3D PRINTING
What exactly 3D printing is, how it works, how to 3D print, the best materials for beginners, and what you need to get started.
3D printers can build three-dimensional objects, out of a variety of materials. They're going mainstream, showing up at retailers such as Staples, Best Buy, and Home Depot, and you can buy numerous 3D printers and their supplies on Amazon.com and through other online outlets. Though still mostly found on shop floors or in design studios, in schools and community centers, and in the hands of hobbyists, 3D printers are increasingly being found on workbenches, in rec rooms, and kitchens—and perhaps in a home near you, if not your own.
In this article...
What Are the Benefits of 3D Printing?
What Does the Future Hold for 3D Printing?
Types of 3D Printing Technologies and Processes
What Is 3D Printing?
3D printing is the process of creating a three-dimensional object, usually done by systematically layering material on top of itself. The printer reads a digital file from the computer which dictates how to layer the material to build the object.
This is why 3D printing is also known as additive manufacturing. 3D printing and additive manufacturing are mostly synonymous, although you may hear additive manufacturing used more frequently in the context of mass consumption or mass manufacturing.
At its most basic, 3D printing is a manufacturing process in which material is laid down, layer by layer, to form a three-dimensional object. (This is deemed an additive process because the object is built from scratch, as opposed to subtractive processes in which material is cut, drilled, milled, or machined off.) Although 3D printers employ a variety of materials (such as plastic or metal) and techniques, they share the ability to turn digital files containing three-dimensional data—whether created on a computer-aided design (CAD) or computer-aided manufacturing (CAM) program, or from a 3D scanner—into physical objects.
Is 3D Printing Even Printing?
Yes, 3D printing can be considered printing, although not as it's traditionally been defined. The relevant Webster's definitions of "printing" center on the production of printed matter, publications, or photographs, and producing by means of impression (the application of pressure). Neither definition really fits 3D printing. But from a technological perspective, 3D printing is an outgrowth of traditional printing, in which a layer of material (usually ink) is applied. Usually it's so thin that there is no noticeable height (though with solid ink printers, it is somewhat thicker). What 3D printing does is greatly extend that height through the application of multiple layers. So it would make sense to expand the definition of printing to include the fabrication of three-dimensional objects in this manner.
How Does 3D Printing Work?
Much like traditional printers, 3D printers use a variety of technologies. The most commonly known is fused deposition modeling (FDM), also known as fused filament fabrication (FFF). In it, a filament—composed of acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), or another thermoplastic—is melted and deposited through a heated extrusion nozzle in layers. The first 3D printers to come to market, made in the mid 1990s by Stratasys with help from IBM, used FDM (a term trademarked by Stratasys), as do most 3D printers geared to consumers, hobbyists, and schools.
Another technology used in 3D printing is stereolithography. In it, a UV laser is shined into a vat of ultraviolet-sensitive photopolymer, tracing the object to be created on its surface. The polymer solidifies wherever the beam touches it, and the beam "prints" the object layer by layer per the instructions in the CAD or CAM file it's working from.
In a variation on that, you also have digital light projector (DLP) 3D printing. This method exposes a liquid polymer to light from a digital light processing projector. This hardens the polymer layer by layer until the object is built, and the remaining liquid polymer is drained off.
Multi-jet modeling is an inkjet-like 3D printing system that sprays a colored, glue-like binder onto successive layers of powder where the object is to be formed. This is among the fastest methods, and one of the few that supports multicolor printing.
It's possible to modify a standard inkjet to print with materials other than ink. Enterprising do-it-yourselfers have built or modded print heads, generally piezoelectric heads, to work with various materials—in some cases printing out the print heads themselves on other 3D printers! Companies like MicroFab Technologies sell 3D-capable print heads (as well as complete printing systems).
Selective laser sintering (SLS) uses a high-powered laser to fuse particles of plastic, metal, ceramic, or glass. At the end of the job, the remaining material is recycled. Electron beam melting (EBM) uses—you guessed it—an electron beam to melt metal powder, layer by layer. Titanium is often used with EBM to synthesize medical implants, as well as aircraft parts.
Depending on the technique, 3D printers can use a variety of materials, including but not limited to metals (stainless steel, solder, aluminum, and titanium among them); plastics and polymers (including composites that combine plastics with metals, wood, and other materials); ceramics; plaster; glass; and even foodstuffs like cheese, icing, and chocolate!
How to 3D Print:
Depending on the specific print you are planning to do there could be more or fewer steps in your process. But in general, 3D printing involves the following actions:
Step 1: Create or Find a Design
The first step of 3D printing typically starts on a computer. You must create your design using a 3D design software, typically a CAD (computer-aided design) software. If you are unable to create the design yourself, you can also find many free resources online with free designs.
Step 2: Export the STL File
Once you have created or chosen a design, you must either export or download the STL file. The STL file is what stores the information about your conceptual 3D object.
Step 3: Choose Your Materials
Typically you may have an idea about what kind of material you will use before you print. There are many different 3D printing materials available, and you can choose them based on the properties that you want your object to have.
Step 4: Choose Your Parameters
The next step is then deciding on the different parameters of your object and the printing process. This includes deciding on the size and placement of your print.
Step 5: Create the Gcode
You will then import the STL file into a slicing software, like BCN3D Cura. The slicing software will convert the information from the STL file into a Gcode, which is a specific code containing exact instructions for the printer.
Step 6: Print
This is when the magic happens! The printer will create the object layer by layer. Depending on the size of your object, your printer, and the materials used, the job can be done in a matter of minutes or over several hours.
Depending on what you want your final product to be or the material you used, there may be additional post-processing steps after printing, like painting, brushing off powder, etc.
3D printing can be used both recreationally and professionally, across various industries. It has applications in many different fields and sectors, from the healthcare industry to engineering, and even fashion.
Increasingly, 3D printing is seen as a sustainable and cost-friendly solution for creating prototypes and tools for different manufacturing projects and processes. Traditionally, acquiring prototypes can be time-consuming and costly, requiring companies to depend on outside manufacturers. 3D printing allows companies to quickly make units of an object, tool, or prototype, all in-house.
A great example of this is shoe company Camper. In-house 3D printing has allowed them to transform their nearly month and a half long modeling and designing process into an operation that takes only several days.
3D Printing For Beginners: How To Get Started
So, what do you need to get started with 3D printing? Your specific needs will depend on why and what you want to print, but in general, there are three considerations for getting started:
- A 3D printer
- Filament
- Slicing software
If you plan on creating your own designs you will also need the appropriate designing software. But, as we mentioned earlier, you can also find many free resources online to download designs.
If you have not yet purchased a 3D printer, we have a guide that can help steer you through the most important considerations.
3D printer Filaments
The material also called filament, you choose for your print will depend on many different factors:
- Do you want your object to be flexible?
- Heat resistant?
- Does it need to be very durable?
These are just some of the factors to consider when choosing your filament.
In general, most beginners start with PLA. This is because PLA is cost-effective and typically easy to print with a standard configuration. Depending on your specific project, PLA could be good starter material.
PET-G is also considered a beginner-friendly material, although it is a bit more technical than PLA. However, it is great for industries like engineering and manufacturing. It is a good material for functional prototypes because it can withstand higher temperatures and has a different chemical makeup that is ideal for these uses.
Software
There are two important pieces of software for 3D printing: CAD and slicing software.
Typically, you can use any CAD system that can create a functional model. CAD is essential if you want to create your own models and objects. You must be able to export an STL file from your CAD software.
The slicing software is the second part of the equation. This software translates the STL file into a language that the printer can understand. The Gcode contains movement information that tells the printer how and where to move its axis, as well as how much material to deposit. The Gcode is sent to the printer via an SD card or wifi.
Bcn3d Beginners-guide-to-3d-printing
Who Invented 3D Printing?
The first 3D printer, which used the stereolithography technique, was created by Charles W. Hull in the mid-1980s. Stereolithography has traditionally been an expensive commercial technique, with machines costing in the five and even six figures, but recent years have seen the advent of desktop professional stereolithography printers costing a few thousand dollars, as well as consumer systems that start well under a grand.
In 1986, Hull founded 3D Systems, a company that today sells 3D printers that use a variety of technologies. They range from entry-level kits to advanced commercial systems, and 3D Systems also provides on-demand parts services, mostly to business users.
What Are the Benefits of 3D Printing?
With 3D printing, designers have the ability to quickly turn concepts into 3D models or prototypes (a.k.a. "rapid prototyping"), and implement rapid design changes. It lets manufacturers produce products on demand rather than in large runs, improving inventory management and reducing warehouse space. People in remote locations can fabricate objects that would otherwise be inaccessible to them.
From a practical standpoint, 3D printing can save money and material versus subtractive techniques, as very little raw material is wasted. And it promises to change the nature of manufacturing, eventually letting consumers download files for printing even complex 3D objects—including, for example, electronics devices—in their own homes.
What Can 3D Printers Make?
Designers use 3D printers to quickly create product models and prototypes, but they're increasingly being used to make final products, as well. Among the items made with 3D printers are shoe designs, furniture, wax castings for making jewelry, tools, tripods, gift and novelty items, and toys. The automotive and aviation industries use 3D printers to make parts. Artists can create sculptures, and architects can fabricate models of their projects. Archaeologists are using 3D printers to reconstruct models of fragile artifacts, including some of the antiquities that in recent years have been destroyed by ISIS. Likewise, paleontologists and their students can duplicate dinosaur skeletons and other fossils. Check out gallery of simple and practical 3D printer objects.
Physicians and medical technicians can use 3D printing to make prosthetics, hearing aids, artificial teeth, and bone grafts, as well as replicate models of organs, tumors, and other internal bodily structures from CT scans in preparation for surgery. A good example is Project Daniel, which 3D-prints prosthetic arms and hands for victims of the violence in Sudan. Also, 3D printers being developed that can lay down layers of cells to create artificial organs (such as kidneys and blood vessels) are already in the R&D phase. There's even a place for 3D printing in forensics, for example to replicate a bullet lodged inside a victim.
Printed electronics is a set of printing methods that enable electronic devices or circuitry to be printed on flexible material such as labels, fabrics, and cardboard, by application of electronic or optical inks. It provides very low-cost fabrication of low-performance devices. Printed electronics is beginning to be combined with 3D printing, allowing for the printing of layered circuitry or devices. A natural outgrowth of this potent combo is that someday you may be able to print out gadgets from 3D plans rather than buying them.
Food preparation is another way 3D printers can be used. The French Culinary Institute has been using a Fab@Home open-source 3D printer developed at Cornell University to prepare artistic delicacies, and MIT has created a 3D food printer called the Cornucopia. A small number of restaurants are testing food-printer prototypes. NASA's 3D printing research has included food printing, such as 3D-printed pizza.
A handful of food 3D printers have become commercially available. They tend to focus on particular food items, like chocolate, or pancakes, or cookies.
What Are 3D Printing Services?
You don't have to own a 3D printer to benefit from one. Many 3D printing services, such as Shapeways and Sculpteo , print gifts and other small items on order on their own 3D printers, then ship them to the customer. Customers can either submit their own 3D object files or choose items, most of them designed by other users of the service, from an online catalog.
But 3D printing services are no longer solely the domain of specialists. Large companies such as UPS have introduced 3D printing services, and some traditional print shops have added on-demand 3D printing to their repertoire.
Where Can I Get a 3D Printer?
Most 3D printer manufacturers sell their products directly online. Many e-tailers now stock them, including online-only companies such as Amazon.com, and others that also have brick-and-mortar stores. Some of the latter, such as Walmart, Best Buy, and Staples, offer them in stores as well as online, but be sure to check for store availability on their websites as not all outlets carry them. Several 3D printer stores have opened in major cities. For instance, iMakr has storefronts in London and New York City.
A few online retailers specialize in 3D printers, such as Dynamism , which sells a range of 3D printers from different brands and also provides customer support.
What Software Do I Need for 3D Printing?
Nearly all 3D printers accept files in what's called STL format (named for stereolithography). These types of files can be produced by most any CAD software, from expensive commercial packages like AutoCAD to free or open-source products such as Google SketchUp and Blender. For those not inclined to make their own 3D files, 3D object databases such as MakerBot's Thingiverse offer numerous 3D object files that can be downloaded and printed out.
Most 3D printers come with a software suite, either supplied on disk or available for download, that includes everything you need to get printing. The suites typically provide a program for controlling the printer and a slicer, which, in preparation for printing, formats the object file into layers based on the selected resolution and other factors. Some suites include a program to "heal" the object file by correcting problems that could interfere with smooth printing. The programs came out of the RepRap open-source movement, out of which hobbyist 3D printing developed. With some printers, you can choose the individual component programs to download rather than going with whatever is provided in the suite.
Which 3D Printers Should I Look At, for Starters?
For deeper coverage of individual printers, and how to buy one, check out guide to the 10 best 3D printers, and some insights from an early adopter.
Tony Hoffman Pcmag 3d-printing-what-you-need-to-know
Types of 3D Printing Technologies and Processes
The American Society for Testing and Materials (ASTM), developed a set of standards that classify additive manufacturing processes into 7 categories. These are:
1. Vat Photopolymerisation
1. Stereolithography (SLA)
2. Digital Light Processing (DLP)
3. Continuous Liquid Interface Production (CLIP)
2. Material Jetting
3. Binder Jetting
4. Material Extrusion
1. Fused Deposition Modeling (FDM)
2. Fused Filament Fabrication (FFF)
5. Powder Bed Fusion
1. Multi Jet Fusion (MJF)
2. Selective Laser Sintering (SLS)
3. Direct Metal Laser Sintering (DMLS)
6. Sheet Lamination
7. Directed Energy Deposition
Vat Photopolymerisation
A 3D printer based on the Vat Photopolymerisation method has a container filled with photopolymer resin. The resin is hardened with a UV light source.
Stereolithography (SLA)
SLA was invented in 1986 by Charles Hull, who also at the time founded the company, 3D Systems. Stereolithography employs a vat of liquid curable photopolymer resin and an ultraviolet laser to build the object’s layers one at a time. For each layer, the laser beam traces a cross-section of the part pattern on the surface of the liquid resin. Exposure to the ultraviolet laser light cures and solidifies the pattern traced on the resin and fuses it to the layer below.
After the pattern has been traced, the SLA’s elevator platform descends by a distance equal to the thickness of a single layer, typically 0.05 mm to 0.15 mm (0.002″ to 0.006″). Then, a resin-filled blade sweeps across the cross section of the part, re-coating it with fresh material. On this new liquid surface, the subsequent layer pattern is traced, joining the previous layer. Depending on the object & print orientation, SLA often requires the use of support structures.
Digital Light Processing (DLP)
DLP or Digital Light Processing refers to a method of printing that makes use of light and photosensitive polymers. While it is very similar to SLA, the key difference is the light source. DLP utilizes other light sources like arc lamps. DLP is relatively quick compared to other 3D printing technologies.
Continuous Liquid Interface Production (CLIP)
One of the fastest processes using Vat Photopolymerisation is called CLIP, short for Continuous Liquid Interface Production, developed by Carbon.
Digital Light Synthesis
The heart of the CLIP process is Digital Light Synthesis technology. In this technology, light from a custom high performance LED light engine projects a sequence of UV images exposing a cross section of the 3D printed part causing the UV curable resin to partially cure in a precisely controlled way. Oxygen passes through the oxygen permeable window creating a thin liquid interface of uncured resin between the window and the printed part known as the dead zone. The dead zone is as thin as ten of microns. Inside the dead zone, oxygen prohibits light from curing the resin situated closest to the window therefore allowing the continuous flow of liquid beneath the printed part. Just above the dead zone the UV projected light upwards causes a cascade like curing of the part.
Simply printing with Carbon’s hardware alone does not allow for end use properties with real world applications. Once the light has shaped the part, a second programmable curing process achieves the desired mechanical properties by baking the 3d printed part in a thermal bath or oven. Programmed thermal curing sets the mechanical properties by triggering a secondary chemical reaction causing the material to strengthen achieving the desired final properties.
Components printed with Carbon’s technology are on par with injection molded parts. Digital Light Synthesis produces consistent and predictable mechanical properties, creating parts that are truly isotropic.
Material Jetting
In this process, material is applied in droplets through a small diameter nozzle, similar to the way a common inkjet paper printer works, but it is applied layer-by-layer to a build platform and then hardened by UV light.
Binder Jetting
With binder jetting two materials are used: powder base material and a liquid binder. In the build chamber, powder is spread in equal layers and binder is applied through jet nozzles that “glue” the powder particles in the required shape. After the print is finished, the remaining powder is cleaned off which often can be re-used printing the next object. This technology was first developed at the Massachusetts Institute of Technology in 1993.
Material Extrusion
Fused Deposition Modeling (FDM)
FDM works using a plastic filament which is unwound from a spool and is supplied to an extrusion nozzle which can turn the flow on and off. The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism. The object is produced by extruding melted material to form layers as the material hardens immediately after extrusion from the nozzle.
FDM was invented by Scott Crump in the late 80’s. After patenting this technology he started the company Stratasys in 1988. The term Fused Deposition Modeling and its abbreviation to FDM are trademarked by Stratasys Inc.
Fused Filament Fabrication (FFF)
The exactly equivalent term, Fused Filament Fabrication (FFF), was coined by the members of the RepRap project to give a phrase that would be legally unconstrained in its use.
Powder Bed Fusion
Selective Laser Sintering (SLS)
SLS uses a high power laser to fuse small particles of powder into a mass that has the desired three dimensional shape. The laser selectively fuses powder by first scanning the cross-sections (or layers) on the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one layer thickness. Then a new layer of material is applied on top and the process is repeated until the object is completed.
Multi Jet Fusion (MJF)
Multi Jet Fusion technology was developed by Hewlett Packard and works with a sweeping arm which deposits a layer of powder and then another arm equipped with inkjets which selectively applies a binder agent over the material. The inkjets also deposit a detailing agent around the binder to ensure precise dimensionality and smooth surfaces. Finally, the layer is exposed to a burst of thermal energy that causes the agents to react.
Direct Metal Laser Sintering (DMLS)
DMLS is basically the same as SLS, but uses metal powder instead. All unused powder remains as it is and becomes a support structure for the object. Unused powder can be re-used for the next print.
Due to of increased laser power, DMLS has evolved into a laser melting process. Read more about that and other metal technologies on our metal technologies overview page.
Sheet Lamination
Sheet lamination involves material in sheets which is bound together with external force. Sheets can be metal, paper or a form of polymer. Metal sheets are welded together by ultrasonic welding in layers and then CNC milled into a proper shape. Paper sheets can be used also, but they are glued by adhesive glue and cut in shape by precise blades.
Directed Energy Deposition
This process is mostly used in the metal industry and in rapid manufacturing applications. The 3D printing apparatus is usually attached to a multi-axis robotic arm and consists of a nozzle that deposits metal powder or wire on a surface and an energy source (laser, electron beam or plasma arc) that melts it, forming a solid object.
Materials
Multiple materials can be used in additive manufacturing: plastics, metals, concrete, ceramics, paper and certain edibles (e.g. chocolate). Materials are often produced in wire feedstock a.k.a. filament, powder form or liquid resin. Learn more about our featured materials on our materials page.
Services
Looking to implement 3D printing in your production process? Get a quote for a custom part or order samples on this 3D print service page.
3dprinting what-is-3d-printing
50 Cool Things to 3D Print
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Minichess Gear Clock USB Extension Desk Mount Bracket Magic Whistle Card Shoe Hairdryer Wallmount Remote Control Holder Speedy Circle Clip Daily Goal Tracker Ultimate Filament Clip Clamp Dead Guy Doorstop Squeeze Drill Wire Stripper Pocket Screwdriver Kit Gravity Broom-Holder 3-Digits Combination Safe Box Cat Feeder Honeycomb Storage Wall Telescope
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Tally Counter Medium Format Camera Battery Missile Launcher Wind-up Boat Zippy Bag Clip Remote Spring Mount Maker Lamp Hexx Case Tool Roll Under-Desk Drawer Oreo Box Center Finder Battery Dispenser Cardboard Molds Modular Desk Organizer Squeeze Fan Charger Cable Organizer
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Circle Lamp LED Hexagonal Panels Slim Credit Card Wallet Anti-Gravity Planter Spring Loaded Box Quick Grab/Release Phone Stand StrandBox - Small Gadgets Storage Box Impossible Table Groovi Monster Sound Amplifier Measuring Cube Self-Watering Planter Toothpaste Tube Squeezer Card Deck Shuffler Digital Sundial
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Click here for images of the above objects
Anatol Locker all3dp.com Useful-cool-things-3d-print-ideas-3d-printer-projects-stuff
What Does the Future Hold for 3D Printing?
A variety of 3D printers for homes and small businesses is readily available--PCMag has reviewed quite a number of them—but they are still often viewed as exotic, and rather pricey, contraptions. Expect that to change within the next few years, when 3D printers will become more commonplace in houses—to be found on workbenches, in studios, in home offices, and even in the kitchen. You may not find them in every household, but they'll become indispensable to those people who do have them. For the most part, items made with 3D printers have had homogenous interiors, but we'll start to see more complex creations combining multiple materials and composites, as well as printable electronics. With today's 3D printers, if you lose your TV remote's battery cover, it may be possible to print a replacement cover. With tomorrow's, if you lose your remote, perhaps you'll be able to print a whole new remote.
Also, 3D printing is gaining a foothold in outer space. NASA is experimenting with 3D printers on board the International Space Station. Eventually, 3D printers could be used to create habitats on Mars and other worlds. To save the Apollo 13 astronauts from dying of carbon monoxide asphyxiation, NASA had to in effect find a way to fit a square peg into a round hole. Had there been a 3D printer on board, they may have been able to easily solve the problem by designing and printing a connector.
Astronauts can't take a swing by Home Depot if they need to replace a valve or widget, but a 3D printer could fabricate one as needed. Likewise, we'll see 3D printers in Antarctic bases and other remote Earthly locations, where folks can't wait six months for the next resupply to replace essential parts or tools.
Medical applications of 3D printing don't stop with prosthetics, hearing aids, and dental crowns. Replacement parts needn't be restricted to the mechanical.
Though it's easy enough to see some of the areas the field of 3D printing will branch into, others are beyond our ability to predict, just as no one around in 1980 could have imagined much of what the personal computer would turn into. It's possible that 3D printing may not have the same impact as the PC on a consumer, everyday-life level, but it does have the potential to revolutionize manufacturing and, perhaps more important, bring it into the hands of everyday consumers. One thing's for sure, though: 3D printing is here to stay.
3D printing is now more beginner-friendly than it has ever been. In the beginning, many people saw 3D printing as something inaccessible to the major public, but this sentiment is changing, and for good reason. While it takes practice to perfect your prints and technique, learning how to 3D print is an attainable skill.
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