Month: August 2021

3D printing has accelerated innovation in numerous industries, including dentistry, eyewear, prosthetics, furniture design, archaeology, paleontology, and forensic sciences. In fact, we’re just getting started in realizing how 3D printing can improve our lives and work drastically.

 

A variety of techniques are available when it comes to 3D printing

Additive manufacturing is characterized by the introduction or bonding of additional materials to create a part. Objects that can be 3D printed are geometrically complex, making them ideal for a variety of manufacturing applications. Parts can be printed using a variety of technologies with machines ranging from hundreds to millions of dollars.

An additive manufacturing process uses 3D printing to create objects. A part is manufactured using additive manufacturing when an additional material is added, as opposed to subtractive manufacturing where a material is subtracted. By using CAD (computer-aided design) files, 3D printers make three-dimensional objects. Many materials and technologies are available for 3D printing, making it easy to design parts for virtually any industry.

 

What Are the Benefits of 3D Printing in Manufacturing?

 

Despite the fact that 3D printing is often linked to toys and simple items, it is actually capable of producing components capable of enduring the most rugged conditions. A wide range of industries, including energy, automotive, and defense, use 3D printed parts in manufacturing. Its transformative effects are being felt in numerous industries and processes, from functional prototypes to tools, fixtures, and end-use parts.

You might be surprised to learn 3D printers have existed since the 1980s, when many people assumed they were a new technology. 3D Printing was primarily used for industrial applications up until 2009, and printers were prohibitively expensive for most companies. The costs of 3D printing have fallen significantly since 3D printers began to be used widely for manufacturing purposes. Several factors are responsible for the growth in the 3D printing industry, such as the increased use of 3D printing in manufacturing, which was considered impossible before the technology gained traction.

 

3D printing uses a variety of techniques

What are the most common 3D printing technologies? Several 3D printing techniques are available. Parts are built in discrete slices called layers in all 3D printing technologies.

 

Fused Filament Fabrication (FFF, also known as Fused Deposition Modeling)
Continuous Fiber Reinforcement (CFR)

 

FFF (Fused Filament Fabrication)

The most common and most affordable type of printing is fused filament fabrication. FFF involves heating thermoplastic near its melting point and extruding it out of a nozzle that generates a cross section image of the layering for each part. Layers are added one after another in this manner.

 

Continuous Fiber Reinforcement (CFR)

FFF parts can be reinforced with continuous fibers using continuous fiber reinforcement. Two kinds of extrusion systems are used in CFR-capable machines — one for conventional FFF filament and another for big strands of continuous fiber. As opposed to FFF infill, these fibers are laid in layers. This technology produces significantly stronger parts (up to 10 times stronger than the equivalent aluminum parts) and can replace standard FFF materials such as ABS and PLA.

 

The most widely used technology for 3D printing today is fused filament fabrication. The carbon fiber reinforced materials provide the same benefits of FFF as they eliminate key parts weaknesses. A CFR part is strong enough to replace machined aluminum in key manufacturing operations, as opposed to FFF components which are usually limited by the strength of weak polymers.

 

In the end, It’s all about

By integrating several printers into its manufacturing process, many companies find that they can significantly reduce the amount of time spent fabricating parts in-house. Using a 3D printer to produce low-volume, custom parts can be a faster and cheaper option. As a result, businesses can spend time and energy focusing on revenue-generating parts, rather than low-volume parts that may not generate revenue. The use of a 3D printer enables rapid production of designs without wasting resources on parts that may not meet quality standards. Therefore, 3D printers are ideal for printing low-volume, custom-designed prototypes, tools, and fixtures that can be complex and difficult to machine, but are essential to a successful production process.

Product development is speeding up, which is causing design rules to change. DMLS (direct metal laser sintering) is a great example of this. A considerable amount of potential exists for direct metal laser sintering in the medical device sector. Early in the design process, however, a new mindset is required. This represents one of the transitions designers have to make when implementing new technologies to make manufacturing and designing medical devices more efficient and effective.

Time and cost can be saved by prototyping designs in unusual shapes. The main difference between DMLS and other 3D printing is that real metal is used. Materials like these have been used for industrial applications for decades.

Design professionals like this process because they can experiment with organic shapes that cannot easily be machined. Developing implantable body parts that are custom-fit to the recipient, for instance, is an intriguing prospect. A delicate five-axis machine would be required to build these implants. A direct DMLS replacement can be printed by scanning a person’s actual bone structure.

Surgical tools in organic shapes are also an opportunity. Depending on the application, these devices may be designed for metal injection molding or casting, both of which have relatively high tooling costs and lead times that can range for weeks. Using 3-D printing, we can produce accurate prototypes of surgical hand tools. Most of the time, it can reach a surgeon within 3 to 5 days. It’s still more expensive per piece for higher quantities to use traditional injection molding, but it’s still a lot slower than a couple of days for a smaller quantity.

For experimentation, design, and seeing what works, it’s critical to have the attributes of time, cost savings, and freedom of design. The engineering cycle can be shortened to only a couple of days for both of these types of products.

It does, however, require a different way of thinking. During the design phase, you have to approach it differently. During the construction process, one of the biggest adjustments is how to cope with internal stresses. It involves melting a metal powder at room temperature, followed by rapid cooling. During the construction process, there is rapid change that puts stress on all layers. During construction, the part bends upwards.

 

 

 

As a method of minimizing the unwanted effects of this process, determining which orientation will yield the most consistent cross-sectional surface area is essential (deciding how the part should be positioned during various phases of the build), along with adding structural support elements generated during the build.

Following construction, each part undergoes a stress relief cycle in a furnace. This prevents the parts from warping after being removed from the structural supports and build plate. It is also important to take building support out of the build plan. It is crucial to arrange parts so that support removal can be achieved with hand tools or secondary machining.

The Layers app provides design guidelines to help its customers identify red flags during design. During the evaluation, each part is evaluated for overall printability, and when necessary, adjustments are made to the design. It is crucial for the designer to know how the piece should be oriented during construction when designing specifically for the DMLS.

 

Initially, you must think about tool paths and parting lines. Design for DMLS must focus on using as little material as possible, as well as integrating self-supporting features. We at Layers.app have created an excellent design guide to help get new users pointed in the right direction.

Additive Manufacturing, also known as 3D printing, is increasingly being used in a variety of industries, including education, manufacturing, robotics, automotive, aerospace, construction, architecture, dentistry, jewelry, and engineering. By bringing fabrication in-house, you can save considerably on costs and have more freedom to design prototypes and iterations.

In the beginning, understanding and separating the various 3D printing technologies, processes and materials can prove difficult for newcomers to 3D printing. Which 3D printing technologies are available to businesses? Taking a closer look at the five 3D printing technologies that are disrupting those industries above will help you understand the different types of 3D printing.

Composite 3D printing

Metal and composite 3D printing are poised to revolutionize additive manufacturing.

 

In Print Scanning/Process Inspection: You can use this feature to print your part, scan it, and measure its dimensional accuracy in real-time.

 

Stepper Motor Encoders: With these encoders on the X, Y, and extrusion motors, the printer can automatically correct position accuracy errors. Eventually, you’ll save more money because the problem can be corrected automatically and more prints can be saved. You will also get those stunning surface finishes with the encoders making sure the head is located exactly.

 

Material Detection: When the material runs out during the print, this feature will pause the process and send you an email notification. With reload, you can continue printing while adding new material.

 

Silent Drives: With silent drives, Markforged’s industrial 3D printers are able to perform 3D printing without making even a sound.

 

MicroController: Since X and Y offsets are already calibrated and stored on the print head, if you replace the printhead that contains the microcontroller, no calibration is needed. Using this tool, you can also detect and prevent faults before they occur and detect maintenance issues.

 

SLA (stereolithography)

Alternatively known as SLA, stereolithography is a 3D printing technique that utilizes light to cure liquid resin into solid plastic. Inverted Stereolithography is the most commonly used SLA system. The resin is usually poured manually by the user or automatically dispensed from a cartridge, depending on the 3D printer. Starting a print requires lowering the build plate into the resin. The bottom of the tank and build plate are separated by a thin layer of liquid. Through a translucent window located at the bottom of the resin tank, the UV laser is directed from the galvanometer or galvos to solidify the material selectively. Every subsequent layer begins with a print that has a micron thickness of fewer than 100 microns.

3D printers with SLA technology can produce parts with complex geometries and fine details with outstanding results. Most of the time, you will have to use support structures since the printed parts must be cleaned and then UV-cured, sometimes in an oven, before they can be used.

At first, SLA was only used on large machines for industrial applications in the 80s. In addition to being more affordable than ever before, desktop stereolithography 3D printers also offer you high-resolution 3D printing that easily fits into your workspace. The flexibility of SLA allows you to create products using an extensive range of materials, giving you an endless amount of creative freedom.

FFF (fused filament fabrication)

The most common additive manufacturing process is fused filament fabrication or FFF. Due to its ease of use, and since it does not use chemicals, it is cost-effective. A roll of thermoplastic filament is typically used for FFF, which is dispensed from a spool. A heated nozzle attached to an automated motion system is used to extrude the filament in Fused Filament Fabrication. While a part is being 3D printed, the motion system travels around the area where the part is to be printed. Melted filament is deposited from the nozzle onto the build plate as the motion system goes around. It takes a while for the filament to cool and harden into a layer. It takes less than a millimeter for the build plate to move, then one layer is added at a time until the part is fully formed.

Certain FFF 3D printers can print with two materials simultaneously using the Dual Extrusion feature. A typical aesthetic use of two different colors for the same material is to give it a more pleasing appearance. Variations in mechanical properties are achieved by using two different materials. Along with the build material, a water-soluble PVA support material can also be used. Submersion in water dissolves the support material, making the final part of the design appear high-quality while requiring minimal post-processing.

A 3D printer with FFF technology is perfect for office settings because the machines are relatively simple to operate and maintain. Contrary to SLA 3D printers, FFF printers will not require good ventilation to produce or post-process objects. As compared to other methods, FFF 3D printers offer a wide range of consumable options at a relatively low cost. Easy to set up, the consumables can be stored for years.

LFS (low force stereolithography)

This next generation of Stereolithography is called Low Force Stereolithography (LFS). Formlabs announced the Form 3 and Form 3L 3D printers in late 2019. These sophisticated 3D printers use linear illumination and the Formlabs Form 3 technology, combining a flexible tank to deliver an immaculate surface finish. Formlabs Form 3, for example, can deliver high-quality prints consistently because of the Low Force Stereolithography print process’ lower print forces. By easily tearing away light-touch supports, it can reduce the amount of time and effort required to build and maintain parts. You can then focus on everything else, like designing and creating.

Metal 3D printing

Metal 3D printing is one of the most advanced 3D printing processes available today. It’s an organized process that allows you to print and post-process ready-to-use parts in-house. In this process, you must:

 

Software part setup: The STL file generated by your CAD software needs to be imported into a software program. 3D printing can be done on a variety of metals. To compensate for material shrinkage, the parts are automatically scaled up.

 

Print: FFF printing uses a plastic-bound metal powder to print layers of metal until your part is fully formed.

 

Wash: Parts have to undergo a rebinding process after being printed. In this step, wax is removed from the part by washing it in a degreaser. As a result, it is ready for the next phase.

 

Sinter: This process is followed by interceding the part in a furnace to burn away all plastic connectors and allow the metal powder to fuse into a 3D part with a relative density of approximately 96%.

 

Final Part: Now, “pure” metal is used to make the part. In this state, it can be post-processed and treated just like any other metal.

 

Final thoughts

Each 3D printing technology has unique applications. SLA is great for smaller, detailed objects with complex features. An LFS machine is best suited for high-volume production that consistently produces high-quality results without requiring additional labor. Budget-conscious people will love FFF. Using this technology is easy, affordable, versatile, and convenient. It is easy to use, does not take up any additional space, and requires no professional staff to set up and operate it. The versatile 3D printing processes of composites and metals make them ideal for manufacturing heavy-duty parts by businesses.

Now is the time, AI services are part of our future and allow us to create already sophisticated equipment. Did you know 3D printing technology can be used to make AI more useful as well? This game-changing technology is continuously evolving, making things better. New wonderful technologies are now available, such as Artificial Intelligence. 3D printing coupled with artificial intelligence is enabling new and exciting applications of additive manufacturing.

Technologies combined with Additive manufacturing are, of course, what we are most passionate about. 3D printing and artificial intelligence are discussed in this article. What benefits can be realized by combining these two technologies? Is there any remaining limitation?

 

What is Artificial Intelligence?

Artificial intelligence, or machine intelligence, refers to intelligence displayed by machines. Machines are capable of learning and acquiring information rationally and conclusively. By doing so, advanced tasks can be performed on these devices.

AI-based machines can mimic intelligent human behavior. Different types of processes can benefit from this AI and automation process. The same is true when it comes to additive manufacturing. Artificial intelligence can significantly improve 3D printing so that it is more effective.

Using AI with 3D printing

Artificial intelligence is often linked to terms such as machine learning, neural networks, automation or artificial vision. The idea here is that a machine can solve a given problem by itself, without human intervention, based on data and past experiences. This is of particular interest when combined with 3D printing technologies as it could increase the performance of a 3D printer by reducing the risk of error and facilitating automated production. Indeed, more and more startups and research projects are integrating AI into a 3D printing product or service.

 

Based on data and previous experience, a machine can solve a problem itself, without human intervention. The combination of 3D printing with this technology holds particular interest as it should increase the performance of 3D printers through the reduction of errors and the automation of production processes. As a result, many startups are choosing to integrate artificial intelligence into their products and services. Developing new materials and automating the entire workflow in 3D printing are just a few examples.

3D printing workflow automation

The automation of 3D printing workflow is, for example, one application. Several steps are involved, including creating the CAD file, preparing it for printing in a slicing software, and finally printing it. We at Layers.app enable the automation of important steps, such as production management, with our software designed for the 3D printing workflow. Our company uses artificial intelligence to automate manual tasks like data collection and cost tracking. By implementing Artificial Intelligence, the software can help improve the utilization of machines and plan production orders based on availability. The selection of material can also be automated with AI; the software recommends the best material depending on the requirements of the printed part.

In order to 3D print your project, you need to work on your 3D model using CAD software. To help you make the perfect 3D printable models, AI is increasingly being integrated into these 3D modeling programs.

 

Artificial intelligence can be clearly incorporated into the 3D printing workflow and may change the future of manufacturing

The combination of artificial intelligence and 3D printing can also enhance the range of materials that are compatible with 3D printers, enabling those sectors to create high-temperature materials, such as aerospace.

 

Where does AI come in?

In order to process new high-performance materials, all process parameters must be precisely tuned. 3D printing processes should be monitored with numerous different sensors. Then, we analyze this data stream using artificial intelligence and identify hidden relationships that humans may not be able to recognize. In these situations, artificial intelligence has the advantage: it is capable of processing very large quantities of data very quickly, which is impossible for humans to handle. In this way, researchers can maintain the material properties of complex alloys.

A process for optimizing 3D printing

Also, AI can be used to improve the printing process for 3D objects. A printability analysis of an object could be performed before any printing process is started. Moreover, a part’s quality can be predicted and printing errors can be avoided, resulting in time savings.

Our goal here at Layers is to use AI in our software to improve the effectiveness and quality of 3D printing departments’ production processes. With the industry moving towards manufacturing finished parts, this is becoming increasingly important.

What are the implications of artificial intelligence and additive manufacturing?

There can be a number of risks associated with any new technology. A number of 3D printers can actually print guns, for example. Adversely, artificial intelligence and additive manufacturing are not an exception. We often hear that artificial intelligence will be able to surpass humans. A wide range of objects can, however, be easily reproduced with today’s 3D technologies. The future security and privacy of these functions could be seriously compromised if artificial intelligence is implemented. On one side, you can print a weapon and on the other, human bones.

Don’t see the glass half empty: Artificial intelligence and 3D printing have a bright future! With Artificial Intelligence, machine learning, and other advanced technologies in Industry 4.0, engineers and operators can spend less time on repetitive manual tasks and more time on more innovative processes.

Artificial intelligence and 3D printing: the combination of the future?

It is clear that both technologies will play a major role in the years to come, especially in industrial applications. The production of parts using additive manufacturing today requires a high degree of specialized knowledge.The 3D printing workflow will incorporate AI rules. With more sophisticated algorithms, humans will have to perform fewer manual tasks. Using AI, large amounts of data can be accessed to better manage 3D technologies.

AI and 3D printing are still in their infancy; however, the few examples here show how these two technologies boost innovation, facilitate production, and enhance competitors’ abilities. One thing is certain: this revolution is promising, no matter how far it goes.

In the last 40 years, 3D printing has undergone significant changes. Over time, Additive Manufacturing has evolved from a groundbreaking technology with few scalable applications to what it is today. A powerful desktop printer, not much bigger than a standard office fax machine, has replaced the enormous, expensive, and dangerous machines of the 80s.
The wide variety of printers available today solve a wide variety of problems, but they all operate by using different types of 3D printing software called slicers. Slicing software provides the print instructions for converting a digital model into a 3D print.

 

What are the functions of a slicer? 

Slicers convert digital 3D models into G-code, or control language, in order to allow the printer to print the model in a three-dimensional space. In the absence of a slicer, 3D printers would be nothing more than fancy paperweights. Slicing software is necessary for every 3D printer on the market today in order to print. A subscription to slicing software is often required to use most hobbyist printers on the market. Moreover, there are several software programs on the market that are compatible with different types of printers; PrusaSlicer, Netfabb Standard, and Simplify3D are a few from the list. Hobbyists and industrial printer manufacturers can benefit from these tools. These programs, however, have their shortcomings. A large number of these sites are inaccurate, unreliable, require paid subscriptions, and are difficult to access. However, industrial 3D printers require more sophisticated software for high-level accuracy. Those software programs are more suitable for more simple machines.

 

Layers Slicing Software offers many advantages

Using Layers, STL files can be digested into bite-size pieces that can then be printed at a high level of accuracy and precision. Software for slicing put on by Layers sets the bar for the entire industry. Thousands of end-use parts are powered by Layers, used in endless applications by manufacturing entities in various parts of the world. What makes Layers different from its competitors?

 

Layers slicer is online

Your company can automate pricing by using the online slicing process. Therefore, your customers can upload their files online and slice the 3D model according to their preferences.

 

Updates in real-time

Manufacturing is a challenging business to run. A dynamic manufacturing landscape is needed to meet the demands of a global economy that is constantly evolving. You should rely on tools that provide consistent results and require little maintenance as the variables to run your business operation evolves. With Layers you only have to press update when there is a new update available. You will never be charged a hidden fee or experience downtime. Layers will update in real-time, changing to the latest material as soon as it becomes available instead of requiring you to reorder spools. So simple.

 

Security

The security of the STL files is not a priority in most lower-quality slicing software. It is very likely that you have patented intellectual property behind your parts, which can bring tremendous value to your company. As a key part of Layers cloud-based architecture, security has been incorporated into its design.

 

Cost

3D printing is made up of many components, including 3D cutting software. Without it, printers will not be able to operate and parts made with CAD software will be restricted to your own preferences.

Besides printing beautiful parts with impeccable surface finishes, Layers is easy to use even for novice users. Press enter after uploading the STL file, selecting your print materials, and setting the print schedule. It takes just a few clicks to create anything you can imagine with Layers.

Have you ever 3D printed a part that had flat spots or faceted surfaces where smooth curves were supposed to be? Or maybe you’ve just seen a picture of a 3D print that looked like it belonged in some low-resolution CGI from the 90’s? You are not alone, and it’s not your 3D printer’s fault — the culprit is likely a lack of resolution in the STL file that was used to create the part!

 

How do STL files work?

 

As the standard file format for taking 3D model files into a slicing program for 3D printing in preparation for actual printing, STL files were originally created to be used with stereolithography 3D printing in the late 1980’s (STL stands for Stereolithography). It is almost certain you have come across an STL file before if you have ever used a 3D printer or designed something for 3D printing – but did you know not all STLs are the same? As a matter of fact, you can design a 3D model that meets your functional requirements, and then create an STL file from that model that will create out-of-spec parts.

An STL file is simply a series of triangles that (usually) form a mesh that approximates a 3D model’s continuous surfaces. STL files contain three dimensional coordinates organized into sets of three along with a normal vector – each of these sets, or vertices (corners) of the triangle, has an orientation normal to the plane that is described by the triangle’s three points.

Ideally, STLs intended for 3D printing should include a well-formed mesh, with 2 faces per edge of every triangle (this is sometimes known as a manifold STL, or one with no gaps).

The STL file specification does not specify any such manifold condition, since it is simply a list of coordinates and vectors. In STL files, especially those created directly from 3D scanners, geometry may be non-manifold or incomplete, making them difficult to 3D print correctly, which can then cause problems during slicing.

Most widely used CAD software packages support STL export, including most commercial CAD packages and many open source packages and hobby packages. You can usually find STL export options by searching the web for your CAD program and your software’s name.

 

The importance of STL 3D printing

Since triangles are flat and 2D shapes, STL files can only accurately represent triangle collections. Essentially, any shape that does not have curved surfaces, such as a cube or a rectangle, assumes that the triangles in the mesh are smaller than the smallest features in the model.

In addition to curved parts, there are holes, fillets, radiuses, revolvers, as well as organic curves and geometries. An STL file can only approximate these curved (non-planar) features and surfaces, regardless of how exact the settings are for STL export.

How should I handle my STL files?

If you are satisfied with the quality of your 3D prints, and how they are processed, then congratulations – there’s no need to change anything! The problem can be caused by STL files that have been generated with either too high or too low export resolution settings, so if you’re having issues this article can help. Low resolution STLs are characterized by excessive flat areas in regions that should be smoothly curved. When you slice STL files with excessively high resolution, your 3D printed parts will look great, but the large files lead to long slice times and may cause lags when adjusting part view in extreme cases.

STL files have become so widely adopted because of their simplicity, which has enabled a wide range of engineering and design software to easily support, edit, and generate STL files from other 3D models, which can then be printed on nearly every 3D printer. The downside of STLs is also their simplicity, since they do not contain any information about the unit system (millimeters, inches, feet, etc.) in which they were designed and the resolution of an STL file cannot be determined by itself or how well it represents the original model.

STL files that are too coarse and that were generated without sufficient resolution are the most common problem users encounter. The most obvious indication of this is the presence of flat spots and faceted areas in parts that were designed with smooth curves.

You can control the density of a triangular mesh when you export an STL from your CAD software so that the geometry of a part will be defined. This is because your CAD software is trying to optimize for a small STL file size, so it will attempt to create the roughest, lowest resolution mesh possible, but the parameters you specify may force the software to use a higher resolution mesh for certain features and geometry. The mental model you should take here is to think about these export parameters as forcing the export process to generate finer, more detailed meshes.

Many CAD software programs nowadays offer users a choice between two export parameters for linear and angular dimensions: one called chordal tolerance (or chordal deviation) and the other called angular tolerance (or angular deviation). It is important that the STL output meets all the criteria specified by the export settings you selected. A mesh setting that requires an upper-resolution mesh can be more restrictive (or simply the limiting parameter) depending on the geometry of that feature. The limiting parameter will typically vary across the geometry of a part in response to different features.

Other settings may be available in certain CAD programs, which may include minimum and maximum triangle facet length options in addition to chordal and angular tolerances. We recommend leaving these at their default values unless you have a specific reason for wanting to change them. In general, these are used to address STL export issues in edge cases.

Measuring mesh quality in relation to file size

If you are looking for a more accurate, smoother STL mesh, you might be tempted to set your CAD program’s resolution settings to maximum and walk away. As a consequence, increasing the resolution of the STL export also results in a larger STL file, which typically results in longer processing times, both in terms of creating the STL, uploading it, and then processing the STL for 3D printing. In some cases, the STL file resolution can exceed the machine precision in your 3D printer, which means you may end up paying a price for STL resolution that isn’t actually reflected in the printed parts.

We recommend that you choose your STL export settings so that both the resolution and file size are balanced to meet your functional requirements. These settings have been found to be useful as a starting point:

• Binary STL format (smaller file size than ASCII)
• chordal tolerance/deviation of 0.1 mm [0.004 in]
• Angular tolerance/deviation of 1 deg
• Minimum side length of 0.1 mm [0.004 in]

We recommend reducing the file size with increases in chordal and/or angular tolerances until the STL file size is no larger than 20 MB. A large file size can prevent the STL from being prepared for 3D printing and slow down the processing. Please keep in mind that your tolerance for what you can handle in terms of STL resolution and software processing time will vary depending on your personal preference.

There can be failures in 3D printing. Every 3D printer operator knows that printing an object isn’t just as simple as creating a model and clicking “print”. Several factors play a role in the success and quality of a printed part. It is possible for even the most experienced engineer, designer or 3D printing enthusiast to fail their print. Design for Printability (DFP) is a conceptual framework for designing printable objects that maximize the success rate of 3D printed parts. Even then, there are times when printed parts simply aren’t correct. We at Layers have made it a priority to provide all of our customers with a fully automated test tool to analyze each 3D model’s printability as soon as we started building a platform that enables manufacturers and engineers to print industrial parts anywhere in the world.

How does the Printability Check work?

3D printing offers the opportunity to customize products in a way which has never been done before. The design of every 3D model makes it unique. That is why it is important to assess the printability of your file to ensure that it can be 3D printed successfully. A full check of all uploaded files is performed automatically by Layers In order to conduct a thorough printability check, the tool analyzes all variables that affect the eventual success or failure of the print. Our printability check was divided into two stages to ensure the highest degree of accuracy and reliability. On Layers, each stage is at two opposite ends of the ordering process:

File upload – Upon uploading a printable document, our software will apply a Geometric Check to that document to identify the following characteristics:

● Size

● Width

● Depth

● Height

● Volume

● Area

 

Through this, Layers software can identify the appropriate material, technology, and printer for the creation of an object. Furthermore, this tool provides a list of the possible print locations of the file.

 

After check-out – Once an order is placed, the exact material and printer type used to make the custom item are confirmed. Once uploaded, the tool checks the file against design guidelines such as:

● Wall thickness

● Bounding Box Size

● Model Density

● Model Integrity

● Orientation

● Holes

● Area

● Strength (based on material properties)

● Other variables

 

 

Preparation of 3D prints automatically

With Layers software, the procedure for preparing a 3D model for printing is completely automated, replacing the manual process of preparing such a model. Using automated processes, prints are more detailed and have higher quality because of textures, lighting, and materials. The Layers software enables complex, non-conventional models to be published physically via 3D printing, scaling and strengthening parts according to the properties of the material. In addition to optimizing the model for the printing technique, it increases the quality of the custom part without affecting its specifications. Thus, printing times are shortened, waste is reduced, and costs are decreased.

 

When a 3D model fails the printability check, what happens?

A 3D model that fails the printability check can be automatically adjusted, prepared, and enhanced by the software. Despite this, most industrial components have extremely specific design guidelines, for instance, in which the addition of 1mm can render the custom product unusable. A Layers engineer will be notified by our tool that the printability check failed, who will then contact the uploader. Layers engineers will either recommend another material or approve the preparation of the file for printing after understanding the exact specifications for the custom part. For companies that want to implement AM, the biggest challenge is making the right decision. Manufacturing companies can use Layers to prepare for the future. With our assistance, you can run a detailed report on the technical and economic feasibility of 3D printing for your company. Layers make it easy for you to plan your 3D printing implementation based on accurate data.

Since 3D printing solutions are increasingly being adopted across different industries, there is an obvious need for solutions that streamline the process of creating parts at every step. Workflow management software for additive manufacturing, also known as MES software, or additive manufacturing execution systems, is a kind of software that can track and document every step of how raw materials become finished products. AM MES solutions have been designed to meet the specific needs of additive manufacturing. A software like this ensures that all steps of the process – from modeling to slicing, to printing, to processing – can be optimized and tracked through one easy interface. In addition, many of this software will track the entire process from purchase to shipment, making them especially important for printing service bureaus given the number of products they produce every month. In these circumstances, why should a business adopt this software? Why would it be beneficial? What are the limitations?

 

Additive manufacturing workflow software: why should a company adopt it?

The increased use of workflow management software in additive manufacturing is one of the reasons why companies working in 3D printing are changing their workflows. In particular, it is vital when a company produces large quantities of 3D-printed parts.

 

What are the benefits of this software for AM businesses?

 

In addition to improving file management, the central system also allows for greater collaboration. In this system, information about a project can be accessed by all stakeholders since it is all located in one place rather than being held by several people in several places. Another benefit, of course, is that such optimizations will theoretically increase a company’s return on investment. A faster and more efficient AM process can enable the fabrication of more parts. Process optimization is made possible by additive manufacturing workflow solutions.

 

Since it is uncertain when people will be able to see each other during the pandemic instead of sending emails or bringing huge files to the lab (made more difficult over the recent months), parts can be ordered quickly and be ready for immediate use in 24 hours. With a single software solution, all billing, reporting, and data for inventory management are automatically completed when components are ordered. As a result of this web-based approach, we at Layers.app are able to make the application available to our entire development and purchasing teams to give them easy access to the 3D file viewer. With so many people working remotely, the remote control is particularly important. Software that creates AM workflows can help eliminate, or at least reduce, these problems. In addition, this software is especially useful when combining different Additive manufacturing technologies.

 

How do you resolve the remaining weaknesses?

The system still has some limitations. The main drawback issues with the software are its limitations in terms of quality management, even though it is versatile. Compatibility with ISO standards, for instance, is not an easy job. It makes sense that as 3D printing becomes increasingly important for prototyping and end-use products, quality management and better standardization will become increasingly important.

 

In most cases, workflow management software solutions have a limited scope. There are some companies that automate quoting, but they don’t offer any solutions after the quote. The others have good project management systems, but their clients are unable to collaborate with them.

 

There is still a lot that can be done to streamline and automate processes with workflow solutions. Once the part design is complete, the part should be printed as soon as possible, and the replacement stock order should go out immediately.

 

As a final note

 

It has been found that AM workflow management software is ideally suited to 3D printing service bureaus and large OEMs. Businesses can truly see the value of 3D printing when they are printing large quantities of parts. Therefore, additive manufacturing can really benefit all sorts of companies that use it. From conception to post-processing to shipping to clients, the ability to organize the entire manufacturing process is crucial to businesses in an era where workers are increasingly expected to work from home.

3D printing, or additive manufacturing (AM), has seen a flight of investment over the past three decades, driven by companies seeking dominance in the market. In order to achieve an acceptable level of printing quality, these investments were needed. The development of advanced materials for 3D printing has also sparked a new wave of investments now that 3D printers can print technically better final parts.

A significant amount of effort and money has been invested in designing and handling print files, automating order intake and nesting software, and 3d printing ERP software. As a result of introducing quality improvement measures in post-processing, such as polishing, dyeing, automated support removal, etc., the next step was to implement these measures.

A growing number of applications are now able to be handled by AM technology, which works across both ‘core’ manufacturing applications as well as those related to aerospace and automotive. In summary, AM has proved to be a powerful technology that can cope with a wide range of applications, including those in manufacturing as well as those in the aerospace, automobile, medical, and pharmaceutical sectors.

The AM manufacturing infrastructure was not designed for sets of high volumes, let alone a mix of high volumes and high mix output

High Volume and High Mix are inevitable
To begin with, the economics of a powder bed 3D printer – industrial print’s most popular technology – dictates that it is run 24/7 and that it prints as many parts as possible. Therefore, nesting should be optimized within the building box, if not maximized.

Additionally, by using as much virgin material during one print run as possible, the possibility of reusing it by mixing it with virgin material is minimized; ensuring quality is a delicate process of balancing the two qualities of powder. One aspect of 3D printing that maximizes material efficiency is its economic value. If the demand for a print job begins to increase, instead of collecting enough suitable orders to print it – a business model still used today – lead times start to impact the economics of printing.

As with external print services as well as internal print services, volumes must be processed according to desired delivery. Due to the long lead times, printers are forced to handle both one-off and serial production, which is high mix and high volume.

 

High volume and high mix have the following effects

The growth of AM as a serious manufacturing technology is expected to be characterized by high mix and high volume production. Post-printing workflows have therefore been able to handle parts coming in all shapes and sizes.

 

 

Post-processing is currently primarily a manual labor-intensive process. There are special workstations specially designed to process printed parts and to improve the quality of the print output: de-powdering units, cleaning units, tumbling units, dyeing, spraying units, polishing units all improve the quality of the final product. Post-processing requirements vary according to the order.

Since factory parts are more variable and have higher volumes, tracing all parts is crucial. Additionally, the individual parts have their own specific menus, so all steps are carried out individually and in batches. Identifying each of these menus individually is the only way to keep track of them all. As soon as you identify parts, you can transport and route them based on their particular menus. Moreover, it is possible at the end of the workflow to combine the different parts of an order to prepare them for shipping (recombination).

Sorting and identification are currently done by hand. Expand your 3D printing output by adding one more printer upfront, and add two to three additional people to process the additional output. Due to an increase in labor costs, prices on individual parts begin to rise, which negatively impacts 3D printing’s competitive strength against traditional manufacturing techniques.

 

Automation is the way out of this loop.

 

Automation of AM workflows

There needs to be automation developed in order to implement this track and trace capability. Layers app is one of the pioneers in this area, providing 1st generation solutions to customers who have already had to face the challenge of print costs and lead times.

Make sure you have gathered all the necessary software “ingredients” before starting to use 3D printers – from modeling and preparing models, to managing the printers themselves.

Some of these are:

 

● CAD software to create a 3D model (you can also use a 3D model that already exists if you prefer or don’t need to create one).

● Slicing software

● Remote printer control software (optional, but convenient)

 

In the following article, we will go over each of these components alongside how the Ultimaker platform brings together hardware, software, and materials seamlessly, unlocking the magic of 3D printing and empowering you to make it happen.

What is a “slicer”?

Slicers – also called print preparation software or slicing software – are programs that translate 3D models into the form that a 3D printer understands.

Slicer software, such as Ultimaker Cura, digitally cuts a model into flat layers, which are then printed one by one by your printer. Due to integrations, it is not always necessary to use slicing software with the Ultimaker platform since it allows printing directly from CAD or the Ultimaker Digital Library.

What is the best CAD software for designing 3D prints?

CAD software allows you to create a 3D model from scratch using computer-aided design software. Different types of CAD software offer a variety of advantages. Since 1982, when AutoCAD, a CAD software program by Autodesk, was released, it stands out as the most popular CAD product among these. There are several CAD platforms available:

 

Fusion 360 – a great tool for designing and building mechanical parts that are efficient

 

3ds Max, a program for creating 3D models, including 3D games, architecture, and 3D printing

 

TinkerCAD – You can build 3D models on TinkerCAD, a free web-based CAD program that lets you use different shapes for your models. For STEAM education and CAD beginners

 

Blender – software for creating 3D models that is open-source

 

Siemens NX – for developing advanced 3D models

 

Solidworks – used for designing and producing industrial parts

 

CATIA – Software that is used for making surfaces and engineering systems

 

 

Choose the right CAD software for your use case before you start 3D printing. With this method, you can design and print the most useful model possible.

You should also verify which file types your slicing software can handle, so you can use it to make 3D prints of your designs.

 

What are the steps in designing 3D printed parts?

 

You can use best practices to get the best results from your 3D printer and the parts it creates when designing for 3D printing. You will reduce costs and improve product development cycle speed by designing parts optimized for 3D printing.

 

Volume should be taken into account. In order to print large 3D models, your printer must have a large build volume. You should know its dimensions before designing a part that can either be printed in one pass within those dimensions or modularized (printed separately and assembled later).

 

Make an early decision about your orientation. In FFF printing, since the layers are printed layer by layer, early orientation choice impacts design choices, text alignment, and snapping.

 

Identify the size and type of overhang support required. Parts printed with FFF are self-supporting up to 45 degrees. Under 45 degrees, overhangs must be supported from the bottom with support materials.

 

Guidelines for bridging support should be followed. FFF printing does not require support if the gap is within 10 mm.

 

The size of the nozzle is important. Height, wall thickness, and the diameter of the nozzle should be considered when designing small features. If the nozzles are larger, faster printing will occur, but your models will have a greater minimum height and thickness.

 

Make sure to consider the diameter of the holes when designing. The hole size in a 3D print should not be smaller than 2 mm. A drilling operation should be carried out if accurate holes are required. To do this, design the holes slightly larger than intended and have them post-processed after drilling.

 

Keep sharp corners to a minimum. A print could warp if the corners are modeled in CAD. In addition to increasing the contact area with the bed, it will also decrease warpage.

 

How do I start a 3D printing workflow? What software do I need?

 

You will need to perform certain steps in the workflow of 3D printing.

Typically, you will need software that can slice a 3D model to get it ready for printing, provided you already have a 3D model. The software you use to manage your 3D printer (or printers) remotely can also be used after you have started printing.

Using a 3D printer integration in your CAD tool, however, you are able to avoid this slicing step. Alternatively, you can go ahead and print a 3D printable file directly from a USB stick (e.g. G-code) without slicing software, as your digital file is already ready to be printed.