Category: 3D Printing Technology

  • 3D-Printing Technology: Fused Deposition Modelling – FDM

    3D-Printing Technology: Fused Deposition Modelling – FDM

    Fused Deposition Modelling (FDM) is the most common 3D-printing technology and is what we commonly associate 3D printing with. This technology is also known as Fused Filament Fabrication (FFF). Some have categorised this as two different technologies, but they are the same. The different names are due to trademarks that Stratasys filed back in 1991.

    How Does FDM Work?

    FDM works by extruding plastic filament through a heated extruder, layer by layer. As there are many iterations and designs of FDM 3D printers, some of the functionalities may differ slightly from the general idea. For most industrial printers, the X-axis and Y-axis controls the print head while the Z-axis controls the build plate. The printer head will follow the path determined by the cross-section of the part. The build plate will move down by the programmed amount after each layer is completed, continuing the cycle to fuse the layers together till the part is complete.

    What Materials Does FDM Use?

    As FDM attracts hobbyists, enthusiasts, as well as industrial users, many companies have developed different types of materials and specialised materials:

    • Thermoplastics Filaments
    • Exotic Filaments
    • Metal Filaments

    For a more in-depth look at the different types of filament materials, click here.

    Beyond Bynd, 3D Printing Service Singapore, Printer, Additive Manufacturing

    Advantages

    Low Cost

    Compared to the rest of the 3D-printing technologies, the price for a mid-range printer is considerably low. This makes it very affordable for businesses, hobbyists, and enthusiasts to get one. The price of the filament material is also relatively cheap.

    User Friendly

    FDM 3D printers are home-safe as it does not use a powder or a liquid. The part is usable once the print is completed and the supports have been removed.

    Large Support Of Materials

    There are many different types of thermoplastics and specialised materials, which provides you with a wide range of different mechanical properties and aesthetics to choose from. A strong 3rd-party market also gives you increased access to more materials.

    Large Amount Of Users

    As FDM is popular for 3D-printing hobbyists, a large community would be able to assist you in any of your problems besides the manufacturer’s customer support.

    Disadvantages

    Mechanical Weak Points

    Due to the way the 3D-printing works, it is mechanically stronger on the axis perpendicular to the build plate compared to the axis parallel to the build plate.

    Part Quality

    As FDM 3D-printing prints in layers, ‘stepping’ lines will appear and will require post-processing to appear smooth. Or it would require tweaking of the settings in order to reduce the visual impact of the lines.

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  • 3D Printing Technology: Multi Jet Fusion – MJF

    3D Printing Technology: Multi Jet Fusion – MJF

    Invented by HP, Multi Jet Fusion (MJF) is a relatively new technology in the additive manufacturing scene. Taking full advantage of HP’s decades of experience and investment in Ink Jetting technology. MJF is taking leaps and bounds and gaining industrial-scale maturity.

    Credits to HP

    How does Multi Jet Fusion work?

    Similar to processes like Selective Laser Sintering (SLS), the build starts off with the printer dispensing a layer of powder across the build platform. After, the Inkjet Head moves across the build platform first depositing a fusing agent at the desired areas and then a detailing agent. After which a heating unit will move across the print area, melting the areas that have the fusing agent applied to it. The areas that were deposited with the detailing agent will continue to remain as a powder. Where it differs compared to the other Powder Bed Fusion Processes is that the new material and deposited agents are added while the previous layer is still in a molten state. This allows for both layers to fuse completely with better part durability and finer detail. Just like SLS, during this process, it does not require any supports as the unfused powder will act as the support.

    What Materials does Multi Jet Fusion use?

    Multi Jet Fusion technology focuses only on polymers or plastics like:

    • Nylon
    • TPU

    For a more in-depth look at the materials, click here.

    Credit to 3D Sourced

    Advantages

    Good Print Quality and Mechanical Properties

    Multi Jet Fusion technology is able to produce parts with a good surface finishing. This is desirable for end-use prototypes and products. It is also able to accurately print fine details and features of 0.5mm in size. Besides that, it also has similar mechanical properties across the part.

    Reduced Cost Per Part

    As MJF technology was designed with production in mind, its quick printing speed and production cycles results in a swift turnaround time and reduces the cost per part. Additionally, the unfused powder can be reused which results in less waste and cost reduction.

    Coloured Parts

    While not all of HP’s machines have full-colour support, their high-end machines are able to support full-colour printing by depositing dying agents during the process. This is a huge plus for end-use prototypes or even products.

    No Supports Needed

    As the unfused powder acts as supports no additional material is needed to be used to create structural support, allowing the designers more freedom to create more complex structures.

    Credits to Stratasys Direct

    Disadvantages

    Expensive Printer Cost

    Although the cost per part may be significantly reduced, the printer itself is very expensive, starting at S$150,000.

    Raised Features May Be Lost During Post-processing

    As the post-processing requires the powder to be removed to retrieve the part, some small, raised features may break off or be damaged during the process.

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  • 3D Printing Technology: Binder Jetting – BJ

    3D Printing Technology: Binder Jetting – BJ

    Binder Jetting 3D printing technology essentially combines the techniques of Selective Laser Sintering (SLS) and Material Jetting (MJ). It uses a binder to bind the material together and can be used in many applications. It is also able to create full-colour prototypes.

    Credits to Desktop Metal

    How Does Binder Jetting work?

    The printing begins when the first layer of powder is deposited onto the build platform. A print head will then sweep through the build platform area selectively depositing the binder. After which the build platform would move down and the cycle repeats.

    The binder acts as a sort of glue. When the binder comes into contact with the powder it fuses them together and creates a solid.

    What Material Does Binder Jetting Use?

    The 2 main materials that Binder Jetting 3D printers use are:

    • Metal
    • Sand

    For a more in-depth look at the type of materials, click here.

    Credits to Desktop Metal

    Advantages

    A Cool Process

    Most 3D Printing Technologies uses some form of heat in the process, which ultimately leads to geometrical distortions such as warping. However, Binder Jetting has a cool process that completely avoids this problem.

    Large Build Volume & Complex Shaped Parts With Full-Colour

    Binder Jetting 3D Printers have a relatively large build area which allows for large parts to be made while allowing for complex geometries as the powder itself acts as a support material that can be removed during post-processing. For sand-like materials, full-colour models can be created.

    Generally Inexpensive

    The powder is generally cheaper as compared to other powdered materials, not to mention that the unfused powder is 100% recyclable which reduces waste which in turn, reduces cost.

    Credits to Desktop Metal

    Disadvantages

    Poor Mechanical Properties

    The biggest disadvantage is that the mechanical properties of the parts created are weak due to the high porosity. This means that the parts printed are only to be used as a visual prototype. If functionality is required, other post-processing methods must be introduced in order to improve its mechanical properties.

    Rough Details

    As the parts are highly brittle, certain details are not easily printed and may be damaged during the post-processing stage.

    Limited Material Selection

    Compared to other 3D Printing Technologies, Binder Jetting’s material is limited to mainly sand and metal.

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  • 3D Printing Technology: Material Jetting – MJ

    3D Printing Technology: Material Jetting – MJ

    Material Jetting (MJ) is a relatively new additive manufacturing technique and is one of the most similar to 2D printing. This process allows for several materials and colours to be combined. It is also sometimes known as Drop On Demand (DOD).

    Credits to Stratasys

    How Does Material Jetting Work?

    It uses an Inkjet print head, that moves on the X and Y-axis. The inkjet will jet/deposit hundreds of tiny droplets of photopolymer at the desired locations. After which a UV light source that is attached to the printhead cures the polymer simultaneously. This solidifies it and creates the first layer. After the layer is completed, the build plate moves down and the process is repeated until the part is completed.

    Multiple inkjet print heads that can be used, which can deposit different materials and colours on the whole print surface. This allows for areas for dissolvable support structures to be used as well.

    What Material Does Material Jetting Use?

    The material used has to be a photopolymer, also known as resins. However, there are many different types, with more being developed.

    • Standard
    • Flexible
    • Castable
    • Simulated plastics
    • Medical grade

    For a more in-depth look at the different types of resin materials, click here.

    Credits to all3dp.com

    Advantages

    High Dimensional Accuracy

    The inkjet printer head allows for very precise jetting/depositing of material and each layer can be printed to be as thin as 0.013mm. This allows for accurate features to be produced.

    Good Surface Finishing

    With good dimensional accuracy and high precision, this allows for the surface finishing to have a smooth surface finishing.

    Fast Build Speed

    As the inkjet deposits on the whole span of the X-axis. Multiple parts do not affect the build speed.

    Full Colour and Multi Material

    One of the most desirable features of this additive manufacturing technology is its capability to print parts with a much more desirable aesthetic.

    Credit to all3dp.com

    Disadvantages

    High Cost

    One of the largest downsides to this technology is the machine’s high price tag. In addition to the cost of the machine, the material can easily cost from SG$400 – SG$1350 for a kg of material.

    Weaker Mechanical Strength

    Compared to other 3D printing technologies, the material used for Material Jetting is generally weaker. However, new resins are being developed to have improved mechanical properties.

    Degradation Over Time

    As this 3D printing technology uses photosensitive resin, parts that have constant exposure to heat and UV light, such as sunlight, are easily affected.

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  • 3D-Printing Technology: Direct Metal Laser Sintering – DMLS

    3D-Printing Technology: Direct Metal Laser Sintering – DMLS

    Direct Metal Laser Sintering, DMLS for short, is a subset of another 3D-printing technology called Selective Laser Sintering. It only uses metal and has a remarkably similar method to Selective Laser Melting (SLM). However, the difference can only be seen on a molecular level where the metal is only sintered together.

    Credit to EOS

    How Does Direct Metal Laser Sintering Work?

    An inert gas fills the build chamber to remove any oxygen to protect both the powder and the part. The powder and build chamber are also heated to a temperature close to the material’s melting point. It starts with the powder delivery system dispensing a dose of powder and distributing it evenly across the build platform. After which the laser will begin its path, sintering the powder layer by layer. This process repeats until the part has been completely 3D-printed.

    What Materials Does Direct Metal Laser Sintering Work?

    Just as its name states, this 3D-Printing Technology utilises metals. However, there are different types of metals, which also have different composites.

    • Metal Powder
    • Plastic/Metal Powder

    For a more in-depth look at the materials, click here

    Credit to EOS

    Advantages

    Materials

    As DMLS is an upcoming technology, new materials are constantly being developed. Metals have higher strength and mechanical properties than polymers which is desirable for certain use cases and needs.

    Reduced Lead Time

    As metal is quite a desirable material, prototypes 3D-printed using this technology has good mechanical properties and is functional.

    Recyclable Material

    During the DMLS 3D printing process, the powder that are not sintered together are able to be recycled and used in a future build. This reduces the amount of wasted material and allows for the cost of the part to be lower.

    Complex Structures

    DMLS allows for complex internal structures to be created. Unlike subtractive manufacturing methods, this additive manufacturing process can easily manufacture complex geometries.

    Credit to EOS

    Disadvantages

    Expensive

    The cost of a DMLS 3D printer is high. Besides that, post-processing requires additional equipment which brings up the costs.

    Requires Skilled Workers

    The DMLS 3D-Printing process requires skilled and knowledgeable workers to optimise the design for the process and to operate the machine with the correct parameters.

    Porous Parts

    During the 3D printing process, internal holes are created on a microscopic level. This causes the part to have slightly reduced density and affects the material strength. While it can be controlled, it cannot be eliminated, even during post-processing.

    Small Parts

    At present, only small parts can be built as most DMLS 3D printers have relatively small build volumes.

    Credit to EOS

    Messy and Handling

    The material must be carefully managed as it is powder-based. Personal Protective Equipment must be worn when operating the machines and handling the powder.

    Post-processing

    Essential post-processing includes separating the parts from the build plate and support removal. Support removal may be difficult at certain areas because of the design and is time-consuming. Further post-processing must be done if a desired surface finishing is needed.  

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  • 3D Printing Technology: Selective Laser Melting – SLM

    3D Printing Technology: Selective Laser Melting – SLM

    Selective Laser Melting, SLM for short, is a metal additive manufacturing method that is also known as Direct Metal Laser Melting (DMLM). It is commonly used interchangeably with Direct Metal Laser Sintering (DMLS) even though the two technologies differ slightly. You can find out more about DMLS 3D printing technology here.

    Credits to SLM Solutions

    How Does Selective Laser Melting Work?

    SLM starts with the build platform covered by a thin coat of laser powder which is deposited using a powder deposition system. After which, a coater arm sweeps over the build plate to evenly distribute the powder. A laser is then used to melt the powder together to build the part up layer by layer. The concept is similar to welding, however, before the start of the whole process, the build chamber is filled with an inert gas to control the atmosphere inside.

    Credits to All3dp

    What Materials Does Selective Laser Melting Use?

    Metals have to be used for this 3D printing technology. However, a wide variety of metals have been developed such as:

    • Steel powder
    • Copper powder
    • Titanium powder

    For a more in-depth look at the materials, click here.

    Advantages

    Wide Range Of Metals Available

    Since the development of SLM 3D-printing technology, many metal materials have been developed. This provides different mechanical properties for varying use cases and needs.

    Reduced Lead Time

    As metallic parts have much higher mechanical strength, a rapid prototype part can be used as a functional part. This reduces the amount of lead time to manufacture the part as compared to traditional subtractive methods.

    Complex Structures

    SLM allows for complex internal structures to be printed where subtractive methods are unable to reach or too complex to obtain. This allows lattice structures and different optimisation of parts to reduce additional material that are not needed.

    Credit to Hubs

    Recyclable Material

    The powder that has not been melted can be reused which results in lesser powder being wasted. This reduces the cost per part.

    Disadvantages

    Expensive

    The cost of an SLM 3D-Printing Machine is extremely high making it difficult to obtain. Furthermore, if the parts are not optimised, the cost of the part will be high. The removal of the part off the build plate also requires additional equipment. If a desired surface finishing is required, an additional machine is also needed.

    Requires Skilled Workers

    The SLM 3D-Printing Technology requires skilled and knowledgeable workers in order to optimise the design for the process and to operate the machine with the correct parameters.

    Credit to Pick3DPrinter

    Small Parts

    The size of the build plate is currently very limiting which constrains the part size.

    Post Processing

    As previously mentioned, the part must go through a process to be removed from the build plate. Support structures may also be required to be removed which is very time consuming and at certain areas, difficult. Moreover, if a desired surface finishing is required, additional processing must be done to obtain that finishing.

    Messy and Handling

    If the powder is not managed carefully, it could get everywhere and create a mess. Personal protective equipment is also required when handling the materials and operating the machine.

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  • 3D Printing Technology: Digital Light Processing – DLP

    3D Printing Technology: Digital Light Processing – DLP

    Digital Light Processing, DLP in short, is used to fabricate 3D models, parts, and prototypes. It is sometimes confused with Stereolithography (SLA), another 3D printing technology. You can find out more about SLA and compare the differences here.

    Credits to all3dp

    How Does DLP work?

    The build platform is placed in a vat of photopolymer (resin). A DLP 3D-printer will then use a digital projector screen to flash an image of light on the entire layer which cures all points simultaneously. This would be done layer by layer until the part is completed. The light is controlled by a device called a Digital Micromirror Device. Which consists of microscopic-sized mirrors laid out in a matrix which is then controlled by a chip. It rapidly toggles the mirrors which helps to define where the light lands by directing the light appropriately to the build platform. Most DLP 3D-printers also build bottom up.

    Credits to FormLabs

    What Material Does DLP Uses?

    Photopolymers, also commonly know as resins, are used as the initial material is required to be liquid and needs to be sensitive to light. However, the manufacturer of the machine determines the types of resins that are supported by their printers. A general guide of the different types of resins are:

    • Standard Resins
    • Engineering Resins,
    • Dental and Medical Resins
    • Castable Resins.

    For a more in-depth look of the materials, click here.

    Credits to FormLabs

    Advantages

    High Accuracy And Detailing

    The resolution of DLP 3D-printers is determined by the resolution of the projector used. As such, the resolution is usually around 0.04-0.1mm. Although there are factors that will affect how accurate a part is, DLP prints are one of the most accurate compared to the other 3D-printing technologies.

    Speed Of Prints

    Since DLP 3D-printers work cures the whole layer at the same time, the speed of print is generally quite fast. The final speed and detailing of the build is then solely determined by the layer height.

    Credits to FormLabs

    Disadvantages

    High Cost

    Although there are some budget options out there, the general starting cost for the machine alone is quite high as compared to an FDM machine with the same build space.

    But the cost really starts to add up when you factor in the material cost. Resins for the DLP 3D-printers are significantly higher; costing almost SG$200 – SG$250 per litre of resin.

    The post-processing of DLP parts will also require additional equipment. This drives up the initial cost of owning and operating the machine.

    Post-Processing

    After the print is done, 3D-printed DLP parts will have excess liquid resin that has to be removed. Depending on the detailing of the print, small crevices and holes may make the print difficult to clean. Generally, dealing with liquids makes the process messier and more time-consuming. Additional time will also be required to remove supports. Due to the way DLP parts are printed, the surface comes out ‘boxy’. To achieve a better surface finishing and surface roughness, like that of SLA 3D printed part, you will need additional processes to achieve a similar finish.

    Material Has Limited Properties And Colours

    Over the years, different types of resins have been developed for DLP 3D-printed to ensure that it has better mechanical properties in comparison to parts 3D-printed on different technologies. However, at present, the mechanical properties still does not match up to that of other 3D-printed technologies. The resin also comes in limited colours which may be a concern to some people.

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  • 3D Printing Technology: Stereolithography – SLA

    3D Printing Technology: Stereolithography – SLA

    Stereolithography, SLA in short, is an additive manufacturing method to create 3D models, parts, and prototypes. SLA is one of the oldest technologies, and in principle, has a process that is very similar to Digital Light Processing (DLP). To find out more about DLP, you can check out our article on it here.

    Credits to 3DNatives

    How Does SLA Work?

    The build plate is placed in a vat of polymer resin after which a UV light is focused to draw the desired design. When the UV light hits the photosensitive resin, it begins to solidify the resin layer by layer. As most of the SLA printers prints the model upside down, the build plate slowly rises higher and higher until the part has been fully printed.

    If you are wondering how the UV light is controlled, a laser, galvanometers, and a series of mirrors are the parts that are controlling the pathing of the laser.

    The laser’s pathing starts off as a CAD 3D Model. The file is then converted to a STL file format. After which it must be sent to a 3D Slicer Software. This would create a G-code for the movement of the laser which is the native language of the 3D printers.

    Credits to 3DNatives

    What Material Does SLA Use?

    As the material is required to be liquid, thermoset polymer, or other known resins, are used for this process. However, there are many different types of resins:

    • Standard Resins
    • Engineering Resins,
    • Dental and Medeical Resins
    • Castable Resins.

    For a more in-depth look on the different type of resins materials, click here.

    Advantages

    Credits to FormLabs

    High Accuracy and Detailing

    SLA printers have some of the best accuracy in comparison to the rest of the additive manufacturing technologies. This allows for very tight dimensional tolerances, to as little as 0.1mm. This allows for thin walls, sharp corners, and complex geometrical shapes to be created while maintaining a smooth surface finishing for the print.

    Very Matured Technology

    SLA technology has been used in this industry for a very long time. The process has been refined over the years with a very stable process and many different machine suppliers. Giving you the ease of mind that if you ever require assistance, it is not too far away.

    Disadvantages

    Credits to FormLabs

    High Cost

    The initial cost of the SLA machine is high, starting at SG$4500. This is significantly higher as compared to budget FDM machines, where it can cost 10 times less with the same build space.

    Besides that, the cost of the material is high, costing almost SG$200 – SG$250 per litre of resin material.

    The post-processing of SLA parts also requires other equipment which drives up the initial cost of owning the machine.

    Post-Processing

    Unlike FDM machines, 3D printed SLS parts have to first be cleared of the excess liquid resin which depending on the print, may be in small crevices and holes making it difficult to clean. In addition to liquid resin being messier to deal with, the supports also require additional time to be removed.

    Material Has Limited Properties And Colours

    Although there are new types of resins in development to counteract this problem, there is still a long way to go in terms of stronger mechanical properties as compared to the other 3D printed parts using different technologies. There is also a limitation in colours which affects the aesthetics of the piece and may be an important factor to certain people.

    Speed

    SLA is able to 3D print parts with high precision and a good surface finishing at a relatively fast speed. However, they are able to go faster than other 3D printing processes like FDM at the sacrifice of quality.

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