Everything you need to know about 3D printing!

If we talk about different market segments, 3D printing is one of the most widespread technologies. However, as we begin to explore its conceptual meaning and history, there is still much to know.

This article will launch an in-depth discussion of the history of 3D printing, its main markets, processes, and the materials used.

Without further delay, let's get the discussion started!

Overview of the history of 3D printing

The history of 3D printing can be traced back to the 1980s in Japan, when Hideo Kodama was looking for a way to create an accelerated and faster prototyping system. It was one of the first attempts to find a layer-by-layer approach that could also be applied to manufacturing. As a result of his experiments, Hideo developed a differentiated approach suitable for manufacturing, involving the use of a photosensitive resin. In addition, it was polymerized with the help of ultraviolet light. Although his invention is not yet patented, he is credited with being the first inventor of the first 3D printing manufacturing systems.

The main growth of 3D printing was seen between 1990 and 2010 when thousands of companies and startups started experimenting with different additive manufacturing technologies. Therefore, this decade marks the beginning of significant developments in 3D printing technology, especially in manufacturing.

The main methods of 3D printing

3D printing technology encompasses a number of different manufacturing processes in which the required materials are built up layer by layer. In any form, the existing 3D printing processes offer the designer a wide range of possibilities, making it easy for him to choose the most ideal and suitable process. Here are some of the leading 3D printing processes:

Stereolithography (SLA)

Also referred to as the original industrial 3D printing process, Stereolithography is ideal for producing parts with great detail and a smooth surface. The resulting quality of stereolithography parts looks good and can help test the function and fit of the assembly. This printing process is used, among other things, in medicine and for anatomical models.

Multi-Jet Fusion

This process is very similar to the previous methods as it helps create functional parts out of nylon powder. In multi-jet fusion, inkjet printers are used to apply fusing agent to the layer of nylon powder. After building this layer, a heating element is passed over the individual layers to fuse them together. Compared to other processes, this process is also easier to handle mechanically and offers better surface quality. Therefore, this method is ideal as it combines the advantages of traditional methods with the acceleration of construction time, resulting in better production quality.

PolyJet

It is a popular 3D printing process that allows the creation of parts with different properties, including materials and colors. Using this method, designers can improve the technology for the production of injection molded parts and prototypes. However, the design is uniform and rigid. Therefore, it is usually ideal to stick with conventional procedures. When the process also includes prototyping of the existing structure, this process eliminates the need to invest in early development cycles and design faster to save the necessary resources.

Selective Laser Sintering (SLS)

Selective laser sintering is a 3D printing process that melts nylon-based powder and turns it into solid plastic. Because this process creates parts from real thermoplastic material, the resulting material is also durable and ideal for functional testing. Compared to other methods, the parts produced with this method are solid, but have a rougher surface. This process also eliminates the need for a support structure, making it ideal for larger volumes not common with other 3D printing processes.

electron beam melting

E-beam melting is another important 3D printing process. It is very popular because it uses an electron beam regulated and controlled by an electromagnetic coil that helps melt the metal powder. This increases the paint bed temperature and stabilizes the vacuum conditions during build-up. The temperature also determines the material used to melt the parts. Another reason why electron beam melting is so widespread is that it helps integrate 3D printing technology so that the resources used in the process are not wasted.

Digital Light Processing (DLP)

This process is very similar to Selective Laser Sintering in that it helps improve the quality of the liquid resin with the help of light. The main difference between the two methods is that digital light processing uses digital light projection screens. In contrast, the other method uses a UV laser. This means that digital light processing technology uses 3D printers that can produce an entire layer of images at once, increasing overall build speeds. While this technique is often used to speed up the prototyping process, it is also useful for low-volume production of units, including plastic parts.

Modeling by Fused Deposition (FDM)

It is one of the most common desktop 3D printing processes used specifically for plastic parts. Fused Deposition Modeling is also an inexpensive and comparable diffusion process when physical models need to be made. Any 3D printer used for fused deposition modeling helps extrude plastic filaments by fragmenting the individual layers and building the entire platform. This method is also ideal for functional testing, but the technology is typically limited as the parts have a relative reference surface and insufficient strength.

Direct metal laser sintering

It is a metal 3D printing process that expands the existing and possible possibilities for the design of metal parts. This process is most commonly used to reduce the volume of metal used in processing and to assemble multi-part functions into a single component. In addition, it is also ideal for the manufacture of lightweight components with internal channels with specially designed features. This process is also ideal for prototyping and production because it uses parts that are dense enough to survive traditional metal fabrication processes such as casting and machining. Therefore, the production of metal components by direct metal laser sintering is also ideal for applications where the design of parts with an organic structure is a key requirement.

Main materials for 3D printing

The variety of main materials for 3D printing is as wide as the methods we presented in the last section. Here are the main print materials used in standard 3D printing processes

Plastic

Plastic is one of the most commonly used materials for 3D printing as it is a diverse material for industries like toys and household. Products made of plastic using 3D printing technology allow the construction of products with a transparent shape and bright colors, which are most read and especially appreciated for their glossy texture. It is also a comparatively affordable option as it is lightweight and pocket-friendly for both developers and consumers. In addition, plastic products made with 3D printers come in various shapes and consistencies, which contributes to further diversification of the scope of applications.

When classifying the types of plastic used in 3D printing, a distinction is made between the following:

Acrylonitrile Butadiene Styrene (ABS)

It is one of the most solid and safest options, especially for home use or other personal use including 3D printer application. It's also known as LEGO plastic because its base material consists of noodle-like structures that provide flexibility and strength. Because of this special property, this type of plastic is also ideal for products such as toys and stickers.

Polycarbonate (PC)

While less popular than other plastics, polycarbonate offers designers unique nozzle designs that are only possible at high temperatures. In addition to many other product categories, polycarbonate is also suitable for the production of low-cost plastics and molded shells, which makes it ideal for these industries in particular.

Polyvinyl Alcohol Plastic (PVA)

Polyvinyl alcohol plastic is commonly used in low-cost home printers because it is typically a suitable substrate for materials with sufficient sustainability and observability. However, polyvinyl alcohol plastic is not suitable for products that require high strength, but is a cost-effective option when it comes to making items that are only intended to be used temporarily.

Polylactide (PLA)

This is one of the most environmentally friendly options for a material suitable for 3D printing. This acid is derived from natural sources such as cornstarch and sugar cane and is often available in both hard and soft forms. In addition, it is made of solid materials and is therefore suitable for a wide range of products. Therefore, it is often considered by technicians and designers as one of the most versatile and environmentally friendly options for 3D printing processes, including the use of plastic.

powder

Even with modern 3D printing processes, different types of powder are often used to create a wide range of products. However, considering how 3D printers work, the powders are usually melted and spread out in layers until the desired thickness, texture and pattern is achieved. This powder can come in different forms and from different sources and materials. However, some of the most common ones include the following –

Polyamide (PA)

Known for its strength and flexibility, this type of powder allows for high levels of detail in the manufacture of 3D printed products. It is also ideal for assembling parts and interlocking different parts to create 3D printed models. Also, it is helpful in printing everything from handles and latches to creative figures and toy cars.

alumide

Alumide is a mixture of gray aluminium, aluminum powder and polyamide, making it one of the most stable 3D printed models. Also, it has a grainy and sandy texture, making it ideal for industrial models and prototypes that require high strength. Additionally, in powder form, it is comparatively easier to transport and mold into any desired shape that a product needs. Therefore, it is of higher value compared to other powder forms commonly used in 3D printing.

resin

Synthetic resins are one of the least used materials in 3D printing. Compared to other materials, resins are used for limited applications and offer limited safety and strength to the end product. They are made from liquid polymers that have longer exposure to UV light and are therefore usually available in black, white and clear versions. However, different products and variants can also be made in the colors orange, red, blue and green. Resins are typically classified into three different categories, including the following

Paintable resins

These are smooth surface 3D prints known for their aesthetics and strength. These resins are also used to create facial details such as B. to depict fairies, which are often difficult to reach.

Transparent resin

This is the most important resin category as it is best suited for 3D printed products. They are characterized by a smooth surface and a transparent appearance, making them the ideal choice for synthetic resins. However, clear and colored variants of transparent resins are most commonly used for the manufacture of chess pieces, figurines, and small household accessories, which typically have transparent surfaces.

Highly detailed resins

These are generally used for small models that need to have intricate and fine detail. For example, highly detailed resins are most commonly used to produce 4 inch fingers that contain complex wardrobe structures and details printed with this resin category.

Metals

Metals are also among the most popular materials for 3D printing. They are most commonly used in direct metal laser sintering and other appropriate processes. Techniques that use metals include manufacturing aerospace equipment that requires 3D printing of heavy metals to speed up and simplify part design. Metals are also commonly used in the manufacture of jewelry. In such cases, production must be rapid and in large quantities. Therefore, there is an opportunity to create a more detailed work using 3D printing technology.

The use of metals in 3D printing is most commonly used in the aerospace industry to manufacture fuel injectors for jet engines. It is estimated that production will increase by 2020% by 10, indicating the increasing use of metals in 3D printing in the aerospace industry. In the printing process, metals help to achieve a certain hardness, so the printers can use these materials directly to make metal parts. Once the product has reached final processing, it is electropolished and passed on to the next market segment.

Carbon fiber

Carbon fiber is a composite material used in 3D printers as a top layer over plastic materials. The main purpose of using carbon fiber in 3D printing is to reinforce plastic, as the combination provides a faster and more convenient alternative to metal.

Paper Industry

Paper is used in 3D printing when the designs require a more realistic prototype than 2D illustrations. Such integrations allow the 3D printed models to convey the main idea of ​​the design with greater accuracy and detail. Additionally, it makes the final product compelling and appealing, and gives a better sense of the technical genius that went into the processes to achieve the desired result.

graphite

While not among the most conventional 3D printing materials, graphite is slowly gaining popularity due to its conductivity and strength. This material is ideal for making products that require much greater flexibility, such as B. solar panels and building parts.

Materials for high temperatures in 3D printing

In 3D printing, especially fused deposition modeling, high temperature materials play an important role as they are the most demanding prospects. These materials typically require higher temperatures than normal materials and have exceptional thermochemical and mechanical properties. Some of the most well-known high-temperature materials for 3D printing include the following materials.

Polyetherketone Ketone (PEEK)

Polyetherketoneketone is one of the most popular alternatives for applications that allow easy processing with an amorphous material. Popularly known as PEEK, it provides an additional and enhanced adhesion layer, making it a highly preferred high temperature material that can also exhibit high strength under compressive loads.

It is also known for its high heat resistance compared to other 3D printing materials, as it has better mechanical and chemical properties that give it greater heat resistance. For this reason, polyetherketoneketone is one of the most popular materials for 3D printing that is suitable for high temperatures.

ULTEM (PEI)

ULTEM, better known as polyetherimide, is a high-temperature material that offers great properties at an extremely low price, making it one of the preferred high-temperature materials for 3D printing. One of the biggest advantages of using it as a high-temperature material for 3D printing is that it can be sterilized due to its excellent chemical and thermal resistance. Therefore, it is the ideal choice for numerous applications that require high resistance, strength and rigidity.

Polyvinylidene Fluoride (PVDF)

Polyvinyl chloride, also called PVDF, is known for its high mechanical strength and its ability to withstand temperatures of up to 150 degrees Celsius. It is also a highly inert thermoplastic closely related to Teflon, making it one of the preferred options.

The main markets for 3D printing

3D printing technology has been around for several decades and has gained popularity in various market segments and industries. Consistent 3D printing applications are evolving, but they have gained popularity in some key markets.

Here are some of the most common use cases from industries using 3D printing:

Medicine

3D printing is widely used in medicine, particularly in bioprinting, where technicians need to use materials like cells and growth factors to study tissue-like structures. 3D printing applications in medicine are also contributing to widespread use of metal implants for osteoporosis. Bioprinting is also helping to 3D print artificial organs, which can help patients with organ failure when faster growth is an essential requirement for treatment.

Construction industry

The construction industry is another popular use case for 3D printing. Concrete 3D printing is considered an earlier and less expensive way to construct buildings. It has enabled the designers to create on-site designs specifically tailored to concrete foundations and buildings.

art and jewelry

The art and jewelry sector is also a popular application of 3D printing technology. Advances in 3D printing have enabled and inspired millions of artists around the world to create their customized and unique pieces of art and jewelry using metal 3D printing. Especially in the jewelry space, 3D printers help designers experiment with design that traditional jewelry-making processes cannot. Also, they help creators to create their own unique and bespoke pieces of jewelry.

Manufacturing and prototyping

As we know, 3D printing was first developed for faster prototyping. However, the technology of 3D printing has contributed significantly to the growth of the manufacturing and prototyping market segment. By combining cloud computing technologies, companies are now offering consumers additive manufacturing services without the expense of purchasing a 3D printer.

Outlook for the future

As a technology, 3D printing has changed the world. It is not only limited to the target industry but also affects the daily life of millions of consumers around the world. In addition, he has made the consumer goods segment more personalized and on-demand, thereby expanding the sources for manufacturing in the future.

Looking ahead, experts predict that 3D printers will also be able to build materials atom by atom, taking lightweight construction technology to the next level. Technology will also help create lightweight and high-performance materials. However, the existing challenges of 3D printing and additive manufacturing in the individual industries would also have to be taken into account. Existing technology is on the way to getting better and cheaper, giving researchers plenty of opportunities to integrate 3D printing with other technologically advanced processes.

In order to enable the industry to use the existing 3D printing technologies in the future, industry and politics must come together and make further recommendations to strengthen politics. In addition, it is also necessary to look at the issue differently so that future technologies will give a better result.