Tag: 3D Printing

  • Plastic Material: Polyetherketoneketone – PEKK

    Plastic Material: Polyetherketoneketone – PEKK

    Polyetherketoneketone (PEKK) is an exceptional semi-crystalline high-performance thermoplastic. Coming from the polyaryletherketone (PAEK) family of polymers, it is recognised for its high-temperature stability and outstanding mechanical strength. Various industries widely regard PEKK as a top-performing material.

    Some manufacturers have incorporated carbon fibers into PEKK to further enhance the rigidity and mechanical properties of the material, resulting in a highly robust composite

    3DXTech PEKK-A Filament
    3DXTech PEKK-A Filament

    Key Features

    • High thermal resistance
    • High Mechanical strength
    • High Chemical Resistance
    • Flame Retardant
    • Great Printability
    • Strong Abrasion Resistance

    Properties

    • Density: 1.28g/cm3
    • Maximum Service Temperature: 150°C
    • Tensile Strength: 87MPa
    • *Please note that these properties serve as general guidelines and may vary based on the specific formulation of the filament. For detailed technical data, kindly contact us to obtain our comprehensive Technical Data Sheet (TDS).

    Applications

    • Aerospace Industry: PEKK’s high-temperature resistance and mechanical strength make it suitable for aerospace components, such as aircraft interiors, engine parts, and structural elements.
    • Transport Industry: PEKK is utilised in the transport sector for manufacturing lightweight but robust components in automobiles, trains, and ships.
    • Energy, Oil, and Gas: The material’s chemical resistance and high-performance characteristics make it valuable for applications in the energy sector. This includes oil and gas exploration, power generation, and renewable energy systems.

    Get your PEKK material or parts that are 3D Printed today! Need help? Contact us and we will get back to you.

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  • Plastic Material: ABS vs ASA – What’s the difference?

    Plastic Material: ABS vs ASA – What’s the difference?

    A frequently asked question in the 3D printing industry is: what is the difference between ABS and ASA? Today, we are going to break down the differences and clear up the air between these two materials.

    Filament PM ABS White
    Filament PM ABS

    Let’s start with the technical data.

    MaterialFilament PM ABS3DXTech ASA
    Density (g/cm3)1.041.07
    Tensile Strength (MPa)4245
    Flexural Modulus (MPA)18002000
    Glass Transition Temperature (Tg)94C105C
    *Contact us for full technical data sheets

    Based on the technical data, the properties between ABS and ASA are mostly similar, with ASA inching out slightly. It has better tensile strength, flexural modulus, and glass transition temperature, but, it comes in at a higher density. In terms of mechanical properties, they are similar. So, what is the catch?

    3DXTech ASA
    3DXTech ASA

    Not on the datasheets.

    One significant advantage that ASA has over ABS is that it has UV resistance and is weather resistant, which makes it great for outdoor use! As you probably already know, ABS is notorious for warping during the printing process, ASA on the other hand is much less prone to warping.

    Cost Effective?

    In the past, ABS was more commonly used, making it cheaper to produce, resulting in a much lower price tag. However, ASA’s popularity has risen over the years, bringing down the production cost, and making it very similar to ABS.

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  • Plastic Material: Polyether Ether Ketone – PEEK

    Plastic Material: Polyether Ether Ketone – PEEK

    Part of the polyaryletherketone (PAEK) family of polymers, Polyether Ether Ketone, PEEK for short, is a semi-crystalline high-performance thermoplastic. Developed in 1978, PEEK is used in engineering applications due to its outstanding resistance to harsh chemicals, excellent mechanical strength, and dimensional stability.

    Depending on the formulation of the Polyether Ether Ketone material by the manufacturer, the properties can be slightly different from one manufacturer’s PEEK filament to another. Some have added carbon fiber to further increase the rigidity of the material.

    3DXTech PEEK Filament

    Key Features

    • High Chemical Resistance
    • Incredible Mechanical Strength
    • Abrasion Resistance
    • High Thermal Resistance

    Properties

    • Density: 1.3g/cm3
    • Maximum Service Temperature: 200°C
    • Tensile Strength: 100MPa
    • *These are general properties and are not indicative of our filament properties. Contact Us for our TDS.
    Craniofacial Implant

    Applications

    • Aerospace Industry
    • Energy, Oil & Gas
    • Food and Beverage Processing
    • Semiconductor Industry
    • Medical

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  • 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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