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3D Printing: A guide to getting started

By Jesse Marin

Chances are you've heard about the use of 3D-printing applications for design and manufacturing. Maybe you've even considered building 3D elements into your process. You're not alone.

According to the Wohlers Report 2019, an industry-leading report on additive manufacturing, revenue for all 3D-printed products and services worldwide is expected to more than double by 2024 -- a large segment of which is derived from manufacturing.

With 3D printing, bringing an idea from prototype to production is no longer bound by the constraints of traditional manufacturing methods. But while the use of 3D printing is expected to grow, successful adoption of the technology and techniques requires preparation and a degree of finesse. It's not without its challenges.

If you've been wondering how to implement 3D printing into your design process, here are some recommendations to get started.

1. Don't limit yourself to one type of technology
When deciding on the right technology for your project, there are several considerations to ensure you move efficiently and effectively. The requirements for each application are unique, and demand careful examination and planning to identify the best 3D-printing process to meet project needs.

For example, functional prototype components that need to resist impact or high temperatures can use FDM^® (Fused Deposition Modeling), the most widely employed 3D-printing technique, for its strong, durable parts from a host of high-performance materials (more on materials below).

If a part's design calls for a complicated undercut for airflow or a durable living hinge, however, laser sintering may be the ideal process. These considerations can be complicated, but careful deliberation of the full spectrum of part performance requirements is needed before beginning the printing process.

2. Don't limit yourself to one type of material
3D-printing materials that are available today are substantial for creating prototypes and production parts in hundreds of plastic and metal materials. Here are just a few that you should consider, which cover an array of applications.

• Photopolymer: Photopolymer materials in 3D printing begin as liquid resins that are cured and hardened with ultraviolet (UV) energy to result in plastic prototypes and parts. Photocurable materials can range in colors, opacities, and rigidities.


This anatomical model was 3D printed in multiple photopolymer materials. The opaque organs and transparent body were built simultaneously, creating a unique effect.

 

 

 

 

• Powdered Plastics: Plastic nylons used in 3D printing begin as powdered composites. These powdered nylons are then "sintered," or heated and fused, layer by layer via a carbon-dioxide laser to form dense plastic designs. Nylon materials in 3D printing are relied upon for their heat deflection, high strength, and excellent elongation properties.
• Metals: 3D-printed metal begins with metals in a powder state. The powdered metals are heated and fused by a fiber laser that essentially welds designs layer by layer into the powder. While 3D printing with metal is an involved process requiring highly trained build engineers and post-processing team, it can achieve complex, dense parts that consolidate old designs into one fluid build.
• Thermoplastics: Thermoplastics used in 3D printing are high-performance, engineering-grade materials that exhibit many of the same properties of injection-molded plastics. 3D-printing thermoplastics include polycarbonate (PC), acrylonitrile butadiene styrene (ABS), acrylonitrile styrene acrylate (ASA), and even ULTEM™ resins. These materials are typically manufactured using FDM 3D-printing technologies.

3. Don't use 3D printing for just rapid prototyping
Rapid prototyping with 3D printing is one of the easiest, most cost-effective ways to turn a great idea into reality. But it's not the only area where 3D printing delivers value.

• Additive Manufacturing: Companies can produce amazing, consistent parts with a range of additive manufacturing technologies tailored to their application. Ideal for low-volume, bridge-to-production runs, spare parts 3D printing offers freedom from traditional design constraints.
• Conventional Manufacturing: 3D printing even has a role to play in conventional manufacturing. It can, for example, quickly create master patterns and silicone molds for urethane casting.
• Manufacturing Aids: It's possible (and advantageous) to maintain high-quality production and efficiency with complex and custom manufacturing aids such as jigs, fixtures, templates, and gauges. 3D-printed jigs and fixtures cut costs and lead times and provide shop-floor flexibility.

4. Don't forget post-processing and finishing needs
From sanding and painting to providing inserts or special coatings, post-processing can include many different methods. Consider the aesthetic goals of the prototype. Does the process you've chosen to use provide the tolerance and smoothness you need for your application straight from the machine? Or will you need to include post-processing time and costs into providing the right part?

It's important to remember that not only are some technologies more expensive, but the need for post-processing can also drive costs upward.

5. Do consider outsourcing even if you have in-house equipment
Purchasing and setting up a new manufacturing technology is a significant investment. That's why many additive manufacturing users choose to outsource a variety of production methods and materials through a service provider, instead of depending on in-house equipment.

There's relatively low risk in trying out new options by outsourcing to an additive manufacturing provider, and you may discover that the new technology can integrate into your operations. Outsourcing can also allow you to explore new 3D-printing technologies and materials that your business might be interested in purchasing.

6. Do consider build orientation
With added manufacturing processes, orientation determines several features found in the final product. Certain build orientations are better for curved or square features, while delicate features require special consideration. For example, because of the build process, orientation can determine the cosmetics of the part, what supports may be needed during the build, and often the overall strength of the part.

Orientation should be considered in the early design stages to avoid these common pitfalls.

7. Do prioritize industry requirements and standards
Many 3D-printing materials have been formulated to meet strict industry standards and requirements. For example, FDM material PC-ISO meets certifications for its strength and medical compatibility, and FDM ULTEM 1010 meets food-contact and bio-compatibility application requirements.

These certifications increase the fields in which 3D printing can make an impact. When designing and manufacturing for applications requiring certifications, it is important to ensure your project is handled in an appropriately certified facility.

8. Do hire a team to champion 3D printing at your company
A dedicated champion who believes in the power of 3D printing can take the time to educate an organization on the technology's potential, and identify areas where 3D printing can improve and advance processes within the company.

This person or team will take on the responsibilities of learning the key elements of the technology and its impact, helping define and communicate its financial, business, and engineering value.

Conclusion
In the era of Industry 4.0, manufacturing with additive can help you reimagine ways to bring your designs to life more easily, efficiently, and cost effectively. While adapting a new technology into your process may be challenging, the benefits abound. 3D printing can open a world of new possibilities for manufacturing productivity in your company.

For more information on Stratasys Direct Manufacturing or to get in touch with one of our customer service experts, visit stratasysdirect.com.

Learn more from Stratasys Direct Manufacturing:

• How To Prepare STL Files
• Developing Flight-Ready Parts: Bell Helicopter Case Study
• Quality Assurance in Additive Manufacturing

About the author
Jesse Marin is the Design Services manager at Stratasys Direct Manufacturing. He lends key consulting and hands-on 3D design expertise on custom additive manufacturing optimization projects across various industries including the automotive, aerospace, and consumer product sectors.

Published December 2019

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