12 Different Types of 3D Printing — From Cheap to Cutting Edge

Using computer-generated blueprints, 3D printing entails constructing three-dimensional items layer by layer. The materials utilized, the type of completed surface, the cost of production, and the manufacturing speed all vary. We may put 3D printing into two groups based on the type of material used: polymer 3D printing and metal 3D printing. 3D printing comes in a variety of forms, from affordable to cutting-edge. It is important to comprehend how 3D printing functions as well as its benefits and drawbacks before selecting the best type. This article will analyze 12 different forms of 3D printing and examine the applications that each is most appropriate for.

Polymer 3D Printing

Polymers are the main materials used in polymer 3D printing to produce three-dimensional things. Let’s look at its divisions:

Stereolithography (SLA)

SLA is a 3D printing technique used in business. The process yields parts with superb details, smudge-free surfaces, and great tolerance. Mirrors on the x and y axes are used in SLA laser-printer/’ rel=’noopener nofollow’>printers to direct the laser beam toward the resin vat. This enables the cross-section of the object to selectively cure and solidify, layer by layer, inside the building region.

The solid resin layers are then pulled up by the cured layers, making room for new layers that are scheduled to undergo laser curing. Because of the pieces’ excellent fit and smooth, high-quality surface finishes, assembly is simple. In the medical field, SLA parts are mostly used for anatomical modeling and microfluidics.

Selective Laser Sintering (SLS)

SLS (Selective Laser Sintering) uses lasers to melt plastic granules to produce three-dimensional objects. Before the wiper/recoating blade deposits extra-thin layers of the polymer to the build platform of the printer, the powder is heated almost to the boiling point of the polymer. The powder is then sintered by a laser to harden the object’s cross sections in accordance with its computer design.

SLS components are strong since they are constructed of thermoplastic materials. The components can endure functional tests such as snap-fits and living hinges. SLS finishes may be rougher than SLA finishes, but because of their rigidity, printing is suitable for even larger constructions because support structures are not required.

Fused Deposition Modeling (FDM)

A sort of 3D printing technique called FDM is used to create plastic parts. In fused deposition modeling, we feed the printer’s nozzle in the extrusion head with one or more filaments after having loaded the printer with them. Typically, the printer warms the nozzle to melt the filament enabling simple layering when building a 3D item.

The digital design that the computer feeds to the printer guides the printing procedure. Up until the object is fully constructed, the extrusion head moves through the prescribed coordinates to produce cross-sections. Many support structures are dissolved in water and other fluids after printing is finished, while certain designs call for support structures to hold the models during the process.

FDM is a somewhat speedy and inexpensive way to print models. However, the parts’ lack of structural integrity and rough surface finishes restrict their use in functional testing.

Digital Light Processing (DLP)

The printer uses light to cure liquid resin in digital light processing. The method is comparable to SLA. While SLA employs UV light to cure the resin, DLP uses a digital light projector screen.

With DLP, you can create enormous builds all at once, with each layer flash taking the same amount of time regardless of the build’s component elements. Rapid prototyping frequently uses digital light processing. DLP printing is ideal for small-scale plastic structures because of its high throughput.

Multi Jet Fusion (MJF)

Polymer powder is used by Multi Jet Fusion to construct pieces. There is a slight difference from SLS, but the procedure is comparable. While MJF employs multiple inkjets to apply fuse agents to the polymer powder bed, SLS uses a laser to sinter the powder. The polymer powder bed is then heated by an infrared heating device, fusing each layer. The fusing agent is applied in accordance with the desired geometry, leaving powder in the absence of the agent. The powdered portions subsequently shed off, leaving the build undamaged. For larger projects, this approach does not require support structures because the lower powder layers act as support.

The entire powder bed is moved to another processing facility for the last step, where a vacuum removes all the loose polymers for reusing. SLS constructions lack the mechanical qualities that MJF builds do. Additionally, the surface polish is finer than in SLS, and because printing takes less time, production costs are lower.

PolyJet

Similar to MJF, PolyJet requires the use of a powder and a liquid binding agent. Although the procedure is the same, the buildings’ characteristics and uses vary. Designers are able to create pieces using a variety of colors and materials.

Consider reinforcing the pieces using different materials since the final builds lack durability and structural integrity. The majority of the applications for the multicolored pieces made using this technology are medical modeling and product prototypes.

Metal 3D Printing

Buildings with metallic components are possible using metal 3D printing. Let’s examine a few of these techniques.

Direct Metal Laser Sintering (DMLS)

Metal assemblies can be combined into a single build with the aid of direct metal laser sintering. To lessen the weight of the models, the technique additionally employs channels and interior hollowing. Since the builds are identical to metal pieces made using conventional techniques, DMMS is suitable for prototypes and working parts.

In DMLS, a laser beam is pointed by the printer at a bed of metal powder made of fused metal particles. The technique makes it simple to create parts with complex shape, making it suitable for applications in the medical field where the printed parts must match the real organic compound.

Electron Beam Melting (EBM)

Electromagnetic coils power an electron beam used in electron beam melting, which melts the metal powder. The procedure takes place in a vacuum room and results in clean, premium metal structures. The type of materials utilized determines the temperature of the printing bed. Despite the lengthy procedure, these constructions have good surface quality.

Wire-Directed Energy Deposition

Wire-Directed Energy Deposition melts metal in wire form using plasma and wire arc energy before depositing it to the building surface layer by layer. The robotic arm places the metal in the proper shape after receiving it from the computer and the printer.

The procedure is widely preferred since it uses metals similar to those used in conventional welding and does not call for a closed chamber. The builds have great tolerance and superb surface finishing, and the process is also economically efficient. To ease stress, you should always think about heating the printed pieces.

Cold Spray

In Cold Spray, metal powder is sprayed at supersonic speed by the printer, which bonds the material without melting it. The thermal stress often associated with melt-based techniques is absent from the final constructs.

Since it doesn’t require vacuum chambers and is far faster than other 3D metal printing techniques, most businesses use it. Since aesthetics aren’t often a priority with such parts, most parts made using this method can be used immediately off the printer despite the surface finishing quality and detailing not being excellent.

Molten Direct Energy Deposition

Heat is used in molten direct energy deposition to melt or soften metals before depositing them one layer at a time on the constructed plate. The printing process use pure metal, primarily aluminum.

The benefits of melting metal deposits with heat are numerous. First off, compared to other metal 3D printing procedures, this one utilizes less energy. Second, recycled metals can be used in place of highly processed metal powders and wires.

Sheet Lamination

In sheet lamination, thin sheets of a laminating material are stacked on top of one another before being laser-cut into the required shape. Heat or sound are utilized, depending on the material, to connect the material sheets together. Materials including metals, papers, and polymers are frequently used.

When time is of the essence, sheet lamination is frequently employed to produce cheap prototypes that don’t work. Additionally, sheet lamination is ideal for composite, multicolored constructions because it allows the designer to easily switch out materials as the structure is being constructed.

When we cut the laminated sections off, sheet lamination causes a lot of waste, which is a drawback. Under this strategy, it is also impossible to reuse materials like paper and polymers.

Factors to Consider When Choosing the Best Type of 3D Printing

To provide you with the greatest results, 3D printers use sophisticated technologies. Given the variety of alternatives, selecting the best 3D printing technique might be challenging. Before printing something in 3D, there are certain things to think about. Let’s look at a few of them:

Budget

If you’re starting a 3D printing business or wanting to purchase a printer, price should be a consideration. The purchasing and operational expenses must fit within your spending limit. The cost of a 3D printer might vary depending on a number of things. The price of the machine varies depending on its size and purpose. Printers that use Fixed Deposition Modeling (FDM) are typically less expensive than printers that use Selective Laser Sintering (SLS). It’s crucial to remember, though, that more expensive does not automatically equate to superior.

Resolution

In 3D printing, resolution refers to the thickness of each material layer used. Due to fewer surface roughness, thinner layers produce more flawless outcomes. Everything is based on the printing technology being used. When you choose high resolution, the facial pre-processing is smoother.

While taking longer to produce, thin layers provide you more precisely defined details. For high-resolution products with a layer thickness of up to 25 microns, stereolithography (SLA) technology is indicated. Higher resolution is available using SLS technology, reaching 100 microns. For individuals who want to build larger products rapidly and at a reduced cost, low resolutions are ideal.

Orientation

The output depends on how you position the item on the printing platform. In 3D printing, orientation refers to how a part is positioned on a platform. It can be positioned vertically, flat, or at an angle. The orientation used during fabrication has a significant impact on the end product. The geometrical parameters and error tolerance will be established.

Orientation is also impacted by the technology being used. When using FDM, 3D printed parts are more brittle in the vertical direction and have a high elastic force on the horizontal axis. If you are not attentive enough, the 3D printed part’s aesthetics will suffer. For various shapes, we employ various orientations. They should overhang the surface for the alignment to be more effective.

Material selection

For 3D printing, we have a variety of materials, each with advantages and disadvantages. Materials made of poly lactic acid (PLA) are the most popular. They are among the safest to use, adaptable, and affordable. For beginner printers, they are the best printing medium.

When printed, PLA doesn’t produce a lot of fumes, and the materials hold up well. The material is ideal for use because of its lower melting point. Before purchasing a 3D printer, take into account what material you prefer to use.

Geometry

Before printing, it is essential to take your item’s geometry and scale into account. Every printing method has ideal sizes, some of which are larger than others. The largest print size that the FDM machine is capable of is 16 x 14 x 16 inches. If you are printing something larger, you can cut it into sections before manufacturing and then professionally glue it back together. The construction of larger, more important elements requires more time and resources, which drives up their cost.

When Is It Appropriate to Use 3D Printing?

There are criteria that determine whether a 3D printer is necessary or not. Let’s look at a few of them:

• Quantity of Parts 3D printing is among your best options if you need fewer parts. Manufacturing is the best option for you when you need parts in large quantities, usually more than a hundred units.
• Complex Design Features and Geometry 3D printing can be your only option when your object has complex design and geometry. It s much easier to print the object than curve it from scratch.
• When the cost of part acquisition is higher Buying a new part is expensive. 3D printing is cheaper when the part has a complex design and high buying costs.
• Saving Time 3D printing requires no tooling; hence, manufacturers can use it to reduce the production time for parts. The technology is cost-effective when producing parts with complex geometry.
• Making custom designs The application of 3D printing is extensive. There are applications in the medical field when printing custom parts, like the crown in the dental department. Doctors use 3D printing technology to make parts that precisely match their patients.

Types of 3D Printing: Bottom Line

As you can see, there are various 3D printing technologies, each of which has advantages, disadvantages, and potential uses. Select the approach based on your requirements, finances, and schedule. In a few years, most components will be produced using 3D printing as opposed to more conventional manufacturing methods because the technology is steadily progressing. The superior quality of the finished products makes 3D printing technologies worthwhile.