3D Printing
Print it, don’t Prime it
What is 3D printing, aka “additive manufacturing”
When you make 3D objects from a digital file via computer-aided design (CAD) software. The object is built through an “additive process” where successive layers of material are laid down until the product is fully formed.
How does it work
- Select or create a 3D model, this is your virtual design that serves as a blueprint for your printer
a. Download one from a 3D library, like Sketchfab
b. Create one using 3D CAD software like Tinkercad
- Free
- Available via web browser, so no need to download software
- Offers beginner lessons and ability to export your model as a printable file (.STL or .OBJ); a common file format is G-code which contains “coordinates” to guide the printer along the X, Y, and Z axes
2. Slice the model using special software to digitally cut your model into hundreds or thousands of thin, horizontal layers to prepare it for printing
3. Upload the sliced file from your PC to your 3D printer via USB or wifi
4. Print — the printer reads every slice and prints layer by layer via a process called “material extrusion”
What is material extrusion
The printer has a nozzle that extrudes a liquified material (plastic, metal, cement) while moving up and down and layer by layer to precisely place the material according to the model blueprint,. As each layer solidifies, the next is printed on top until the object is complete. Similar to pixels on a screen, the more layers, the higher the “resolution” or quality. It looks better, but takes longer to print.
What are the pros of 3D printing
- 5x cheaper than traditional manufacturing costs; cost is directly related to the quality, type, and amount of the material used
- 10x faster than traditional prototyping processes; designs are easy to create, customize and alter to address flaws
- Positive environmental impact — aerospace and auto industries can create lightweight substitute parts with special materials, the lighter the vehicle, the less fuel consumed and the better off the environment
What are the cons of 3D printing
- 10–50% weaker/more brittle than objects created via traditional manufacturing as the layer by layer construction reduces strength and durability (metals and concrete are your strongest available materials)
- More expensive at high volumes/less cost effective when producing 100+ units
- Accuracy imitations — accuracy depends on the type of printer and process used; for example, printers with lower tolerances yield products that stray slightly from the design and small desktop models depreciate quickly resulting in products that stray slightly from one batch to the next
- Post-processing requirements — most 3D printed products require post-processing, like sanding to create a polished finish, or heat treatment to remove support struts which help the products to be built
- Harmful to health — toxic fumes are emitted as the plastic melts to create the layers; however, sufficient ventilation can resolve this issue
What products can you print
- Consumer — eyeglasses (frames and lenses), shoes (Adidas 4DFWD have a 3D printed midsole), furniture, jewelry, toys, tools, clothes, ceramics
- Medical — dentures, prosthetics, hip replacements (GE Additive produced 10k+ from 2007–2018), hearing aids
- Auto — spare parts, speciality parts no longer in production to restore old cars
- Aerospace — fuel nozzles, engines, rockets
- Construction — homes; New Story Charity used a 33-foot long printer to build the first 3D-printed neighborhoods in Mexico, Haiti, and El Salvador. Each community consists of 2k+ homes, and each 500 square-feet with walls, windows and two bedrooms, the intent is to resolve homelessness
- Food — pureed or melted ingredients like meat, vegetables or chocolate
- Education — robotics, fossils
- Human organs — hearts, kidneys or livers can be created using a combo of living cells and polymer gel (bioink) to reduce the number of patients on the organ donation waitlist
What materials (filaments) can you use to 3D print
- Metals — gold, steel, brass, bronze or copper can be finely ground and mixed with polymer glue and fed to the printer
- Wood — finely ground into powder and mixed with polymer glue
- Plastic — e.g. Lego material
- Edibles — e.g. chocolate
- Ceramics
- Glass
- Rubber — used to create bendable, yet durable products
- Carbon fiber — used to create strong, yet lightweight objects
What is the history of 3D printing
The first 3D printer was invented by researcher Hideo Kodama of the Nagoya Municipal Industrial Research Institute in Japan, 1981 for companies to quickly develop prototypes.
How long does it take to 3D print something
Anywhere from a few minutes to several hours or days, depending on the size and desired quality/resolution of the object. For example, a toy can take a couple of hours, but a house can take days.
What are some types of printers
- Fused Deposition Modeling (FDM) — a hot nozzle melts filaments and the object is built via layering as the material hardens; most common
- Stereolithographic (SLA) — a laser hardens the liquid into a solid
- Selective Laser Sintering (SLS) — a laser fuses powder into a firm entity
- Digital Light Processing (DLP) — lamps dry layers in seconds; one of the oldest methods
- Material Jetting — UV light hardens droplets of material emitted via a nozzle
How much do printers cost
It varies based on the size and use case:
- Cheap models for entry-level hobbyists: $100-$500
- Advanced models for professionals: $300-$5,000
- Industrial models for manufacturers: $100,000+
What is the future of 3D printing
By 2029, the industry is estimated to reach a value of $84b.
Now what
3D printing can disrupt the way consumers procure products thanks to sophisticated software that enables precise personalization and speed of delivery that parallels the amount of time it takes to order something online. 3D printing is already disrupting industries across the board, and the technology only continues to innovate as new use cases are introduced.
