THE 3D PRINTING
Chuck Hull is typically credited with the invention of the 3D printer via his Stereolithographic Apparatus (SLA), patented in 1984. The 3D printing uses computer-aided design to create three- dimensional objects through a layering method. Sometimes referred to as additive manufacturing, 3D printing involves layering materials, like plastics, composites or bio-materials to create objects that range in shape, size, rigidity and color.
Process of 3D Printing: All 3D printing processes start with a CAD model that is sent to software to prepare the design. Depending on the technology, the 3D printer might produce the part layer by layer by solidifying resin or sintering powder. The parts are then removed from the printer and post-processed for the specific application.
1. Design: The 3D printers create parts from three-dimensional models, the mathematical representations of any three-dimensional surface created using computer-aided design (CAD) software or developed from 3D scan data. The design is then exported as an STL or OBJ file readable by print preparation software.
2. 3D Print: Some 3D printers use a laser to cure liquid resin into hardened plastic, others fuse small particles of polymer powder at high temperatures to build parts. Most 3D printers can run unattended until the print is complete, and modern systems automatically refill the material required for the parts from cartridges.
3. Post-Process: Depending on the technology and the material, the printed parts may require rinsing in isopropyl alcohol (IPA) to remove any uncured resin from their surface, post-curing to stabilize mechanical properties, manual work to remove support structures, or cleaning with compressed air or a media blaster to remove excess powder. Some of these processes can be automated with accessories.
Types of 3D Printers: The three most established types of 3D printers for plastics parts are stereolithography (SLA), selective laser sintering (SLS), and fused deposition modeling (FDM). Form labs offers two professional 3D printing technologies, SLA and SLS, bringing these powerful and accessible industrial fabrication tools into the creative hands of professionals around the world.
1. Stereolithography (SLA): Stereolithography was the world's first 3D printing technology, invented in the 1980s, and is still one of the most popular technologies for professionals. SLA 3D printers use a laser to cure liquid resin into hardened plastic in a process called photopolymerization. SLA resin 3D printers have become vastly popular for their ability to produce high-accuracy, isotropic, and watertight prototypes and parts in a range of advanced materials with fine features and smooth surface finish. SLA resin formulations offer a wide range of optical, mechanical, and thermal properties to match those of standard, engineering, and industrial thermoplastics.
2. Selective laser sintering (SLS): This type of 3D printers use a high-power laser to sinter small particles of polymer powder into a solid structure. The unfused powder supports the part during printing and eliminates the need for dedicated support structures. This makes SLS ideal for complex geometries, including interior features, undercuts, thin walls, and negative features. Parts produced with SLS printing have excellent mechanical characteristics, with strength resembling that of injection-molded parts.
The most common material for selective laser sintering is nylon, a popular engineering thermoplastic with excellent mechanical properties. Nylon is lightweight, strong, and flexible, as well as stable against impact, chemicals, heat, UV light, water and dirt.
3. Fused deposition modeling (FDM) or fused filament fabrication (FFF): It is the most widely used type of 3D printing at the consumer level. FDM 3D printers work by extruding thermoplastic filaments, such as ABS (Acrylonitrile Butadiene Styrene), PLA (Polylactic Acid), through a heated nozzle, melting the material and applying the plastic layer by layer to a build platform. Each layer is laid down one at a time until the part is complete.
Applications and Uses of 3D Printing: 3D printing accelerates innovation and supports businesses across a wide range of industries, including engineering, manufacturing, dentistry, healthcare, education, entertainment, jewelry, audiology etc. some of these are explained below:
1. Engineering and Product Design: Rapid prototyping with 3D printing empowers engineers and product designers to turn ideas into realistic proofs of concept, advance these concepts to high-fidelity prototypes that look and work like final products, and guide products through a series of validation stages toward mass production.
2. Manufacturing: Manufacturers automate production processes and streamline workflows by prototyping tooling and directly 3D printing custom tools, molds, and manufacturing aids at far lower costs and lead times than with traditional manufacturing. This reduces manufacturing costs and defects, increases quality, speeds up assembly, and maximizes labor effectiveness.
3. Education: 3D printers are multifunctional tools for immersive learning and advanced research. They can encourage creativity and expose students to professional-level technology while supporting STEAM curricula across science, engineering, art, and design.
4. Healthcare: Affordable, professional-grade desktop 3D printing helps doctors deliver treatments and devices customized to better serve each unique individual, opening the door to high- impact medical applications while saving organizations significant time and costs from the lab to the operating room.
5. Entertainment: High definition physical models are widely used in sculpting, character modeling, and prop making. 3D printed parts have starred in stop-motion films, video games, bespoke costumes, and even special effects for blockbuster movies.
6. Jewelry: Jewelry professionals use CAD and 3D printing to rapidly prototype designs, fit clients, and produce large batches of ready-to-cast pieces. Digital tools allow for the creation of consistent, sharply detailed pieces without the tediousness and variability of wax carving.
7. Dental: Digital dentistry reduces the risks and uncertainties introduced by human factors, providing higher consistency, accuracy, and precision at every stage of the workflow to improve patient care. 3D printers can produce a range of high-quality custom products and appliances at low unit costs with superior fit and repeatable results.
8. Audiology: Hearing specialists and ear mold labs use digital workflows and 3D printing to manufacture higher quality custom ear products more consistently, and at higher volumes for applications like behind-the-ear hearing aids, hearing protection, and custom earplugs and earbuds.
Advantages of 3D-printing
1. Speed: With traditional manufacturing processes, it can take weeks or months to receive a part. 3D printing turns CAD models into physical parts within a few hours, producing parts and assemblies from one-off concept models to functional prototypes and even small production runs for testing. This allows designers and engineers to develop ideas faster, and helps companies to bring products more quickly to the market.
2. Affordable: The 3D printing can utilize low-cost plastics and concrete that are easily accessible. Also, because there is no need for a mold in 3D printing, this makes it affordable and cost effective.
3. Customization: From shoes to clothes and bicycles, we are surrounded by products made in limited, uniform sizes as businesses strive to standardize products to make them economical to manufacture. With 3D printing, only the digital design needs to be changed to tailor each product to the customer without additional tooling costs.
4. Design Freedom: 3D printing can create complex shapes and parts, such as overhangs, microchannels, and organic shapes, that would be costly or even impossible to produce with traditional manufacturing methods. This provides the opportunity to consolidate assemblies into less individual parts to reduce weight, alleviate weak joints, and cut down on assembly time, unleashing new possibilities for design and engineering.
5. Reduced Risk: Product development is an iterative process that requires multiple rounds of testing, evaluation, and refinement. Finding and fixing design flaws early can help companies avoid costly revisions and tooling changes down the road. With 3D printing, engineers can thoroughly test prototypes that look and perform like final products, reducing the risks of usability and manufacturability issues before moving into production.
Disadvantages of 3D Printing
1. The 3D Printers May Not Provide Enough Strength: A downside to building an object up layer by layer, is that this can affect the durability and strength of the object. Of course, the strength of 3D printing relies heavily on what materials are used; metals and concrete will always be some of the strongest materials used in 3D printing.
2. The 3D Printers May Have Accuracy Issues: Although CAD is often an accessible and accurate way to design, there can be errors. Accuracy with 3D printing is dependent on the techniques and printers use. For example, some smaller 3D printers, like desktop models, can wear out easily. This means that as the production of a design goes on, the products made later on may vary from the first batch.
3. The 3D Printers May Require Post-Processing: Another pitfall of 3D printing is the work required to finish up a product. This might include sanding or smoothing out an object, heat treatment or removing support struts. Post-processing of 3D printed products can sometimes lead to additional costs.
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