3D printing, also known as additive manufacturing, is revolutionizing the way we create objects. It involves building a three-dimensional object from a digital design by adding layers of material, typically plastic, one on top of another. This guide will provide a comprehensive overview of 3D printing, covering its history, technology, applications, and how to get started.
Research indicates that the history of 3D printing began in the 1970s. While early additive manufacturing equipment and materials emerged in the 1980s with Hideo Kodama filing a patent for the technology, it wasn’t until the 1990s that 3D printing gained global attention. A notable achievement during this period was the creation of functional human organs for transplants using 3D printed methods combined with the patient’s own cells.
Despite these early advances, widespread functional production using 3D printing remained limited until the 2000s, when additive manufacturing gained popularity. Additive manufacturing contrasts with subtractive manufacturing, which removes material to create an object, often resulting in significant material waste. While “3D printing” often refers to technologies using polymers, and “additive manufacturing” to metalworking, these terms became interchangeable in the market by the early 2010s.
Around 2008, the first self-replicating 3D printer model was created, capable of printing its own components. This innovation allowed users to produce more printers. Later that year, a person successfully walked with a 3D printed prosthetic leg made in one piece. By 2012, with the introduction of various materials, the potential of 3D printing for developing countries became apparent.
In subsequent years, applications for 3D printing expanded, including the creation of the world’s first aircraft. Makers found 3D printing faster and cheaper than traditional methods, making it ideal for rapid prototyping. Terms like “desktop manufacturing,” “rapid manufacturing,” and “rapid prototyping” became synonymous with 3D printing.
The market today offers a wide range of 3D printers, from sophisticated, expensive machines to more affordable models with high-quality printing capabilities, making them accessible to schools and engineers.
How 3D Printing Works
At its core, 3D printing builds objects by layering material. A 3D printer utilizes instructions from 3D modeling software to precisely control this process.
This image illustrates the basic steps involved in a typical 3D printing workflow, from design to finished product.
3D printing encompasses various manufacturing technologies, all following the same layer-by-layer approach. However, each technology may utilize different materials, offer varying finishes, and incur different costs.
Some of the most common 3D printing technologies include:
- Fused Deposition Modeling (FDM): Also known as Fused Filament Fabrication (FFF), FDM involves melting and extruding plastic filament through a heated nozzle to create layers. ABS and PLA are common materials.
- Selective Laser Sintering (SLS): SLS uses a laser to sinter powdered plastic material into a solid model. This technology is popular for rapid prototyping and small-batch manufacturing.
- Selective Laser Melting (SLM): SLM employs a high-power laser to melt and fuse metallic powders, creating solid 3D metal parts layer by layer.
- Stereolithography (SLA): SLA creates parts with high levels of detail, smooth surfaces, and flawless finishes, making it suitable for mechanical industry applications and models.
- Digital Light Processing (DLP): Similar to SLA, DLP cures resin materials using light from a projector screen, allowing an entire layer to be built simultaneously.
Steps in the 3D Printing Process
Let’s explore the key steps involved in bringing your digital designs to life:
1. Create a CAD (Computer-Aided Design) File
The initial step involves creating a virtual design using CAD software or a 3D scanner. This simulates the object’s dimensions to visualize the final 3D printed product. Designing in CAD minimizes printing errors, as corrections can be made beforehand. Alternatively, objects can be created manually, such as through sculpting, using a 3D scanner to capture the object’s data, shape, and appearance.
An example of a 3D model being designed using CAD software, showcasing the complexity and precision possible.
2. Convert the CAD File
After the design is complete, it needs to be converted into a format readable by the 3D printer. The most common file format is STL (standard tessellation language), although this can result in larger file sizes due to the number of surfaces. An alternative is the AMF (Additive Manufacturing File format), which stores information more efficiently.
3. Manipulate the STL File
Once the STL file is created, the orientation and size of the object need to be set before sending it to the 3D printer. The STL file also allows for repairing any inconsistencies in the original design.
4. Prepare the 3D Printer
Before printing, all necessary materials must be prepared. The STL file is processed by slicing software, which converts the object into layers and provides instructions for the 3D printer.
5. Build the Object
The printing process can now begin. The time required depends on the object’s complexity. High-end printers offer faster printing capabilities. The object is built layer by layer with incredible resolution, often using layers as thin as 100 micrometers.
6. Process the Final Piece
After printing, the object must be handled carefully. Wearing gloves is recommended. Any residual powder should be brushed off to clean the piece. One significant advantage of 3D printing is the ability to create objects in hours, a stark contrast to traditional manufacturing processes.
How FFF 3D Printers Work
Fused Filament Fabrication (FFF), also known as Fused Deposition Modeling (FDM), emerged after Stereolithography (SLA) and Selective Laser Sintering (SLS) techniques. The term FFF was introduced as an unconstrained alternative to the trademarked FDM term.
A diagram illustrating the FFF 3D printing process, showing the filament being extruded and layered to build the object.
An extrusion heated nozzle moves over a built platform, depositing molten plastic in thin layers, one on top of another, forming the 3D printed object. The nozzle and print bed move simultaneously while plastic is extruded. Slicing software plays a crucial role by separating the design into layers for optimized 3D printing.
3D printing utilizes various materials like pastes, raw materials, and thermoplastics or filaments, with filaments being the most common. These come in different colors, thicknesses, and sizes to suit the 3D printing model. Filament materials include thermoplastics like ABS, PLA, HIPS, TPU, ASA, and PETG.
What Can Be 3D Printed?
3D printing has transformed model and prototype creation. Rapid prototyping (RP) allows for product creation in hours or days, compared to weeks with traditional methods. Almost any object imaginable can be 3D printed.
Statista projects the worldwide market for 3D printing products and services to exceed $40 billion by 2024, with an expected annual growth rate of 26.4 percent between 2020 and 2024.
A visual representation of the diverse industries and applications that are benefiting from 3D printing technology.
New materials and applications are constantly emerging, leading more companies to adopt 3D printing for quicker prototyping and production, often utilizing their own printers.
3D printing significantly impacts product development, research, and education across many industries, promising to transform them.
3D Printing Across Industries
The versatility of 3D printing is evident in its applications across numerous industries:
- Consumer Goods: Companies are using 3D printing to customize products, accelerate design, and rapidly introduce products to the market. Eyewear, footwear, lighting design, and furniture are being 3D printed. Brands like Nike and Adidas have used 3D printing for athletic shoes.
- Medical Industry: 3D printing is advancing healthcare with applications like implant designs, surgical planning, training, and prosthetics. It’s also being explored for organ generation. 3D printing has been used to produce masks during the COVID-19 pandemic.
An example of a 3D printed prosthetic limb, highlighting the potential for customized and affordable medical solutions.
- Automotive Industry: 3D printing is transforming the automotive industry from creating simple prototypes to printing entire cars and customized auto parts.
- Aerospace: Airbus uses 3D printing to create plastic parts and metal parts for wing slats, tail wing sections, and door hinges, resulting in lighter, stronger parts with reduced manufacturing time and waste.
- Dental Applications: 3D printing is used to create crowns, aligners, bridge models, retainers, and orthodontic models.
- Prosthetics: 3D printing offers fast processing times, low costs, and customization for implants and prosthetics. Organizations like e-NABLE are creating prosthetic designs for individuals in need.
- Architecture: 3D printing allows for rapid creation of architectural models and has been used to create entire buildings and urban structures, such as the first 3D printed pedestrian bridge in Madrid, Spain.
- Archeology: Museums and archeologists use 3D printing to reproduce exact copies of artifacts for research and educational purposes.
- Art Restoration: 3D printing is used to restore artwork, such as the work done by the Scuola di Alta Formazione (SAF) of the Instituto Superiore per la Conservazione ed il Restauro (ISCR) in Italy.
- Forensics: 3D printing is used in forensics to create skulls and shoe prints for solving cold cases. Forensic artists use 3D printed skulls with clay to reconstruct faces of missing and unidentified victims.
- Film Industry: 3D printing is used for makeup preps and special effects, enabling the creation of intricate characters and props.
Getting Started with 3D Printing
Here are some key steps to consider:
Step 1: Choosing the Right 3D Printer
Select a 3D printer that meets your specific needs. Compare models and choose a printer with the right features for your projects. Consider dual extruders for increased production, high-resolution cameras, video-assisted calibration systems, and safety features. Industrial-grade 3D printers are suitable for larger, more complex parts and offer features like motion controllers, remote user interfaces, and interchangeable nozzles.
Step 2: Choosing 3D Slicing Software
Choose modeling software. Numerous websites offer free downloadable software programs for design and modeling, while others provide a variety of 3D models. Research and find slicing software that is intuitive, user-friendly, and offers advanced features. Ensure that the software supports a multi-lingual interface if needed.
Step 3: Set the Design for Printing
Prepare the design for printing. When the printer receives data from the software, it initiates the printing process using a filament that passes to the printer plates. The most common file format is STL (Standard Triangle Language). The design is translated into triangles, enabling the printers and hardware to construct the object. An optimal file resolution ensures smooth operation of machines and software.
Step 4: Building the Object
In this process, the object is built through layering. Each layer is added until the final shape is formed. The process of repeatedly printing over the same area is called Fused Depositional Model (FDM). The most common material is plastic, but various other materials like PLA, ABS, HIPS, and carbon fiber can be used.
Where to Find 3D Printing Files
Numerous websites offer files for 3D printing, including free options. A variety of STL files, 3D printed models, and designs in other file formats are available online.
The Future of 3D Printing
3D printing is transforming industries and the world economy. Despite certain limitations, this advanced technology is universally adopted by big corporations as a crucial mainstay of the manufacturing industry. As technology continues to advance, we can expect even more innovative applications of 3D printing in the future.
