3D printing is one of the remarkable gifts of technology that allows us to print three-dimensional models of various objects. The 3D printing process has been beneficial across different sectors. However, how much do we truly understand about 3D printing? If you want to know more about this fascinating subject, look no further. Here is all you need to know about 3D printing.
What is 3D Printing?
3D printing is an innovative additive process that involves laying down materials layer by layer to form three-dimensional objects using a digital file. In the 3D printing process, Until the desired object is fully formed, the ‘3D printer’ lays down sequential layers of materials.
How 3D Printing Works
Just like traditional printers, 3D printers use various technologies, and the most common is known as fused deposition modelling (FDM. Although different technologies are used for 3D printing, the 3D printing process usually involves three steps: creating a digital model, preparing it using computer-aided design (CAD) software, and then printing it layer by layer using a 3D printer.
Depending on the techniques, 3D printers can use different materials, including but not limited to
(Stainless steel, solder, aluminium, and titanium, among others), plastics and polymers (including composite that combines plastic with metals, wood, and other materials); ceramics, plaster, glass, etc.
Different Types of 3D Printers
3D printers are available in different types, and most work by creating a component layer by layer. The difference is majorly in the raw materials and the techniques used to fuse each layer to make up the final part.
- Fused Deposition Modeling (FDM): the plastic is delivered as filament on a spool for this printer. In order to melt the plastic, the filament is pushed through a hot cavity. A nozzle pushes the plastic through a nozzle, which deposits it one layer at a time.
- Stereolithography (SLA): This printer transforms A liquid photopolymer into a solid part. A high-powered laser traces the cross-sectional image of the part in 2D. This light polymerizes the plastic layer on the bed plate. Afterwards, there is a slight movement of the build plate, followed by a fresh layer of photopolymer application, and then the laser process continues. Then solidifies it to the previous layer.
- Selective Laser Sintering (SLS): This process of 3D printing starts by putting a thin layer of powder on a plate. A special laser then heats the powder to make it solid and form it into the shape of the object being printed. This process is repeated layer by layer until the entire object is complete.
- Digital Light Processing (DLP): This printer rapidly produces photopolymer parts. It’s similar to a stereolithography (SLA) printer, with only one substantial difference. Unlike SLA machines, which use lasers to trace layers, DLP machines use projected light to cure the entire layer. The part is formed layer by layer. Due to DLP curing the whole layer at once, it is much faster than SLA. DLP printers can print intricate resin design items like toys, jewellery, dental, and figurines with fine details.
Applications of 3D Printing
The application of 3D printing cuts across various industries due to the remarkable versatility of the process. Notably, automotive, aerospace, medical, robotics, printing services, and many more industries use 3D printing technology. The top applications of 3D printing are:
- Prototyping and Manufacturing
3D printing reduces manufacturing lead times, enabling prototyping to be completed in a few hours and at a lower cost. This makes it especially ideal for projects where users must upgrade the design with every iteration.
It is also suitable for manufacturing products that do not need mass production or are usually customized. SLS is often used to manufacture final products, not just prototypes.
- Automotive
Automotive industries, especially those specialized in racing automobiles, such as those used in F1, leverage 3D printing for prototyping and manufacturing specific components. Organizations in this space are also exploring the possibility of using 3D printing to fulfil after-market demand by producing spare parts as customers request.
- Construction
Construction is one of the major applications of 3D printing. Specific applications of 3D printing in construction include additive welding, powder bonding, and extrusion.
Recently, large-scale 3D printers designed to print concrete have been used to pour foundations and erect walls. They are also capable of printing modular concrete sections for onsite assembly. These solutions allow higher accuracy, more complexity, faster construction, and improved functional integration while lowering labour costs and minimizing waste. 3D printing is also useful for producing architectural scale models.
- Healthcare
Regarding the healthcare industry, 3D printing creates prototypes for new product development in the medical and dental fields. In dentistry, 3D printing helps create patterns for casting metal dental crowns and manufacturing tools for creating dental aligners.
It is also helpful for directly manufacturing knee and hip implants and other stock items and creating patient-specific items such as personalized prosthetics, hearing aids, and orthotic insoles. The possibility of 3D-printed surgical guides for particular operations and 3D-printed bone, skin, tissue, organs, and pharmaceuticals is being explored.
- Aerospace
In aerospace, 3D printing is used for prototyping and product development. It is also critically helpful in aircraft development, as it helps researchers keep up with the strenuous requirements of R&D without compromising on high industry standards. Certain non-critical or older aircraft components are 3D printed for the flight.
In addition, 3D printing has gained popularity in the consumer market, enabling the creation of personalized items, fashion accessories, and even home décor.
Conclusion
3D printing encompasses numerous technologies and techniques that collectively offer various capabilities for producing components using different materials. 3D printing is also an evolving technology with immense potential, and more materials are being explored daily to improve the printing processes and expand the already impressive capabilities of 3D printers.
As this groundbreaking technology expands, it is expected to significantly impact various industries, including healthcare, manufacturing, and construction. Brace yourself for a future where the boundaries of what can be created are pushed to extraordinary limits.