3D Printer Guide: Types, Uses & How It Works

Table of Content

• What exactly is a 3D printer?
  
• How do 3D printers actually work?
  
• The Main Types of 3D Printer Technologies
  
• Materials to Print with on your 3D Printer
  
• Practical applications of 3D printers
  
• Conclusion
  
• FAQs
  

Manufacturing has never been the same since the 3d printer arrived. What once took whole factories, molds, and weeks for delivery can now be done right at your desktop, slowly, layer by layer, hour by hour. A 3-D printer doesn't carve material away; it adds layer on top of layer until a desired part has been formed by placing small bits of material in precisely the right place. This idea of adding layers, additive manufacturing, is the foundation of what makes 3-D printing so unique in comparison to almost all forms of production that came before it.

The effect on manufacturing has been astronomical. Engineers can test out their models in a matter of hours. Doctors can get implants tailored exactly to a patient. A designer can test out ideas that they never could have conceived, testing out in the weeks it would have taken to produce a part traditionally. Whether you're just starting to become aware of 3-D printers or whether you've been trying to find out all you can about additive manufacturing for an upcoming project, knowing how 3-D printers work and what sort of 3-D printer to choose is critical. Here we simplify everything.

What exactly is a 3D printer?

Essentially, a 3D printer is a device that creates physical objects from digital 3D models – in most cases, CAD files – without any molds or heavyweight tooling or waste-heavy machine processing. A 3D printer is what we call an "additive manufacturing device". This means material is added in sequential layers till the entire object is made. It is not the case of cutting off chunks from a block of material (like in the traditional "subtractive manufacturing") or pushing and molding materials into shape by applying heat and pressure (which is called "formative manufacturing").

All a 3d printer does is pile up material layer upon layer, as directed by the software derived from the initial 3D model, and the resulting component is an accurate replica of the digital design. The benefits derived from 3D printing can be amazing.

Key advantages include:

●     No costly setup costs-No molds or fixtures required

●     No limits to design-complex geometries can be printed that would be very difficult or impossible to machine

●     Very fast design iteration-prototypes can be produced from concept to component in hours, not days

●     No extra cost for individual customization-each part can be unique with no additional cost

How do 3D printers actually work?

The process of creating something with a 3D printer follows a clear path.

1. Design your model. The process begins on the computer with CAD software, which designers use to model what they want. The resulting output file is often an STL or OBJ file. Examples of the software that designers use are Fusion 360, SolidWorks, and Rhino 3D.

2. Slice the model. This is the second step, and the 3D model is cut up into hundreds, sometimes thousands of slices, and also the support structures and print path are calculated. The most common slicing software is PrusaSlicer, Cura, or MakerBot Print.

3. Print the object. This is the final step when the 3D printer gets the sliced model and creates the object layer by layer, depending on what technology you are using; whether that is burning it out of plastic filament, burning and melting of resin, or sintering of powder with a laser.

4. Post-process your object. Depending on what material and technology are used, your object will need something done to it before it can be used. This will depend on the technology that you have used, for example, support removal, sanding, or curing of painting, and so on.

The Main Types of 3D Printer Technologies

Even though there are many types of 3D printers out there, there are also many different types of 3D printer technologies with their advantages and disadvantages. Also, the decision really depends on what you are producing and what your material must be made of, and how strong and accurate you need the resulting object to be.

FDM - Fused Deposition Modeling

Fused deposition modeling is by far the most common type of 3d printer technology among users and hobbyists. The thermoplastic filament is pushed through a heated nozzle that is kept at a temperature that melts the material, which then extrudes it through the nozzle, and the object is built layer by layer by being laid down onto the printing platform, and fused onto the layer below as it solidifies.

Best for: Functional prototypes, consumer printing, and prototypes quickly created

●     Materials typically printed with this method are: PLA, ABS, PETG, TPU

●     Advantages: Fast printing, the cheapest method of 3D printing, easy to use, and most common

●     Disadvantages: Visible lines, bad surface resolution, anisotropic part strength (the material is weaker when trying to be pulled in the Z direction)

●     FDM printers are relatively inexpensive and simple to use, making it the most popular out of all the current printers on the market.

SLA-Stereolithography

SLA prints parts by curing layers of liquid photopolymer resin with a UV laser from a vat of resin. SLA prints are extremely smooth and have a very fine level of detail that FDM can not.

●     Good for: dental models, jewelry prints, medical models, intricate prototypes

●     Pros: High resolution, Excellent detail, and surface finish

●     Cons: The parts are relatively brittle, require a post-cure stage, more expensive material.

Where fine detail and surface finish are more important than the speed or robustness of the prints, SLA often wins out.

SLS-Selective Laser Sintering

SLS works by using a high-powered laser to sinter (fuse together) particles of a powder like Nylon or a variety of other plastics. The parts print from within a bed of loose powder, which acts as the support for any elements of the print extending outwards, which means there are no support structures needed – a great benefit for complex designs.

●     Good for: Functional engineering parts, complex assemblies, low to medium runs

●     Pros: Strong parts, unlimited geometry, no support material.

●     Cons: Expensive, long prints, rough surface finish needs to be addressed

Materials to Print with on your 3D Printer

Materials available on 3d printer have exploded in the last 10 years, and the material of choice depends solely on the function the part serves.

The common plastics for FDM printing are:

●     PLA - biodegradable and easy to print, ideal for display models

●     ABS - durable and heat-resistant, ideal for automotive and consumer products

●     PETG - durable and chemically resistant, good for functional parts

●     TPU - rubber-like, good for grips and wearables

●     Nylon 12 - tough and durable, often used in industrial SLS applications

Resins for SLA and DLP:

●     Standard resin - for prototyping

●     Engineering resin - for functional testing

●     Dental resin, castable resin - for professional and medical applications

Advanced materials:

●     Metal powder (stainless steel, titanium, inconel, etc.) for DMLS and SLS industrial applications

●     Carbon fiber composite - for high-strength parts with low weight

●     Ceramics - heat and electrically resistant components

Wrong material choice is the biggest mistake to make when selecting a 3D printing workflow. Ensure the material fits the job!

Practical applications of 3D printers

3D printing technology actually has much more reach than many people give it credit for.

Health care and medical devices

Additive manufacturing in the medical field is one of the fastest-growing fields. Doctors have used patient-specific bone models to plan difficult surgery. Prosthetics of the limbs can be 3D printed to fit each individual patient. It can be used to produce dentures, dental guides, and other orthodontic devices more rapidly. Over 20 implants have already received FDA approval and they will continue to do so in the future.

Aerospace and aviation

In aerospace, reducing weight is the priority, and topology-optimized parts with lower mass but the same or greater strength can be created. Dozens of machined part assemblies can now be manufactured as one single 3D printed part, saving mass and time from assembling parts together.

Automotive

In the automobile sector, 3d printer are mainly utilized for prototyping, jigs, fixtures, grips, bellows, and other difficult shape parts. The cost of producing a part that has an intricate shape is greatly reduced because you do not have to pay for a specific tool to make a part of that shape. Formula 1 racers often use this technology to test aerodynamic parts under narrow timing.

Consumer electronics

In this field, custom housings, supports, or even low-volume parts can be produced without the significant tooling expense that is associated with injection molding. The spare part could even be printed as it is needed, which greatly reduces the stock that companies must keep in inventory.

Jewelry Design

Jewelry makers use 3D printers to produce forms that are much more complicated and detailed than what may be performed using hands, CNC machined parts, or stereolithography. Resin material that is used for this kind of printing can be made out of a wax-like substance used for the lost-wax casting of metal.

Conclusion

The 3D printer has far outgrown being just another piece of modern technology. Today, they are serious manufacturing instruments found in hospitals, aerospace factories, auto research labs, and design studios throughout the globe. Familiarity with the distinct types of technologies, ranging from FDM to SLA to SLS and even beyond, allows you to appropriately apply a suitable tool for tasks ranging from the creation of rough models to precise custom medical implants for patients.

As materials are developed and machine prices fall further, the 3d printer will likely become even more ubiquitous in production in various industries. Understanding the basic principles is more than just informative; it can provide an edge for those involved in design, engineering, or production industries.

FAQs

How much do 3D printers cost?

Basic 3D FDM printers vary from between $200 to $500; Professional SLA and SLS 3D printers can vary from $3,000 to over $50,000; and industrial metal printers can cost more than $500,000.

Is 3D printing slow?

It really depends. Small, simpler items may take an hour or three to produce; large, complex parts can take more than twenty hours; so it is unlikely to be more rapid than traditional manufacturing for volume production.

Which is the easiest 3D printer for beginners to use?

FDM(Fused Deposition Modeling) printing technology is likely the easiest for beginners to use because it is relatively accessible and cheapest form of the 3D printing technologies, and there are lots of help available online, as well as widely available materials like PLA.

Can 3D printers make metal parts?

Yes, DMLS and SLM are two techniques that can be used to make solid parts from metal by using a laser to fuse layers of metal powder; and this is already being used in fields such as aerospace engineering and medicine.

Are 3D printers high maintenance?

The only maintenance on an FDM 3D printer involves keeping the nozzle clear and leveling the build bed; and sometimes having to replace parts, resin printers involve replacing the FEP film and cleaning the tank, industrial printers could require the machine to be maintained professionally.