The process of creating a physical object from a three-dimensional model via thin layers of filament, typically made of plastic, is known as 3D printing. A digital file creates the model which eventually transfers to the printer.
The 3D printer creates thin layers, one on top of another, until a 3D printed object is formed. 3D printing also allows the production of models of more complex shapes with less material than traditional manufacturing techniques. According to research, the history of 3D printing dates back to the 1970s. It was not until 1980 that early additive manufacturing equipment and materials were developed. Despite initiating a patent for this technology, Hideo Kodama never brought it to market.
In the ’90s 3D printing began to attract attention from technologies around the world. These years also saw the invention of fully functional human organs for transplants in young patients using 3D printed methods covered with particles and cells from their very own body. It was a significant achievement for the medical industry. Until the 2000s, when additive manufacturing gained popularity, 3D printing had limited functional productions despite these advancements.
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Additive Manufacturing is the process of adding materials together to produce an item. Contrast the idea of subtractive manufacturing with the process of additive manufacturing. The process of cutting a surface to remove material and create an object is known as subtractive manufacturing.
Additionally, this procedure generates a lot of waste materials. In this regard, the technologies that make use of polymer materials are still referred to as “3D printing,” while “additive manufacturing” is used more to describe the manufacturing of metal products. But by the early 2010s, the terms of these two processes were used in popular language across the market, media, companies, and manufacturers. Around 2008 the first self-replicating 3d printer model was created.
That means a 3D printer was able to recreate itself by printing its parts and components. This enabled users to produce more printers for others. Studies show that later the same year, a person successfully walked with a 3D printed prosthetic leg fully printed in one piece. Then in the 2010’s the additive processes matured, and 3D printing work began to create objects layer by layer.
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In 2012, with the addition of plastic and other various materials for 3D printing, several authors began to think that 3D printing could be important for a developing world. During the following years, more applications for 3D printing have emerged, including the world’s first aircraft. Makers using 3D printers agree that this method is faster and cheaper compared to traditional methods and are ideal for those who need rapid prototyping (RP). Terms such as desktop manufacturing, rapid manufacturing, and rapid prototyping have since become synonymous with 3D printing.
There are many different kinds of 3D printers on the market. Sophisticated machines are expensive, but there are also more affordable models available with high-quality printing and features. Desktop printers made possible by 3D printing are also becoming increasingly popular with engineers and schools. How Does 3D Printing Work? In a nutshell, 3D printing constructs an object by combining material layers. The computer’s 3D modeling software directs the operation of the 3D printer machine during this procedure, which is controlled with extreme precision.
There are a variety of manufacturing technologies used in 3D printing, but they all function in the same way, layer by layer, to create models. Each one of these types of 3D printing manufacturing processes may utilize a different type of material, finish, and cost. Some of the most common and utilized types of technologies are FDM, SLS, SLM, SLA, and DLP. Below read on a summary of each one of these technologies. Let us begin with the most widely used of these, the FDM—also known as Fused Deposition Modelling—which is marketed under the name Stratasys.
Even though this concept has been around since the ’90s, a lot of 3D printers since 2009 starting to utilize this process. This technology is also known as FFF (Fuse Filament Fabrication). By melting plastic that is deposited through a heated extruder, this kind of process involves aligning several layers until a shape is formed. ABS and PLA are the most frequently utilized materials or filaments in this kind of process. Another SLS or Selective Laser Sintering uses a laser to sinter powdered plastic material and turn this into a solid model. Normally, this type of technology is a popular choice due to the rapid ability to create prototypes and small-batch manufacturing.
SLM or Selective Laser Melting uses a high-power density laser to melt and fuse metallic types of powder. With his type of technology, the metal material can be fully melted into a solid 3D model. This process also allows for the shape to be created layer by layer and create parts that cannot be easily cast with other conventional methods. Typically and, the file is divided into layers using CAD software. STL file, and then it is loaded onto a file preparation software, then the material is melted using a high- power laser beam until a part is complete. Continuing SLA or Stereolithography creates parts with high levels of detail, smooth surfaces, flawless finishes, and quality.
Modeling and the mechanical industry both benefit greatly from the widespread application of this kind of technology. Finally, DLP or Digital Light Processing is a technique similar to SLA that cures the resin materials by using light through a light projector screen. Because of the light usage, an entire layer can be built at once making this process relatively faster but recommendable for low-volume production runs of mostly plastic parts. 1. Produce a file for CAD (computer-aided design).
The first step to creating a 3D printed object is creating a virtual design with computer software or a 3D scanner. On this, the exact dimensions of the object to build are simulated to see how this will look like when finishing the 3D printing. When designing a 3D object utilizing CAD, fewer errors may result while printing, and fortunately, these can be corrected before the process. There is also another way of creating an object manually, like sculpting where a 3D scanner is needed to collect the data, shape, and appearance of the desired object.
2. Convert the CAD file The next step is to convert the file into a format that the 3D printer can read after the design has been created. One of the most common files used is STL (standard tessellation language). Because there are so many surfaces in an STL file, it can sometimes result in a larger file. There is also another option of a file format used named AMF, Additive Manufacturing File format that stores information more conveniently. 3. Change the STL file. Once the STL file is created, and ready to be sent to the 3D printer, the orientation and size for the object to be printed must be set. STL files also allow us to repair any inconsistencies in the original.
4. Prepare the 3D printer To begin the printing process, all materials must also be prepared once the digital file is ready to be printed. Once the STL file is ready, then it must be processed by a slicing software that the thermoplastic material in thin layers, one on top of another onto a print bed, which is where eventually the 3D printed object is formed. While the plastic is being extruded, both the nozzle and the printed bed move. In this process, the slicing software is crucial due to this being the one that separates the design into different layers for 3D printing optimization.
3D printing uses a wide range of different variations of materials such as pastes, raw materials, and thermoplastics or filaments, being these the most used and come in different colors, thickness, and sizes to fit the purpose of the 3D printing model. Filament materials used for extrusion include thermoplastics, ABS, PLA, HIPS, TPU, ASA, PETG, PLA, etc. What can be 3D Printed? 3D printing has revolutionized the way models and prototypes are being created for the industry. The idea of rapid prototyping (RP) allows the creation of products usually within hours of days rather than weeks when traditional methods are used. With 3D printing, almost every object you can think of can be printed. According to Statista, the worldwide mark
