3D Printing: Process, Pros & Cons, and Applications

Welcome to IDEAL's ultimate guide to 3D Printing: Process, Pros & Cons, and Applications!

Our blog is a comprehensive resource for anyone interested in learning more about this versatile and affordable option.

What is 3D Printing?

3D printing, also known as additive manufacturing, is a process of creating three-dimensional objects by adding material layer by layer, based on a digital model. Unlike traditional manufacturing methods, which often involve subtracting material (like cutting or milling), 3D printing builds objects up from scratch, which allows for more complex and customized designs.

How 3D Printing Works?

Create a Digital Model

The process begins with a 3D model, usually created with computer-aided design (CAD) software. Alternatively, a 3D scanner can be used to create a model of an existing object. The model is saved in a format that the 3D printer can understand, typically STL or OBJ files.

Prepare the Printer

The 3D model is then uploaded to the 3D printer's software, which slices it into thin horizontal layers (like a digital blueprint for each layer). The software also sets the printing parameters, such as material type, print speed, temperature, and layer thickness.

Print the Object

The 3D printer starts building the object by laying down material layer by layer. The material is usually thermoplastic, resin, or metal powder, but there are also printers that use concrete, ceramics, or even biological materials! The printer heats or hardens the material as it's deposited, bonding it to the previous layer. The process continues until the object is fully built.

Post-Processing

After printing, the object may need some post-processing steps like removing support structures, sanding, painting, or curing (especially in resin printing).

Types of 3D Printing Technologies At IDEAL 

Fused Deposition Modeling (FDM): One of the most common and accessible types of 3D printing. It uses a spool of filament (usually plastic) that is heated and extruded through a nozzle. Great for rapid prototyping, hobbyists, and simple parts.

Stereolithography (SLA): Uses a laser to cure liquid resin into solid layers. It produces very high-resolution prints and is often used for detailed prototypes, jewelry, dental models, and similar applications.

Selective Laser Sintering (SLS): A laser is used to fuse powder particles (usually plastic, metal, or ceramic). SLS can create more complex shapes and is often used for industrial applications and functional parts.

Direct Metal Laser Sintering (DMLS): A type of 3D printing that fuses metal powder with a laser. It’s used to create metal parts directly, and is common in aerospace, medical devices, and high-performance engineering.

Applications of 3D Printing

3D Printing is a highly versatile manufacturing process with various applications across numerous industries. One of the reasons behind the versatility and widespread usage of this process is the variety of 3D printing technologies available. Each of these technologies has unique capabilities, compatibilities, benefits, and drawbacks, collectively making 3D printing capable of most manufacturing applications.

3D printing can produce countless complex geometries and is compatible with a wide range of materials. The applications of this additive manufacturing process can be categorised into:

Prototyping

Custom one-off productions

Batch Manufacturing

Prototyping 3D printing is a go-to rapid prototyping technique for manufacturers. This process allows engineers to rapidly design and produce multiple prototypes, speeding up product development cycles and facilitating innovation.

Custom One-off Productions Custom builds account for the largest portion of 3D printing applications. One of the biggest driving forces behind 3D printing's invention and widespread use is the ability to create one-off, complex custom parts rapidly. Custom one-off pieces range from highly complex machinery spare parts and medical implants to personalised gift items and toys.

Batch Production Outside of custom applications, manufacturers often use 3D printing to carry out batch productions of standalone parts, components in an assembly, and fully functional assemblies.

Advantages of 3D Printing

Customization: 3D printing allows for highly customized, unique designs that would be hard or expensive to achieve using traditional methods.

Cost-Effective for Prototypes: It’s faster and cheaper for creating prototypes or small runs of parts, compared to traditional manufacturing.

Complex Geometries: It’s great for parts with complex internal structures or intricate details that would be hard or impossible to produce with traditional methods.

Reduced Waste: Since the material is added layer by layer, 3D printing often results in less material waste compared to subtractive manufacturing methods.

Limitations of 3D Printing

Speed: Although faster than traditional manufacturing methods for small quantities, 3D printing can still be slower compared to mass production techniques.

Material Limitations: While the range of printable materials is growing, it’s still limited compared to traditional methods like injection molding, particularly for large-scale production.

Surface Finish: The surface quality can sometimes be rough and may need post-processing (e.g., sanding or painting).

Size Constraints: Most 3D printers have build size limitations, meaning large parts may require printing in sections or using specialized equipment.

Guidelines for Producing High-Quality 3D Printing

Producing high-quality 3D prints involves a mix of the right equipment, materials, and techniques. Whether you’re printing prototypes, artistic objects, or functional parts, following best practices and guidelines can help ensure that your prints come out as intended. Here are some key guidelines for achieving high-quality 3D prints:

Optimize your design for printability
 (appropriate wall thickness, support placement, and geometries).

Wall Thickness

Ensure your model has sufficient wall thickness. Too thin, and the part may be weak or fragile; too thick, and you may waste material.

Avoid Overhangs and Bridges

Overhangs that are unsupported can lead to print failure. Design with angles no steeper than 45 degrees to minimize the need for support structures. Bridges can often be printed, but make sure to test and optimize.

Check for Non-Manifold Edges

Non-manifold edges (where geometry is incorrect or incomplete) can confuse the slicer and cause print issues. Use tools in your modeling software to check and repair geometry.

Use Supports Wisely

If your model has overhangs or complex geometries, make sure to use supports. Many slicing software options can auto-generate support structures, but it’s often good to manually adjust them for easier removal and less material use.

Calibrate your printer regularly for accurate results.

Ensure that your printer is well-calibrated. The bed leveling process is crucial to achieve good first-layer adhesion, and any misalignment can lead to issues throughout the print. Use a proper print bed surface for your material. For example, blue painter’s tape, buildtak sheets, or glass beds are common for PLA, while Kapton tape is great for ABS. PEI sheets work well for a variety of materials. Keep the print bed clean and free from dust, oil, or debris to ensure proper adhesion and prevent warping.

Select the right material and ensure you're using optimal settings

 (temperature, speed, and bed adhesion).

Choose a material that matches the needs of your print (e.g., PLA for simple models and prototypes, ABS for stronger parts, TPU for flexibility, resin for detailed prints, or PETG for toughness).

Adjust the extruder temperature based on the material being used. Too high, and it may over-extrude; too low, and it may not extrude enough or cause clogging. Use recommended temperature ranges for the material.

Slower speeds generally improve the quality of prints, especially for finer details. However, if you are printing large objects, increasing the speed can help reduce print time while still maintaining good quality. Smaller layer heights (e.g., 0.1mm) will give more detailed prints but will take longer to print. Larger layer heights (e.g., 0.2mm) are faster but may reduce detail. Find a good balance depending on the level of detail needed.

Use proper slicing settings for layer height, infill, and supports.

The smaller the layer height, the more detail the print will have, but it will also take longer to print. For functional parts, a balance between speed and detail (e.g., 0.2mm) is often ideal. Infill density impacts both the strength and weight of your part. If your model doesn’t need to be extremely strong, use a lower infill density (e.g., 15-20%). For strong functional parts, 50-100% is better. Use supports where necessary, but try to minimize their use for ease of post-processing. If possible, orient the part in a way that minimizes overhangs and reduces the need for excessive supports.

Consider your environment and make adjustments to avoid warping and defects.

Keep your printer in an environment with consistent temperature and no drafts. ABS in particular is prone to warping if the print environment is too cold or there are fluctuating air currents. Filaments like Nylon and PVA are highly sensitive to moisture. Store these materials in a dry environment or use a dry box or desiccant to prevent them from absorbing moisture, which can lead to print defects (bubbling, weak parts).

3D Printing Technology Comparison

Conclusion

3D printing is revolutionizing manufacturing by enabling faster prototyping, reducing costs, and offering a new level of design freedom. It’s widely used in various industries, from consumer products to aerospace, and its potential is still growing. Would you like to know about any specific 3D printing technology or material?

Contact IDEAL whenever you need help assessing the manufacturability of your product designs.