deliver final products with a shorter lead time.
Minimum material wastage - The material wastage while producing metal parts is significantly lower than the conventional subtractive methods.
There are many widely-used types of techniques that are used in industrial work which are:
- Direct Energy Deposition
- Powder DED
- Wire DED
- Powder Bed Fusion
- Selective Laser Melting (SLM)
- Electron Beam Melting (EBM)
- Binder Jetting
There are many high-level uses of 3-D metal production in several businesses and these applications are much more proficient than the conventional manufacturing techniques. Some of the popular applications are:
- Manufacturing production tools
- Fully functional prototypes
- Manufacturing of tooling fixtures
- Rigid coverings
- Spare parts manufacturing
- Ductwork
- Heat exchangers & heatsinks
There are fundamentally four varieties of metal filaments available in the market but engineers can produce custom materials by the mixture of more than two elements. The widely-used materials are:
- Inconel
- Titanium
- Stainless steel
- Aluminium
All these metal filaments have their unique characteristics and are used in various industrial applications.
This method utilizes a powder bed method and, in this method, the metal is in powdered form and is fused to create solid custom parts. In another method, the machine employs a powerful laser that heats up the metal particles and then creates a solid object.
The 3d printers produce the metal parts in a continuous way and once the items are prepared, they are ready for post-production activity. Based on what material and method are used for manufacturing, the turnaround time varies.
It is one of the most robust manufacturing processes. This method can be majorly categorized into two sections. The first section is the Laser Metal Deposition technologies and the second category is powder bed technologies. Both types of metal additive manufacturing methods have unique properties used suitable for producing 3d printed objects.
In powder bed 3-D technology, the metal powder is fused over a bed and then the objects are produced additively. In laser metal deposition, the machine warms up the metal filament powder to make a solid item. Apart from these two robust categories, Binder Jetting and casting are also popularly used metal additive manufacturing technologies.
The selective Laser Melting (SLM) additive manufacturing method is commonly used for producing 3d printed metal alloys. In this manufacturing process, the metal is sintered using a strong laser in a layer-by-layer fashion following the instructions of the CAD model. In this method, the metal filament powder is fully melted throughout the process.
SLM uses inert gases like argon and nitrogen for the sintering process. Selective Laser Melting is perfect for pure metals like aluminium and it can deliver robust metal parts. This method does not need support elements for small angles and hangovers. Once the manufacturing is completed, the supports are then detached from the main object.
Direct Metal Laser Sintering (DMLS) is a robust and widely-employed technique that holds similarities with the SLM method. In DMLS additive manufacturing, the machine sinters the powdered filament following the instructions of the CAD file. But the main contrast is that DMLS does not melt the metal powder fully. Due to this variation, the filament doesn't need to arrive at the top high temperature and the cooling time is lower in this process.
The most significant benefit of DMLS is that it's more comfortable for producing 3d printed components. These mechanical items are extensively used in automotive, aerospace, and more.
In Directed Energy Deposition additive manufacturing technology, the material block is drawn and welded at the same term through a nozzle. The DED method holds various similarities with the Fused Deposition Modeling method and the core operating system remains identical. In this method, the metal filament powder is first melted and then hardened using a strong laser.
This technology offers great precision and the substrate is placed at 3−axis systems which is the stable position. On the other hand, it can be placed at 5+ axis systems, which is the rotating position. The objects manufactured from Directed Energy Deposition have high-grade mechanical characteristics.
Binder Jetting is a widely-used 3d printing technology and in this process, the printhead of a 3d printer accurately places a liquid binding agent over a thin layer of powder particles. Binder Jetting is a metal additive manufacturing method that is applied to build high-quality and strong custom parts and tooling components.
Like any other printing methods, Binder Jetting technology also follows instructions from the CAD file and outlines the required object. Once the printing job is finished, the build box is removed from the 3d printer and then put into an oven for curing.
Casting, which is also known as lost-wax casting, is an alternative to additive and subtractive manufacturing and this technique creates multiple models from the main master model. This metal casting method uses the master model as a reference and then produces a high-quality copy of the same. The items are 3-D printed in wax.
Once the master pattern is ready, the mold made up in plaster is spilled over it. When the mold is ready to use, the liquid metal is injected into the mold. This will take the place of the wax which is poured through a tree-shaped arrangement to create the object.
A 3-D model is a computer digital file that includes the mathematical description of an item that is going to print using 3d printers. This 3d model CAD file is designed using CAD software or using the 3d scanning method. The CAD file is first uploaded and then the additive manufacturing process begins.
To upload a file, you need to navigate to the G-Code Files section and there, you will find the upload option. You need to click on the Upload G-Code File(s) button and choose the file. Once the design is uploaded, it's ready for manufacturing.
The STL file includes all the information about models that are going to be manufactured. This file format contains the data of the item's surface geometry and it does not involve any color or texture-related information. CAD software produces these STL files and the full form of this file format is "Standard Tessellation Language" or "Standard Triangle Language." It is the most used file format of additive manufacturing. When this STL file is used as a combination with a slicer, then it allows engineers to create a communication with the 3D printer’s hardware.
Multi-jet modelling is a widely-used rapid prototyping technique that is used for producing 3d printed plastic-based models taking information directly from the CAD file. This method uses multi-nozzles print heads arranged in a linear way. In Multi-jet modeling, the wax-based thermoplastics are sprayed on as tiny drops by a heated print head.
For overhangs extensions in MJM, a custom support structure of lower-melting wax is formed which is removed later when the job is completed. This method is ideal for producing very high-intricate models. 3d designed models are easier to work on in the post-production stage.
PLA or Polylactic Acid is one of the widely-used popular materials and is produced using renewable resources. The PLA plastic is formed using natural materials that include corn starch, tapioca roots, or sugarcane. The PLA plastic is based on the usage of natural products' extracts for items. When we compare PLA plastic or ABS, the PLA material is stiffer and stronger than ABS but the heat endurance is on the lower side. PLA materials are bio-based and they are easy to recycle as compared to other plastic-based filaments.
Injection molding is a commonly used manufacturing method for the production of plastic parts. A wide variety of objects are made using plastic injection molding which are of different sizes and complexities. This process uses an injection molding machine and it takes raw plastic material as filaments produce objects using a mold.
In plastic molding, the filament is first melted in the machine and then injected at speed into the mold. This process is used for producing thin-walled plastic parts which are widely used in households. Along with this, the injection molding process is also used in the automotive industry.
The major benefit of injection moulding is that it is simple to scale without complicating the production process. The price per unit included in injection-moulded production is relatively lower than other conventional manufacturing methods. This production process is ideal for the large-scale production of identical items. It is a highly repeatable method which makes it a perfect technique for creating objects with practically identical characteristics.
As compared to other manufacturing techniques, material wastage is lower and manufacturers can apply the material block to its highest usability factor. High volume production in injection moulding is more affordable as compared to other manufacturing techniques.
The injection moulding manufacturing process involves heating and then injecting plastic filament under high pressure. It is performed into a closed-shape metal mould tool. In this method, the molten plastic solidifies inside the mould tool. Once the process is completed, the object is then ejected from the mould. The plastic material granules from the tank are fed into the heated barrel. The melting is either done by heat, friction or strong shear force. This method is a perfect pick for manufacturing very complex parts that hold intricate geometrics.
There are mainly 3 types of Plastic Injection Molding machines that are commonly used in various industries.
Hydraulic Injection Molding Machine
The hydraulic injection moulding machines come with an excellent clamping force which makes them an ideal choice for producing objects. The parts of hydraulic moulding machines have a higher endurance to wear and tear.
Electric Injection Molding Machines
The electric injection moulding machine is a highly power-efficient machine and it comes with fewer down-time. The production is faster with these electric machines.
Hybrid Injection Molding Machines
This Plastic Injection Molding PLC Machine is an aggregate of the above machines and it offers higher mechanical flexibility and material durability.
CNC machining is a productive manufacturing technology in which computer software commands the machine, so in this process, no manual control is required. CNC machining technique is used for managing a variety of complex machinery with greater accuracy and shorter lead times. Lathe, grinder, milling machines are some of the popularly used equipment of this production method.
As the CNC gets instructions from the program, the entire production process becomes error-free. CNC reduces the need for manual administration and supervision of production processes.
CNC machining production method is extensively used in various industries and there are many applications of this technology including:
- Cabinets and furniture manufacturing
- Signage board creation
- Modelling & Rapid prototyping
- Aluminium and brass machining
- Instruments manufacturing
CNC machining method offers a wide array of benefits over the traditional processes including:
- CNC machining brings easy scalability to the manufacturing process
- It helps in making components with greater accuracy
- Less manual efforts are required in CNC service
- Faster turnaround time
- Uniform manufacturing
Vacuum casting is a replicating or casting method for elastomers polymers and this process uses a vacuum to extract the liquid filament into the mould. This manufacturing technique is an excellent fit when there is a problem with air capture with the casting mould. Vacuum casting or reproduction technology is an ideal manufacturing method for creating complex details.
Vacuum casting with metal is also possible where this method offers higher accuracy of complex geometries. This process is also known as thermoforming because it also includes a rapid prototyping method in which the plastic or other material is preheated.
The vacuum casting technique begins with the production of a master pattern utilising Stereolithography technology. After this, the master model is arranged with a casting gate and then attached over the parting line of the casting frame mould.
In this formative manufacturing method, the silicone rubber is mixed and poured into a mould casting frame which is under vacuum. This silicone rubber will run around the master model and it will produce a silicone mould. After this, the mould is kept under the heating chamber and once the mould is fixed, it is removed. The master model or pattern is finally excluded before placing the casting funnel & the mould is then sealed.
The vacuum casting machine uses a powerful vacuum to suck the molten fibre into the mould. During this process, a force is needed to overcome the surface tension of the molten metal. If the force is not enough, the molten filament will grow into a blob.
Using SLA or laser sintering, the original model is developed which brings an excellent surface finish. Then, the silicone mould is produced by moulding the silicone material around the master pattern copy. This method is done under vacuum to evade any kind of air bubble from originating. Once the curing is finished, the silicone mould is cut as per the predefined design.
There are many high-performance uses of vacuum casting like:
- Production of high-quality plastic models and spare parts for various industries like consumer goods.
- Vacuum casting is massively used in prosthetics and medical equipment production.
- In aerospace and automotive parts creation.
- Engineers also make use of vacuum casting in functional testing
- Preparing home decorative items.
Vacuum casting carries a variety of elements that offer many physical properties and stress levels. Following are some of the most used vacuum casting materials:
- Glass-filled polymers
- Polypropylene (PP)
- Acrylonitrile Butadiene Styrene (ABS)
- Rubber
- Wax
- Polycarbonate (PC)
There are many prolific benefits of choosing vacuum casting for manufacturing. The silicone moulding produces excellent quality parts as compared to other conventional manufacturing methods. Vacuum casting is a perfect manufacturing method for doing functional testing. Vacuum Casting delivers a wide degree of finishing options and even in limited quantities, it delivers superior quality. Vacuum Casting is ideal for both small-batch and bulk production.
There are various vacuum casting practices in multiple industries. Some of the widely-used applications of this manufacturing technology are:
- Pre-launch product functional testing
- Small-series manufacturing of covers and housings
- Manufacturing of prototypes and concept models
- Validation of product design
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