Alternatively, breakaway support materials are also possible, which can be removed by manually snapping them off the part.
Support structures, or lack thereof, have generally been a limitation of the entry level FFF 3D printers. However, as the systems have evolved and improved to incorporate dual extrusion heads, it has become less of an issue.
At the entry-level, as would be expected, the FFF process produces much less accurate models, but things are constantly improving. The process can be slow for some part geometries and layer-to-layer adhesion can be a problem, resulting in parts that are not watertight. Again, post-processing using Acetone can resolve these issues.
As is the case with other powder bed systems, once a layer is completed, the powder bed drops incrementally and a roller or blade smoothes the powder over the surface of the bed, prior to the next pass of the jet heads, with the binder for the subsequent layer to be formed and fused with the previous layer.
Advantages of this process, like with SLS, include the fact that the need for supports is negated because the powder bed itself provides this functionality. Furthermore, a range of different materials can be used, including ceramics and food. A further distinctive advantage of the process is the ability to easily add a full colour palette which can be added to the binder. The parts resulting directly from the machine, however, are not as strong as with the sintering process and require post-processing to ensure durability.
Material jetting: a 3D printing process whereby the actual build materials in liquid or molten state are selectively jetted through multiple jet heads with others simultaneously jetting support materials.
However, the materials tend to be liquid photopolymers, which are cured with a pass of UV light as each layer is deposited. The nature of this product allows for the simultaneous deposition of a range of materials, which means that a single part can be produced from multiple materials with different characteristics and properties. Material jetting is a very precise 3D printing method, producing accurate parts with a very smooth finish. However, that is where any similarity ends.
The SDL 3D printing process builds parts layer by layer using standard copier paper. Each new layer is fixed to the previous layer using an adhesive, which is applied selectively according to the 3D data supplied to the machine. After a new sheet of paper is fed into the 3D printer from the paper feed mechanism and placed on top of the selectively applied adhesive on the previous layer, the build plate is moved up to a heat plate and pressure is applied.
This pressure ensures a positive bond between the two sheets of paper. The build plate then returns to the build height where an adjustable Tungsten carbide blade cuts one sheet of paper at a time, tracing the object outline to create the edges of the part.
When this cutting sequence is complete, the 3D printer deposits the next layer of adhesive and so on until the part is complete. And because the parts are standard paper, which require no post-processing, they are wholly safe and eco-friendly.
Where the process is not able to compete favourably with other 3D printing processes is in the production of complex geometries and the build size is limited to the size of the feedstock. The key difference is the heat source, which, as the name suggests is an electron beam, rather than a laser, which necessitates that the procedure is carried out under vacuum conditions.
EBM has the capability of creating fully-dense parts in a variety of metal alloys, even to medical grade, and as a result the technique has been particularly successful for a range of production applications in the medical industry, particularly for implants.
However, other hi-tech sectors such as aerospace and automotive have also looked to EBM technology for manufacturing fulfillment. The materials available for 3D printing have come a long way since the early days of the technology.
There is now a wide variety of different material types, that are supplied in different states powder, filament, pellets, granules, resin etc. Specific materials are now generally developed for specific platforms performing dedicated applications an example would be the dental sector with material properties that more precisely suit the application.
However, there are now way too many proprietary materials from the many different 3D printer vendors to cover them all here. Instead, this article will look at the most popular types of material in a more generic way. And also a couple of materials that stand out.
Nylon, or Polyamide, is commonly used in powder form with the sintering process or in filament form with the FDM process. It is a strong, flexible and durable plastic material that has proved reliable for 3D printing.
It is naturally white in colour but it can be coloured — pre- or post printing. This material can also be combined in powder format with powdered aluminium to produce another common 3D printing material for sintering — Alumide.
It is a particularly strong plastic and comes in a wide range of colours. ABS can be bought in filament form from a number of non-propreitary sources, which is another reason why it is so popular. PLA is a bio-degradable plastic material that has gained traction with 3D printing for this very reason.
It is offered in a variety of colours, including transparent, which has proven to be a useful option for some applications of 3D printing. However it is not as durable or as flexible as ABS. LayWood is a specially developed 3D printing material for entry-level extrusion 3D printers. A growing number of metals and metal composites are used for industrial grade 3D printing.
Two of the most common are aluminium and cobalt derivatives. It is naturally silver, but can be plated with other materials to give a gold or bronze effect. In the last couple of years Gold and Silver have been added to the range of metal materials that can be 3D printed directly, with obvious applications across the jewellery sector.
These are both very strong materials and are processed in powder form. Titanium is one of the strongest possible metal materials and has been used for 3D printing industrial applications for some time. Ceramics are a relatively new group of materials that can be used for 3D printing with various levels of success. The particular thing to note with these materials is that, post printing, the ceramic parts need to undergo the same processes as any ceramic part made using traditional methods of production — namely firing and glazing.
The company operates a notably different business model to other 3D printing vendors, whereby the capital outlay for the machine is in the mid-range, but the emphasis is very much on an easily obtainable, cost-effective material supply, that can be bought locally. There is a huge amount of research being conducted into the potential of 3D printing bio materials for a host of medical and other applications. Living tissue is being investigated at a number of leading institutions with a view to developing applications that include printing human organs for transplant, as well as external tissues for replacement body parts.
Other research in this area is focused on developing food stuffs — meat being the prime example. Experiments with extruders for 3D printing food substances has increased dramatically over the last couple of years.
Chocolate is the most common and desirable. There are also printers that work with sugar and some experiments with pasta and meat. Looking to the future, research is being undertaken, to utilize 3D printing technology to produce finely balanced whole meals. And finally, one company that does have a unique proprietary material offering is Stratasys, with its digital materials for the Objet Connex 3D printing platform. This offering means that standard Objet 3D printing materials can be combined during the printing process — in various and specified concentrations — to form new materials with the required properties.
Up to different Digital Materials can be realized from combining the existing primary materials in different ways. The customisation value of 3D printing and the ability to produce small production batches on demand is a sure way to engage consumers AND reduce or negate inventories and stock piling — something similar to how Amazon operates its business.
Shipping spare parts and products from one part of the world to the other could potentially become obsolete, as the spare parts might possibly be 3D printed on site. This could have a major impact on how businesses large and small, the military and consumers operate and interact on a global scale in the future.
The ultimate aim for many is for consumers to operate their own 3D printer at home, or within their community, whereby digital designs of any customizable product are available for download via the internet, and can be sent to the printer, which is loaded with the correct material s. Currently, there is some debate about whether this will ever come to pass, and even more rigorous debate about the time frame in which it may occur.
The wider adoption of 3D printing would likely cause re-invention of a number of already invented products, and, of course, an even bigger number of completely new products. Today previously impossible shapes and geometries can be created with a 3D printer, but the journey has really only just begun. The use of 3D printing technology has potential effects on the global economy, if adopted world wide. The shift of production and distribution from the current model to a localized production based on-demand, on site, customized production model could potentially reduce the imbalance between export and import countries.
There is an opportunity for professional services around 3D printing, ranging from new forms of product designers, printer operators, material suppliers all the way to intellectual property legal disputes and settlements.
Piracy is a current concern related to 3D printing for many IP holders. The effect of 3D printing on the developing world is a double-edged sword. One example of the positive effect is lowered manufacturing cost through recycled and other local materials, but the loss of manufacturing jobs could hit many developing countries severely, which would take time to overcome.
The developed world, would benefit perhaps the most from 3D printing, where the growing aged society and shift of age demographics has been a concern related to production and work force.
Also the health benefits of the medical use of 3D printing would cater well for an aging western society. Even within the same build chamber, the nature of 3D printing means that numerous products can be manufactured at the same time according to the end-users requirements at no additional process cost.
The advent of 3D printing has seen a proliferation of products designed in digital environments , which involve levels of complexity that simply could not be produced physically in any other way. While this advantage has been taken up by designers and artists to impressive visual effect, it has also made a significant impact on industrial applications, whereby applications are being developed to materialize complex components that are proving to be both lighter and stronger than their predecessors.
Notable uses are emerging in the aerospace sector where these issues are of primary importance. For industrial manufacturing, one of the most cost-, time- and labour-intensive stages of the product development process is the production of the tools. For low to medium volume applications, industrial 3D printing — or additive manufacturing — can eliminate the need for tool production and, therefore, the costs, lead times and labour associated with it. This is an extremely attractive proposition, that an increasing number or manufacturers are taking advantage of.
Even medicines, bones, organs and skin made to treat your injuries. After all, the notion of doing your supermarket shopping on an iPad was like something out of Star Trek 20 years ago. But, like so many household technologies, the prices will come down and 3D printer capabilities will improve over time.
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Already subscribed? Because of 3D printing, millions of PPE and ventilator parts have been shipped to hospitals on the frontlines of this deadly fight. What are 3D printers? In short, 3D printers use computer-aided design CAD to create 3D objects from a variety of materials, like molten plastic or powders. Rather, the printers, which act somewhat similarly to traditional 2D inkjet printers, use a layering method to create the desired object.
They work from the ground up and pile on layer after layer until the object looks exactly like it was envisioned. These printers have extreme flexibility in what can be printed. They can use plastics to print rigid materials, like sunglasses. Some 3D printers even have the ability to print with carbon fiber and metallic powders for extremely strong industrial products. Why are 3D printers important to the future?
As explained above, 3D printers are incredibly flexible; not only in the materials they use, but also with what they can print. Today, many 3D printers are used for what is called rapid prototyping. Companies all over the world now employ 3D printers to create their prototypes in a matter of hours, instead of wasting months of time and potentially millions of dollars in research and development.
Many 3D printers are being tasked with printing finished products. The construction industry is actually using this futuristic printing method to print complete homes. Schools all over the world are using 3D printers to bring hands-on learning to the classroom by printing off three-dimensional dinosaur bones and robotics pieces.
The flexibility and adaptability of 3D printing technology makes it an instant game-changer for any industry. Taken a step further, companies across many industries will also utilize 3D printing for rapid manufacturing, allowing them to save costs when producing small batches or short runs of custom manufacturing. Additionally, machines and devices wear down over time and may be in need of swift repair, which 3D printing produces an easily accessible solution to.
Like functional parts, tools also wear down over time and may become inaccessible, obsolete or expensive to replace. While 3D printing may not be able to replace all forms of manufacturing, it does present an inexpensive solution to producing models for visualizing concepts in 3D. From consumer product visualizations to architectural models, medical models and educational tools.
As 3D printing costs fall and continue to become more accessible, 3D printing is opening new doors for modeling applications. It takes a combination of top-of-the-line software, powder-like materials and precision tools to create a three-dimensional object from scratch.
Below are a few of the main steps 3D printers take to bring ideas to life. The first step of any 3D printing process is 3D modeling. Some designs are too intricate and detailed for traditional manufacturing methods. Modeling allows printers to customize their product down to the tiniest detail. This modeling software is especially important to an industry, like dentistry, where labs are using three-dimensional software to design teeth aligners that precisely fit to the individual. Since 3D printers cannot conceptualize the concept of three dimensions, like humans, engineers need to slice the model into layers in order for the printer to create the final product.
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