What is 3D printing?

3D printing is an additive manufacturing process that can create physical three-dimensional objects based on digital models by continuously laying thin layers of materials. It is widely used in all walks of life such as automobiles, consumer products, construction, medical, etc., because 3D printing can produce parts of different geometries with high precision in a short period of time. With the continuous development of 3D printing technology, the global 3D printing market is expected to reach $4.1 billion in 2026 as Acumen Research and Consulting claims.

Therefore, we can conclude that this technology will become mainstream in the near future and change our way of life and work.

How does it work?

First, we need to use computer-aided design to design a virtual 3D model (computer-aided design) software that can clearly present drawings and technical illustrations. Then, we need to cut the virtual model into hundreds or even thousands of thin layers by applying another software. We call this process “slicing”.

Second, we need to convert the CAD file into an STL file so that we can successfully recognize it when we upload the file to the 3D printer.

Finally, we will enter the printing process. The nozzle of the 3D printer will spray molten materials such as metal and plastic. It moves horizontally and vertically according to the instructions in the STL file to ensure that the materials can be placed accurately. This process will be repeated to form each layer and eventually form the entire 3D product.

3D printing is widely used in all walks of life

automobile vehicles

3D printing has a long history of application in the automotive industry. It can be used to print tools, fixtures and fixtures, and test the form and suitability to ensure that all auto parts can operate as expected. In addition, many automakers use this technology to repair old cars with parts that have been discontinued.

aviation field

3D printed parts have the characteristics of lightweight and high precision, and more importantly, they can be made into complex shapes, so 3D printing is widely used in the aviation industry. Manufacturing complex parts using traditional manufacturing methods requires welding different individual components together, while 3D printing can create a project as a complete component, which will reduce material waste and shorten production time.

Construction industry

3D printing has a wide range of applications in the construction industry, including the private, commercial, and public sectors. 3D printing can present the works of architectural designers in the shortest possible time, and it is also convenient for them to make some modifications and adjustments. In addition, many real estate developers will also use this technology to display buildings so that customers can observe them more clearly.

Consumer products

3D printing technology has a large market in the field of consumer goods, from things we use in our daily lives, such as glasses and shoes, to luxury like jewelry. Taking glasses as an example, not only the frame can be printed, but the lens can also be printed. Traditionally, we make lenses by removing excess materials, but 3D printing can reduce material waste when making lenses.

Health care

3D printing technology can be used to create models for different medical purposes, such as dentistry, printing crowns and braces. Implants such as hip and knee joints, as well as hearing aids, prostheses, and more, can also be made, which will help the surgeon's work and the patient's rehabilitation. The application of 3D technology in this industry will promote medical progress and improve people's health.

Types of 3D printing processes

Adhesive spray

Adhesive spraying is a 3D printing process that requires two materials in the manufacturing process: substrate powder and adhesive. We use adhesives to selectively bond the powder, and the powder particles will bond layer by layer to form the final part. The raw materials used for adhesive spraying can be metal, sand, and ceramics.

The process has the characteristics of high efficiency. We can increase the number of print head holes to speed up production. In addition, it can print various parts by changing the nature of the material and the ratio of the two materials, which is really versatile.

Fused deposition modeling

Fused deposition modeling, also known as FDM, creates 3D parts by selectively depositing molten materials based on previously designed virtual 3D models. Generally, thermoplastic polymers are used as raw materials, including ABS, PC, PP, thermoplastic polyurethane, etc. These materials are presented in the form of filaments and can be combined layer by layer to form the shape of 3D parts. It is the most widely used 3D printing process. We can find this process in different industries and applications, such as consumer goods, the automotive industry, and medical care.

Selective laser sintering

Selective laser sintering is a 3D printing process widely used to print medical device components, electronic products, and automobiles. It selectively applies a laser beam to sinter the powder based on CAD data, and then binds the sintered powder layer by layer to make three-dimensional parts. A variety of materials can be used for selective laser sintering, such as nylon, elastic thermoplastics, and polystyrene.

Stereo lithography

Stereo lithography is a 3D printing process with high resolution and accuracy. The tolerance of stereo lithography parts is about 0.05 mm. In addition, it has a smooth surface finish and the versatility of the material. The working principle of stereo lithography is to use laser light and photopolymerization to harden the liquid resin to form the final solid 3D part. This 3D printing process is very suitable for manufacturing high-precision parts, such as certain functional parts and demonstration models.

How to choose the right 3D printing process?

Choosing the right printing process to create parts is a bit difficult for us, because there are a variety of 3D printing processes to choose from, sometimes more than one process is suitable, maybe two or three processes are feasible. But here are some factors that should be considered before making a decision:

First, the material properties required for the parts, including strength, hardness, etc. As we all know, the raw materials of various processes are different, so the characteristics of the materials need to be considered when choosing the process.

Second, the requirements for function and aesthetics. For example, do you have requirements for the heat resistance and strength of parts, or do you need a very smooth surface?

Finally, the ability of the 3D printing process, which may include high precision, build size, etc.

What benefits can 3D printing bring us?

Reduce costs

3D printing can significantly reduce manufacturing costs for the following reasons:

First of all, 3D printing is all done by the machine. Unlike traditional production processes, a large number of employees are required to operate different machines and equipment, so a large part of labor costs can be saved. In addition, although the cost of pre-purchasing equipment is relatively expensive, the high production capacity of 3D printing is enough to offset the cost of equipment. Finally, 3D printing is an additive manufacturing process, which means that there is no material waste in the manufacturing process and the cost of raw materials can be reduced.

Short turnaround time

Another benefit that 3D printing can bring us is that it allows us to manufacture 3D parts and products in a very short turnaround time. Using CAD software, even for some complex designs, we can complete the design quickly, and the virtual 3D model can be converted into a physical 3D model within a few hours. The traditional method may take weeks or even months to complete the entire process from design, rapid prototyping to final product manufacturing.

Tool-free

Used in industrial manufacturing, the production of tools requires a lot of development costs, time, and labor. The use of 3D printing can solve this problem well, which can eliminate the need for tool production. During the design phase, engineers can design products and components in a specific way to avoid assembly requirements. Tool-free is a highlight of 3D printing, which can further reduce the cost of the assembly process.

Sustainability

3D printing is environmentally friendly because of its high material utilization rate in the production process, which can reach 90% for standard materials. Moreover, the 3D printed parts are lightweight and durable, and can be used for a long time, which can significantly improve sustainability. In addition, 3D printing can solve the problem of inventory backlog, because the production time is fast, suppliers do not need to manufacture parts long in advance and store them in the warehouse.

Design flexibility

3D printing supports the use of multiple materials, which helps to break down material limitations and provide engineers with more options to design more creative products. On the other hand, this technology can be used to manufacture parts of different geometries from simple to complex.