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How do you choose the best 3D printing method for your mechanical design?

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3D printing, or additive manufacturing, is a powerful tool for mechanical engineers who want to create prototypes, test parts, or produce custom components. But with so many different 3D printing methods available, how do you choose the best one for your mechanical design? In this article, we will explore some of the factors that influence your decision, such as material, accuracy, speed, cost, and complexity.

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Gustavo Hernandez

Sr. Principal Mechanical Engineer
Leonard Kigen

Graduate Mechanical Engineer|? | Freelance Mechanical Engineer|?|

1 Material properties

One of the first things to consider when choosing a 3D printing method is the material you want to use. Different materials have different properties, such as strength, stiffness, flexibility, durability, and resistance to heat, moisture, or chemicals. Some 3D printing methods can only use certain types of materials, such as plastics, metals, ceramics, or composites. For example, fused deposition modeling (FDM) is a common method that uses thermoplastics, while selective laser sintering (SLS) can use metals or polymers. You should choose a 3D printing method that can handle the material you need for your design.

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Leonard Kigen

Graduate Mechanical Engineer|? | Freelance Mechanical Engineer|?|
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Material properties are crucial in 3D printing because they determine the physical characteristics of the printed object, including strength, flexibility, and durability. The choice of material and its specific properties directly impact the functionality and performance of the final product, making it essential to select the right material for a particular application in additive manufacturing.

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2 Accuracy and resolution

Another factor to consider is the accuracy and resolution of the 3D printing method. Accuracy refers to how closely the printed part matches the digital model, while resolution refers to the level of detail and smoothness of the surface. Different 3D printing methods have different levels of accuracy and resolution, depending on the size and shape of the nozzle, the layer thickness, and the precision of the movement. For example, stereolithography (SLA) is a method that uses a laser to cure liquid resin, and it can achieve high accuracy and resolution. However, it may also require more post-processing, such as washing and curing, to remove excess resin and improve the mechanical properties.

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Leonard Kigen

Graduate Mechanical Engineer|? | Freelance Mechanical Engineer|?|
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Accuracy refers to how closely the printed object matches the intended design, with higher accuracy resulting in a closer match. Resolution, on the other hand, relates to the level of detail and surface finish achievable in the printed object, with higher resolution leading to finer details and smoother surfaces. Both accuracy and resolution play a significant role in determining the overall performance and functionality of 3D-printed parts, making them essential considerations for various applications, from prototyping to manufacturing end-use products.

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3 Speed and efficiency

A third factor to consider is the speed and efficiency of the 3D printing method. Speed refers to how fast the 3D printer can create a part, while efficiency refers to how much material and energy it consumes. Different 3D printing methods have different speeds and efficiencies, depending on the complexity of the design, the size of the part, and the number of parts to be printed. For example, direct metal laser sintering (DMLS) is a method that uses a laser to fuse metal powder, and it can create complex and dense parts. However, it may also require more time, material, and energy than other methods.

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Leonard Kigen

Graduate Mechanical Engineer|? | Freelance Mechanical Engineer|?|
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Faster 3D printing speeds can reduce the time required to produce objects, improving overall efficiency in manufacturing. However, increased speed may sometimes sacrifice print quality or accuracy. Striking the right balance between speed and efficiency is essential to optimize production while maintaining the desired level of quality in 3D printing processes.

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4 Cost and availability

A fourth factor to consider is the cost and availability of the 3D printing method. Cost refers to the initial investment and the ongoing expenses of the 3D printer, the material, the maintenance, and the post-processing. Availability refers to how easy it is to access and use the 3D printer, either in-house or through a service provider. Different 3D printing methods have different costs and availabilities, depending on the popularity, demand, and supply of the technology and the material. For example, binder jetting is a method that uses a binder to glue powder particles together, and it can be cheaper and more widely available than other methods. However, it may also produce weaker and more porous parts than other methods.

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Leonard Kigen

Graduate Mechanical Engineer|? | Freelance Mechanical Engineer|?|
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The cost of 3D printing includes expenses related to materials, equipment, maintenance, and energy consumption. Availability pertains to the accessibility of 3D printers, materials, and skilled operators. Balancing cost-effectiveness and the availability of resources is crucial to make 3D printing an economically viable option for various applications, whether in prototyping, small-scale production, or personalized manufacturing.

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5 Complexity and functionality

A fifth factor to consider is the complexity and functionality of the 3D printing method. Complexity refers to how well the 3D printer can handle intricate shapes, overhangs, supports, and internal features. Functionality refers to how well the printed part can perform its intended function, such as mechanical, electrical, or thermal. Different 3D printing methods have different capabilities and limitations in terms of complexity and functionality. For example, multi-material jetting is a method that can print multiple materials with different properties in a single part, and it can create functional parts with embedded sensors, circuits, or actuators. However, it may also require more calibration, alignment, and integration than other methods.

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Gustavo Hernandez

Sr. Principal Mechanical Engineer
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Functionality should be your number one consideration. Going though a rapid prototyping design cycle will narrow down your 3D printing process. Typically for non functioning parts FDM with PLA should be strongly considers. This option is quick and easy to produce, allows you to iterate at low cost, the drawback is that the parts are only to be used for fit checks and prototyping. Once the models are verified, the user can move to a high fidelity process. SLA or SLS can produce deliverables.

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Leonard Kigen

Graduate Mechanical Engineer|? | Freelance Mechanical Engineer|?|
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Complexity and functionality are closely tied in 3D printing. The technology allows for the creation of highly complex and intricate geometric designs that are often unattainable through traditional manufacturing methods. This complexity enables the production of objects with advanced and unique functionalities, making 3D printing a versatile tool for various industries, including aerospace, healthcare, and automotive. The inherent design freedom in 3D printing allows engineers and designers to optimize structures and components for specific purposes, enhancing overall product performance and functionality.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How do you choose the best 3D printing method for your mechanical design?

1

2

3

4

5

6

1 Material properties

2 Accuracy and resolution

3 Speed and efficiency

4 Cost and availability

5 Complexity and functionality

6 Here’s what else to consider

Mechanical Engineering

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How do you choose the best 3D printing method for your mechanical design?

1

2

3

4

5

6

1 Material properties

2 Accuracy and resolution

3 Speed and efficiency

4 Cost and availability

5 Complexity and functionality

6 Here’s what else to consider

Mechanical Engineering

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