Month: September 2021

Whether you run a 3D printing business or printer farm, or even plan to start one, knowing the running costs of the business is imperative. Obviously, the cost of producing each printed part is an important factor in any business that deals with 3D printing. Even for hobbyists, it can be useful to get a sense of the costs before undertaking a large printing project.

Pricing 3D prints seems to be the most difficult aspect people face. It’s crucial to approach each job in a systematic way so that you can charge your customer fairly while also making enough profit to justify all your efforts.

In this article, we will outline how to price your 3D print projects.

how much does it cost in electricity to run a 3d printer

A 3D printer that uses a 30A 12V draws a maximum of 360 watts of power (Power = Current x Voltage). A printer with a hotbed of 205 degrees Celsius and a heated bed of 60 degrees Celsius uses 70 watts per hour, which equates to 0.7KWh for a 10-hour print. Typical 3D printers run for eight or more hours a day. FDM filament printers run for 2-3 days, meaning the printer runs continuously for more than 24 hours. The average 3D printer consumes 50 watts per hour. As a result of the non-stop nature of FDM printing, a lot of power is consumed. This may result in a large power bill. To heat their print beds, other printers require 120 Volts of electricity. Therefore, it needs a power supply of 600 watts per hour to heat up and peak the bed.

Labor Rate

To begin with, you must determine the value of your time. According to your skill level, this could range from $10 to $50 (or more!). Furthermore, you should consider supply and demand and see what others are charging in your industry. It may be difficult for you to charge more than $20/hour unless you can justify it.

Printer Rate

Due to the slow nature of 3D printing, even small changes in your printer’s hourly rate will have a significant impact on your quote. Many people are surprised at how low this number usually is. For example, charging your printers $3 per hour is not uncommon. I recommend filling in this item at the end, and then watching how it affects the final piece price as you adjust it. Using this approach, you can ensure your pricing is in line with what a customer might be willing to pay.

Design Time

Whenever you are doing design work for a project, you should figure out how long it will take you to complete all that 3D modeling. You might find this difficult in the beginning, but as you practice you will become more adept at making design estimates. As your portfolio grows, you can use actual information from past work you have completed to make educated guesses based on what you know now. Your pricing will become more competitive as you become more proficient at 3D modeling.

Slicing (Programming) Time

It is vital to factor in the amount of time required to import your model into your slicer and tweak settings, no matter whether you designed the model or received it from a client. Give yourself enough programming time to ensure you are able to produce a quality print that the customer will appreciate. If your printers have proven profiles, it may take less than 10 minutes. Models of greater complexity may require hours in which various settings are tinkered with.

Print Time

For scheduling and informing your customer about lead times, it is imperative that you estimate print time accurately. There is nothing that makes a customer more unhappy than discovering their items will take a week longer than promised. If your customer provides you with a file beforehand, you can drop it into your slicer and get an estimate quickly. You can estimate based upon similar projects that you have worked on in the past if you do not have access to the file. For the most accurate estimate, you can also use file sharing sites and similar items others have made for you.

Post Processing Time

Often, even when your printer is finished, your project is still incomplete. It’s not always necessary to remove all supports, while other times you might have to paint and sand for hours. Each project will vary in this regard, but it is important to keep this step in mind. It’s a common mistake to leave this part off of your quote, as it devalues your time.

Part post-processing costs

After a printer has finished printing a part, post-processing costs are incurred. In most cases, you need to let the part cool and then remove it from the printing surface with a spatula. If any markings have been left on a part with a support or raft, we must carefully remove them.

The best finish can also be achieved by using a file, knife to remove remaining plastic pieces and imperfections. Additionally, it is possible to post-process the piece with more advanced techniques, like sanding, painting, covering it with epoxy, gluing, etc. The possibilities for post processing are endless, but all of them require a lot of time from the person responsible for it.

Miscellaneous Cost

Any information that doesn’t fit into another category will be gathered here. Any number of fasteners or heat-set inserts could be used on the project. Although some projects may not need final touches, keeping this in mind will prevent you from forgetting important items.

Hourly printing costs

The hourly printing costs are one of the most important factors to consider when estimating the cost of 3D printing. In these costs we include all the costs that are proportional to the number of hours the machine prints our part. This includes:

Amortization cost of the machine. To calculate the cost of using any equipment, it is common to use amortization or depreciation, assuming that we wear down or consume the equipment as we use it. Another way to think about amortization is to divide the total cost of the equipment between the parts we are going to make with it, so that after some time we have “amortized” it. In order to calculate amortization, divide the printer’s price by the number of hours it will be used until it is amortized.

Electricity cost. 3D printer owners are often concerned with their printers’ energy consumption, however the truth is that electricity is one of the cheapest inputs when calculating the cost of printing in 3D. Based on our calculations (the kWh at 0.15€ and a printer that consumes 500W) the price is only 8 euro cents per hour.

Operator cost. This is the cost of having a person watch the print. It’s not relevant to a company that isn’t exclusively dedicated to 3D printing, since the printers are self-sufficient and can print without constant operator supervision. The most significant cost, however, is the labor, as we have a single employee constantly on hand to put in, take out, maintain, and monitor all the printers.

Maintenance cost

It is sometimes overlooked that maintenance is an important part of operating 3D printers. As a mechanical system, printers require periodic maintenance, just like cars and CNC machines.

Frequently, moving machine parts need to be cleaned and greased, components like the printing surface or extruder need to be renewed, or damaged components need to be replaced. The printer can be maintained by the person responsible for it or by the manufacturer, who offers maintenance and warranty plans.

Error costs

No matter how good your 3D printer is, you have to throw out parts from time to time because of printing errors, jams, laminating errors, running out of filament….

Printers have come a long way and are becoming more reliable and easy to use, but there will always be a rate of errors when printing, especially when you don’t spend enough time servicing them. Lamination also contributes to many errors. We usually decide on the optimal print orientation when we see a part and then get it printed. Some details don’t print correctly with that orientation, or with the lamination parameters we selected, so we have to repeat the printing with a different configuration.

Training cost

Training is another cost that is often overlooked, but it is very important if we want to maximize the benefits of 3D printing in our company.

In an ideal world, employees should be trained on how to exploit the technology, from the design phase for 3D printing to machine operation and maintenance. There are many companies and trainers that offer online and in-person courses, and more and more printer manufacturers are offering introductory courses when the machine is purchased.

Additional Profit Percentage

What’s usually the last stage of calculating the price of a 3D print is adding a certain percentage on top of the price of the material, print time, and manual labor combined. For example, if the cost of the material, print time, and manual labor is $20 and your markup percentage is 10%, the total price of a print would be $22.

How do you calculate material cost for 3D printing?

In 3D printing, this is a major recurring cost. To a large extent, the quality of the printing material determines how well the 3D model will turn out. Let’s look at some of the most popular printing materials.

Cost of FDM Printing Materials

FDM printers use thermoplastic filaments. In printing, filaments are selected based on their strength, flexibility, and conditions. The price of these filaments is determined by the quality of the filament.

The most popular filaments are PLA, ABS, and PETG. They are used by most FDM hobbyists due to their low price (around $20-$25 per spool). There are several color options available. LA is one of the easiest filaments to print with, but they can have the disadvantage of being too brittle or weak for some applications. Parts can be strengthened through settings like infill density, number of perimeter walls, or even printing temperature. We can move onto stronger materials if this doesn’t provide enough strength. Special purpose filaments such as wood, glow in the dark, Amphora, flexible filaments (TPU, TCU), etc. are also available. These filaments are used for special projects that require these types of materials, so their prices are above the average range. We also have high-quality filaments like metal-infused, fiber, and PEEK filaments. These are expensive filaments that are used in situations where the quality and strength of the material is critical. Prices range from $30 to $400 per kilogram.

Cost of SLA Printing Materials

SLA printers use photopolymer resin as the printing material.Resin is a liquid polymer that Hardens when exposed to UV light. There are many types of resins, ranging from the standard entry-level resins to high-performance resins and even dentistry resins used by professionals. Some of the most popular resins on the market are Anycubic Eco Resin and Elegoo Water Washable Resin. The resins allow the material to cure quickly, allowing for faster printing. The buyer can also choose from a variety of colors. Prices range from $30 to $50 per liter. There are also resins for special applications such as dental 3D printing and ceramics. The resins can be used to print anything from dental crowns to metal-infused 3D parts. The cost of these resins can range from $100 to $400 per liter.

Cost of SLS Printing Materials

Powdered media is used by SLS printers. Standard printing powder for an SLS printer is PA12 nylon, which costs between $100 and $200 per kg.Powder costs can be as high as $700 per kg for metal SLS printers, depending on the type of metal.

How Much Do 3D Printing Consumables Cost?

Electricity, maintenance costs, etc., also contribute to the price of the 3D model. Costs are determined by the printer’s size, frequency of printing, and average time of operation.Here are some consumables for these printers.

Cost of FDM Consumable Parts

FDM printers contain a lot of moving parts so, a lot of parts need to be changed and serviced regularly for the proper running of the machines. One of these parts is the print bed.

The print bed is where the model is assembled. To ensure the model sticks well to the print bed during printing, the bed is covered with an adhesive. This adhesive can be printer’s tape or a special type of tape known as Kapton tape.

The average cost for the printer’s tape is $10. Many people use glue sticks for good bed adhesion.

Instead, you can choose a Flexible Magnetic Surface which has great adhesion without requiring any extra substances. When I first got mine, I was surprised how effective it was compared to the stock bed.

Another part that needs periodic maintenance is the nozzle. Due to the extreme heat it undergoes, the nozzle has to be changed every 3 to 6 months to avoid bad print quality and misprints.

Another part is the timing belt. This is an important part that drives the print head, so it is necessary to upgrade and change it to avoid loss of accuracy. The average price of a new belt is $10, though it doesn’t require change often.

Cost of SLA Consumable Parts

For SLA printers, maintenance often involves cleaning the light sources with an alcohol solution to avoid dirt buildups that can reduce the light quality. But still, some of the parts need to be checked or changed periodically.

FEP film is one of them. The FEP film is a non-stick film that provides a way for the UV light to cure the liquid resin without it sticking to the tank. The FEP film needs to be replaced when it is bent or deformed. The price for a pack of FEP films is $20.

The LCD screen of the printer also needs to be replaced because the intense level of heat and UV rays it faces damages it after some time. The advisable time for changing the screen is every 200 working hours.

With new releases and developments of 3D printers, there is the new monochrome LCD which can actually last for around 2,000 hours without needing replacement. That’s why it’s a good idea to go above budget 3D printers in some cases.

Cost of SLS Consumable Parts

SLS printers are complex, expensive machines with high-power parts, such as lasers. Maintenance of these machines is best handled by qualified professionals, which can be very expensive.

In order to keep printers in top condition, periodic preventive maintenance such as cleaning, lubrication, and calibration should be performed regularly. This can add to labor costs.

My own experience shows that even troubleshooting can take a long time if something goes wrong or if you upgrade something without closely following a tutorial.

How Much Does a 3D Printer Cost?

The cost of 3D printing is largely determined by this. This is the cost of purchasing the 3D printer.

Let’s look at the costs of some of the most popular printing technologies at various price points.

FDM 3D Printers

FDM printers are some of the most popular on the market due to their low cost. Budget offerings like the Ender 3 V2 start at $270. This relatively low price point makes it popular with amateurs, students, and even professionals to 3D printing.

Budget FDM printers produce good print quality for the price, but for more professional prints, you’ll be looking to upgrade to a more expensive desktop printer. The Prusa MK3S is one of these.

Priced at $1,000, it straddles the range between cost and performance offering a higher print volume and great, professional print quality at a decent price.

Large volume industrial grade FDM printers like the BigRep ONE V3 from Studio G2 are available, but the $63,000 price tag is sure to put it out of the range of most consumers.

It has a build volume of 1005 x 1005 x 1005mm, weighing about 460kg. This isn’t the usual 3D printer of course, compared to the standard build volume of 220 x 220 x 250mm.

SLA & DLP 3D Printers

Resin-based printers like the SLA and DLPare used by people who want slightly better print quality and speed than what the FDM printers offer.

Cheap SLA printers like the Anycubic Photon Zero or the Phrozen Sonic Mini 4K are available in the $150-$200 range. These printers are simple machines geared at beginners.

For professionals, benchtop units like the Peopoly Phenom are available for the whopping price of $2,000.

Another respectable SLA 3D printer is the Anycubic Photon Mono X, with a build volume of 192 x 112 x 245mm, at a price tag well under $1,000.

Printers like this are used for creating fine detailed large-sized prints that budget models cannot handle.

SLS 3D Printers

SLS printers are the most expensive on this list. They cost more than your average 3D printer with entry-level units like the Formlabs fuse going for $5,000. These expensive units might not even be able to keep up with the rigors of industrial printing.Large scale models like the Sintratec S2 are ideal for this with a price range of about $30,000.

Is 3D printing cheap or expensive?

Is 3D printing inexpensive?

The hobby of 3D printing is no longer expensive or niche. Over the last decade, advances in additive manufacturing have lowered the cost of 3D printing significantly. For around 200 dollars, you can get a cheap budget 3D printer.

The price of 3D printing is affected by the size, complexity, and purpose of the model once you have a 3D printer. In many cases, these factors determine the type of printer, printing technology, and materials to be used.

Even though large 3D printers are ideal for large prints, you can actually separate models, arrange them on the build plate, then glue them together afterwards.

Among 3D printer hobbyists, especially for character models and figurines, this is pretty common practice.

On the budget end of the spectrum are technologies like FDM and resin SLA printers. Due to their relative affordability and simplicity, these printers are popular with beginners. These are usually used for aesthetic purposes rather than for functional purposes.

These budget models can produce pretty good print quality. NASA has even used these printers to create functional models aboard spaceships for astronauts. However, the quality can only be so high.

If you want better quality, you will most likely need to upgrade your printer.

For industrial and functional applications, better materials and higher precision are needed. At this level, high-level printers like the SLS are used. You get high-quality prints with great accuracy and precision from these printers.

Their prices are usually out of reach for the average consumer.

In the right industrial applications, FDM printing is definitely useful, even laying down concrete for the construction of houses.

Consumables also add to the cost of 3D models. Recurrent costs include printing materials, upgrades, replacements, electricity, and finishing costs such as spray coatings or sandpaper.

Consumables for high-level printing technologies cost more than those for their budget equivalents.

For hobbyists printing models at home, a budget desktop 3D printer will probably be adequate.

Their printing materials are cheap, they only require a minimum amount of consumables like electricity, and they are very easy to use.

Keeping prices low requires getting a high quality 3D printer, which can cost a little more than those very budget options.

Is 3D Printing Cost-Effective for Making Things?

Making objects with 3D printing is cost-effective. Common models or objects can be easily manufactured and customized with a 3D printer. Consequently, this helps reduce the cost of these objects and streamline the supply chain. They are especially cost-effective if you combine them with CAD skills.

However, 3D printing does not scale well. Currently, 3D printing is only cost-effective over traditional methods when it comes to manufacturing small objects in small batches due to current technology limitations.

The cost-effectiveness of 3D printing decreases as models grow in size and quantity.

In terms of 3D printing and its effect on industries, a very interesting fact is how it has taken over the hearing aid market.

For specialized objects that can be customized for each individual, 3D printing is perfect. Over 90% of hearing aids manufactured today are made using 3D printers since 3D printing was adopted into the hearing aid industry.

The prosthetics industry has also made huge strides, especially for children and animals.

Depending on the industry, 3D printing can be a very cost-effective and rapid way to manufacture many objects. As technology advances in 3D scanning and software, the process of creating designs is becoming much easier.

 

with hundreds of industrial-grade 3D printers for business and manufacturing, it’s not easy to find the best fit for your needs. Whether you’re buying your first printer or your tenth, evaluating the latest technology and newest companies can be a challenge.

Your first step should be to understand your needs, then to learn about 3D printing technology, and finally to narrow down your search to select manufacturers. Additionally, you’ll need to request and evaluate sample prints, understand the factors that contribute to cost, and then create a business case for upper management.

Plan your 3D printer purchase based on a business case

Find out why you want a printer before deciding which to buy. What business needs will 3D printing address, what strategic goals will 3D printing help your company achieve, or what new opportunities will 3D printing present to your company? Link these needs to your company’s overall strategic plan, and detail them clearly in a 3D printing proposal designed to capture management’s attention. Consider these questions when determining your printer purchasing objectives.

 

Do you wish to purchase a 3D printer to:

• to lower prototyping or tooling costs?
• as a means to make prototyping iterations or production part prints faster?
• to produce spare parts on-site, at the time of need?
• to improve your overall production efficiency?
• to gain a competitive edge by getting new products to the market faster?
• to print unique parts that cannot be made any other way?
• to reduce material costs or waste?
• to keep the development of your intellectual property in-house?
• to offer customized products to customers (such as in healthcare or consumer products)?

To establish your printer selection criteria, you need to determine what business needs your printer will satisfy. You may find along the way printers and materials that will help you with problems you didn’t know you had and open the door to new opportunities you hadn’t imagined.

Here’s how companies are taking advantage of 3D printing today

It’s useful to find companies that faced the same printer purchasing challenges that you are facing now in order to better define your needs. Case studies are a great way to learn how similar companies made purchasing decisions. You can find case studies on manufacturer websites, although they can be a bit biased.

Hire a consultant who can help you with 3D printing

The process does not have to be performed by you alone. In addition to printer resellers, 3D printing consultants are available to guide you through the process of assessing your needs and evaluating your options.

Many printer manufacturers have created consulting subsidiaries, such as Additive Minds 3D Printing Consulting by EOS and AddWorks by GE. Also, the usual suspects in business consulting, such as Deloitte, PwC, and EY, provide experts in additive manufacturing, as well as useful industry research and summits.

There are also a number of smaller, independent consulting firms that specialize in sectors (such as healthcare and automotive) or applications (such as prototypes, metal spare parts, etc.) that fall within the additive manufacturing spectrum.

 

What you have to know before purchasing a 3D printer

Throughout the years, 3D printing technology, materials, and software have evolved continuously. Even if you have solid base knowledge, stay up-to-date.

Types of 3D Printers

You may not yet know which kind is right for you, so you must familiarize yourself with different types of 3D printing technologies.

Types of Materials

There is a huge range of materials you can 3D print, from titanium to paper and everything in between. View these articles to see what is most commonly printed in which materials. You should also familiarize yourself with the general cost of materials, which can vary widely, and whether you want a printer that prints with third-party materials or only with those from the manufacturer.

Types of Software for Digital Design & Printing

Although you may already be familiar with the range of software used for digital design, from AutoCAD to SolidWorks, 3D printing has some unique applications and file formats to master if you want to make the most of your prints.

The Top Professional & Industrial 3D Printer Brands

There’s no longer a clear distinction between a consumer 3D printer and one used in a business or manufacturing environment. Many printer manufacturers popular with consumers, including Ultimaker and Formlabs, have transitioned to professional markets while maintaining their ease of use. Advances in technology have also allowed powerful printers to take up less space. In summary, stay flexible.

In some industry reports, anything below $5,000 is not considered an “industrial” machine, but this can be misleading. Using labels such as industrial or professional does not necessarily reflect industry standards, capabilities, or feature levels, so feel free to be skeptical about their applications.

When you narrow your printer search using detailed criteria of what you need, you’re likely to find a wide range of printer price points from a long list of manufacturers.

Here’s how to request a sample print you can count on

You may not be able to see a large industrial machine in action without visiting the manufacturer, a customer, or a trade show, but you can always request sample prints.

Ask manufacturers to print a sample of a part that is representative of your typical printing needs, and resist manufacturers who try to dictate your sample print. Be sure to request a print sample that accurately reflects the complexity and material of the parts you intend to print. When comparing different models from the same manufacturer, request the same print from both machines (where possible).

You’re good to go if you already have a CAD model of your part. You may need to hire an industrial design firm to scan your part and create a digital file if it doesn’t exist digitally.

The manufacturer should provide you with a report stating exactly how long the part took to complete, what post-processing was required (if any), and how much material was used. By using this information, you can estimate 1) how many printers you need to meet your output goals, 2) how much material costs you should budget for, and 3) what additional equipment you might need.

Test Your Sample Part

Review your prints’ functionality, weight, feel, and strength, as well as any other features that are critical to your needs. You can also share it with the staff who will be working on it to get their feedback. Compare sample parts from several vendors and submit them to the same tests and evaluations.

 

Expenses not anticipated

In order to make an informed purchase decision, it’s important to know how to calculate the total cost of a 3D printer. The sticker price of your machine is only one factor to consider.

When estimating the amount of your final investment, take into account the costs of:

• the printer
• materials, including whether or not you’re locked in to buying materials from the manufacturer or can buy third-party materials
• required additional equipment, such as a furnace to sinter metal parts or a wash-and-cure station for resin parts
• optional equipment, such as a print monitoring system
• a production space, which may require special ventilation, sinks, tables, etc.
• software subscription in addition to standard design and slicing programs, which may include simulation software,
• training staff, including designers, engineers, and machinists
• installation and maintenance, which may include travel expenses if the reseller is far away

Materials can significantly increase your 3D-printing budget. For many reasons, it is normal to underestimate how many prints you will do. A final satisfactory print will require a lot of experimenting. The process of additive manufacturing is complex and involves many variables. Despite optimizing your digital design and testing it with simulation software, small inconsistencies in the surface finish or materials can affect your final print. Additionally, unpredictable effects can always occur during the printing process.

Find out how often the printers fail by talking to the manufacturer.

Another reason you may underestimate your material costs is that you may find that 3D printing has more applications than you originally anticipated. Some companies buy 3D printers to produce prototypes and then realize its benefits for end-use parts, such as tools and fixtures, or even production parts.

The price of industrial 3D printers is declining as more companies enter the market. In addition, keep in mind that price and size aren’t always a reflection of quality, so compare a variety of machines.

 

Where is the best place to buy?

During your printer decision journey, you probably worked directly with manufacturers. At some point, they may refer you to a local reseller who will handle purchases, installations, training, maintenance, supplies, etc. Additionally, you can buy machines that bridge the consumer and professional categories, and don’t need installation or service, through a variety of resellers and online sellers, including Dynamism, iMakr, and MatterHackers.

There may be few resellers available for larger machines, so it is important to know what to expect from them. For example:

• How well do they know the machine?
• When will the initial installation take place?
• Do they offer training?
• What is the turnaround time for repairs?
• Is it possible to bundle additional items with the printer (software, post-process equipment, training) to make the deal more attractive?
• It is common for printer manufacturers to have a number of resellers that specialize in different industries, such as higher education, dental, and hospitals, which require specific knowledge.

A printer manufacturer’s resellers will submit bids on the same proposal if your company or government procurement office requires multiple bids on major equipment. Resellers can negotiate their own prices with manufacturers, but their profit margins can be lowered or they can bundle other items or services to make their offers more attractive.

Manufacturers today also offer leasing instead of buying as an alternative to financing.

The investment casting process, also known as precision casting or lost-wax casting, involves the forming of a ceramic mold from a wax pattern. Wax patterns are made in the exact shape of the item to be cast. Refractory ceramic is used to coat this pattern. Once the hardened ceramic material has been turned upside down, the wax melts and drains out. Hardened ceramic shells become disposable investment molds. The molten metal is poured into the mold and allowed to cool. The metal casting is then removed from the spent mold. The process of “investing” (enclosing) a pattern with refractory materials is called investment casting. The advantages of investment casting over other molding methods include fine details and excellent surface finishes as-cast. Castings with thin walls and complex internal passageways are also possible. Investment casting does not require a draft, as does sand casting.

The process quality can produce net shape or near net shape castings, resulting in significant material, labor, and machining cost savings for the customer. It can be made from most common metals, such as aluminum, bronze, magnesium, carbon steel, and stainless steel. Turbine blades, medical equipment, firearm components, gears, jewelry, golf club heads, and many other complex machine components are manufactured with investment casting.

 

A Description Of The Investment Casting Process

There are several steps involved in the investment casting process: die construction, wax pattern making, ceramic mold creation, pouring, solidification, shakeout, and cleanup.

 

Metal die construction

In investment casting, the wax pattern and ceramic mold are destroyed, so each casting requires a new wax pattern. The wax patterns must be manufactured from molds or dies unless the investment casting is being used to produce a very small volume (such as for artistic work or original jewelry).

When calculating the size of the master die, it is important to take into account the shrinkage of the wax pattern, the shrinkage of the ceramic material invested over the wax pattern, and the shrinkage of the metal casting itself.

Wax pattern production

A wax pattern is always necessary for every casting; each casting needs a wax pattern.

The mold or die is filled with hot wax and allowed to solidify. Any internal features may require cores. The wax pattern is an exact replica of the part to be manufactured. Wax is used instead of molten metal in this method, which is similar to die-casting.

Mold creation

The wax mold is equipped with a gating system (sprue, runner bars, and risers). Several wax patterns are attached to a central wax gating system in order to form a tree-like assembly for smaller castings. In order to introduce molten metal into the mold, a pouring cup is normally attached to the end of the runner bars.

An assembled “pattern tree” is dipped into a slurry of fine-grained silica. Each time it is dipped, more refractory slurry is added. As the refractory coating reaches the desired thickness, it is allowed to dry and harden; the dried coating forms a ceramic shell around the patterns and gating system.

It is determined by the size and weight of the part being cast, as well as the pouring temperature of the metal. Walls are typically 0.375 inches thick. (9.525 mm). The hardened ceramic mold is placed in an oven and heated until the wax melts and drains away. As a result, a hollow ceramic shell is created.

Pouring

A ceramic mold is heated between 1000°F and 2000°F (550°C and 1100°C). Heating further strengthens the mold, removes any remaining wax or contaminants, and evaporates water from the mold material.

While still hot, molten metal is poured into the mold – liquid metal flows into the pouring cup, through the central gating system, and into each mold cavity. Metal flows easily through thin, detailed sections due to the preheated mold. As the mold and casting cool and shrink together, the casting has improved dimensional accuracy.

Cooling

After the metal has been poured into the mold, it cools and solidifies. The time it takes for a mold to cool into a solid state depends on the material used and the thickness of the casting.

 

Shakeout

As the casting solidifies, the ceramic molds break down, and the casting can be removed. Typically, ceramic molds are broken up manually or with water jets. Using methods such as manual impact, sawing, cutting, burning, or cold breaking with liquid nitrogen, the individual castings are separated from their gating system tree.

 

Finishing

Grinding or sandblasting operations are typically used to smooth the part at the gates and remove imperfections. Depending on the metal from which the casting was poured, heat treatment may be employed to harden the final product.

 

The Best Time To Use Investment Casting

Because of its complexity and labor requirements, investment casting is a relatively expensive process – although the benefits often outweigh the costs. Almost any metal can be investment cast. Typically, investment cast parts are small, but the process can be effectively applied to parts weighing 75 pounds or more.

As-cast investment casting can produce complex parts with excellent surface finishes. Because ceramic shells break away from the part upon cooling, investment castings do not require a taper to remove the components from their molds. With this production feature, castings with 90-degree angles can be designed without shrinkage allowance, and without the need for additional machining. Investment casting produces parts with superior dimensional accuracy; net-shaped parts can often be produced, and finished forms often do not require secondary machining. To produce wax patterns, each unique casting run requires a new die. Investment casting tools can be quite expensive; tooling costs can range from $1000 to $10,000, depending on their complexity.

For high volume orders, the time and labor saved by eliminating or reducing secondary machining easily offset the cost of new tooling. Investments in small casting runs are less likely to be recouped. If you need to make more than 25 parts, investment casting is a logical choice.

It usually takes 7 days for a wax pattern to become a complete casting; the majority of that time is spent creating and drying the ceramic shell mold. Castings can be produced more quickly at some foundries that have quick-dry facilities. The labor-intensive nature of investment casting affects more than just cost. Because investment casting foundries have limited equipment and production capacity, lead times are typically long.

3D Printing ERP Software will Transform Manufacturing

3D Printing, also known as additive manufacturing, has been causing a ton of waves throughout the world in manufacturing. Cutting-edge manufacturers will find 3D printing a compelling investment due to its ability to rapidly adapt to customization, as well as its high cost-efficiency.

Increasing technical sophistication necessitates the gathering of valuable business intelligence as well as the monitoring and controlling of processes. Building a successful infrastructure for 3D printing manufacturers will require powerful enterprise resource planning (ERP) software.

What Is Enterprise Resource Planning (ERP)?

Enterprise resource planning (ERP) is the process by which companies manage and integrate the key elements of their business. ERP includes enterprise performance management, software that helps an organization manage its finances by planning, budgeting, predicting, and reporting. Business process management systems tie together multiple processes and enable the flow of data between them. ERP systems eliminate information duplication by bringing together an organization’s shared transactional data from a variety of sources into a single database. Many companies and industries use ERP systems today. ERP is as necessary to these companies as electricity keeps the lights on.

ERP applications aid companies in implementing resource planning by integrating all of the processes that companies need in order to run their businesses in one place. An ERP software system can also integrate planning, purchasing inventories, sales, marketing, finance, and human resources.

Understanding Enterprise Resource Planning

A large organization’s enterprise resource planning system is like the glue that binds together its various computer systems. With no ERP application, each department would have its own customized system. With ERP software, each department retains its own system, but all of them can be accessed with one application.

ERP applications also allow the different departments to communicate and share information more easily with the rest of the company. It collects information about the activity and state of different divisions, making this information available to other parts, where it can be used productively.

By linking information about production, finance, distribution, and human resources, ERP applications can help corporations become more self-aware. As ERP applications integrate different technologies used by different parts of a business, they can eliminate duplicate and incompatible technology costs. Customers’ databases, accounting systems, stock control systems, and order monitoring systems are often incorporated into one system.

Over the years, ERP models have evolved from traditional client-server software to cloud-based software that can be accessed remotely.

Benefits of Enterprise Resource Planning (ERP)

Enterprise resource planning (ERP) is used by businesses for a variety of reasons, such as expanding business, reducing costs, and improving operations. Benefits sought and realized by one company may differ from those realized by another; however, there are a few worth mentioning.

Integrating and automating business processes reduces redundancies, improves accuracy, and increases productivity. Efforts from departments with interconnected processes can now be synchronized to achieve better results.

The reporting of real-time data from a single source can be beneficial for some businesses. Companies need accurate and complete reporting in order to plan, budget, forecast, and communicate the state of operations to the organization and interested parties, such as shareholders.

ERP systems assist businesses in quickly accessing information for clients, vendors, and business partners, resulting in higher customer satisfaction, faster response times, and increased accuracy. The associated costs decrease as the company operates more efficiently.

As a result, employees can better see how each functional group contributes to the company’s vision and mission; a newly synergized workforce can improve productivity and employee satisfaction. Furthermore, employees are freed up from menial, manual tasks, which allows them to devote more time to meaningful tasks.

What Are the Benefits of an ERP?

Having a modern ERP system allows for free flow of communication throughout an organization, resulting in increased synergies between business lines, increased efficiencies as processes are streamlined, and information is readily available to those who require it; and reduced costs associated with outdated technology. The adoption of an ERP can be costly, but the return on investment (ROI) can be quickly realized. Clearly, the benefits realized (e.g., increased productivity and lower administrative costs) may far outweigh the costs of implementing an ERP.

What Should an ERP System Include?

The components of an ERP system depend on the needs of the organization. However, there are a few key features that every ERP system should have. An ERP system should be automated –to reduce errors –and flexible, so that it can be altered as the company grows or changes. Mobile devices are becoming increasingly popular; therefore, ERP platforms should allow users to access them via mobile devices. Lastly, an ERP system should provide a means for analyzing and measuring productivity. The system can be integrated with other tools to improve a company’s capabilities.

 

The Future of Additive Manufacturing Will Be Shaped by ERPs

 

A deep understanding of the 3D printing market will require the use of abundant data mining and information. ERP systems will be necessary to acquire this data and offer companies the competitive advantages they need to lead the industry. 3D printing will require companies integrating ERPs to understand the total cost of resources including labor hours, materials, and even sales and marketing.

Integrated ERP systems, like Layers app ERP software, collect information and automate processes that can shed light on the definition of efficiency in the additive manufacturing industry. An enterprise-wide resource management platform is necessary to strategize business growth through decisions based on informed data, reducing the requirement for manual labor and increasing the need for unique materials and skilled engineers.

ERPs will enable better prototyping capabilities

At the start, 3D printing was especially useful for manufacturing prototypes or proofs-of-concept. A physical model of a new idea (or improvements to an existing idea) allows inventors and innovators to demonstrate concrete and tactile examples of their ideas. Engineers and designers can scale and adapt formulas for improvement by using ERPs’ powerful quoting, modeling, and quoting modules.

By encouraging businesses to experiment with various inputs and CAD models and compare the effects of variable changes to the final product, ERPs will enable more advanced prototypes. By linking advanced data management tools to cost and materials input, managers and analysts can easily spot trends and make smart decisions about prototypes.

How ERP and Additive manufacturing interact

Production planning, inventory tracking, and analysis are integral parts of ERP solutions that drive the manufacturing industry.

In the coming years, additive manufacturing and 3D printing will reshape how companies use their ERP systems. Embracing additive manufacturing in their supply chains and logistics operations will affect ERP systems and functionality in several ways.

Planning, creation, and procurement of material data

A manufacturing or distribution company typically has an ERP system in place to manage supplies, procurements, inventory, shipments, and other aspects of moving products and materials globally. Data analysis is another feature of ERP systems that continually improves operations by simplifying logistics and streamlining supply chains.

ERP solutions are able to track all aspects of additive manufacturing, from the procurement of raw materials to the management of inventory (printers and materials) to relationships with suppliers and license deals necessary for designers and manufacturers. As 3D printing becomes more popular across different types of supply chains and industries, ERP systems will likely evolve to incorporate specific modules for the creation of 3D printing materials and products.

Management of time and raw materials (Product Management and Conservation)

A key component of additive manufacturing is the integration of digital data. 3D printed objects are created from digital images or scanned drawings made to scale from digital images. Besides managing inventory and supplier relations required for additive manufacturing, ERP software is also very useful for managing costs and procuring materials. By analyzing the patterns and trends emerging in 3D printing operations, AI-enabled ERP systems can help maintain efficiencies throughout the additive manufacturing process. Utilizing advanced analytics, data visualization, and modeling, the system can make predictions for future materials needed (based on consumption and use) and identify any inefficiencies that need to be addressed in your processes. In addition to reducing raw material waste, it will also save time and energy in the supply chain.

Almost every kind of product and process will be affected by the 3D printing revolution, especially in terms of quality and cost. Specifically, additive manufacturers as well as conventional manufacturers interested in incorporating additive manufacturing can use ERP software to encourage the use of this innovative process.

Through the creation of the same digital workspace and automating the background processes of your entire operation, business management systems like CSI can assist your entire operation. By defining user roles and eliminating menial tasks, you can make your team more valuable by allowing them to focus on learning and understanding additive manufacturing. You can create a more open-minded shop floor culture when you empower your team to learn.

 

 

Binder jetting is an additive manufacturing technique in which a printhead selectively deposits a liquid binding agent over a thin layer of powder particles – metal, sand, ceramics or composite – in order to create unique, high-value components. A map from a digital design file is used to repeat the layering process until the desired result is achieved.

 

Turning industrial powders into tools and parts 

Binder Jetting is a family of additive manufacturing processes. In Binder Jetting, powder bed areas are selectively smeared with a binder, which bonds area by area to form solid parts one by one. Metals, sand, and ceramics in the granular form are commonly used in Binder Jetting.

The application of binder jetting includes the fabrication of full-color prototypes (such as figurines), the manufacture of large sand casting cores and molds, and the production of low-cost 3D printed metal parts.

For those who intend to use the benefits of Binder Jetting to the fullest, it is crucial to understand the basic mechanics of the process and how they relate to its key advantages and limitations.

Binder Jetting: How does it work?

 

The Binder Jetting process involves the following steps:

1. The build platform is coated with powder with the help of a recoating blade.
2. Following that, a carriage equipped with inkjet nozzles (like those used in desktop 2D printers) passes over the bed, selectively depositing drops of glue (binding agent) to glue the powder particles together. Full-color Binder Jetting also incorporates this step of distributing colored ink. Each drop is approximately 80 *m in diameter, so good resolution is possible.
3. In order to recoat the surface, the build platform moves downwards at the end of each layer. The process is repeated until the whole part is complete.
4. The part is encapsulated and cured in powder after printing. Pressurized air is then used to remove the excess powder unbound from the part and clean the part.

Most materials require some post-processing. Metal Binder Jetting parts, for example, must be sintered (or otherwise heat treated) or infiltrated with a low-melting-temperature metal (usually bronze). To improve the vibrancy of colors, prototypes are also filled with acrylic and coated. Typically, sand casting cores and molds can be used immediately after 3D printing.

As a result of this, the parts leave the printer in a “green” state. As green parts, Binder Jetting parts suffer from poor mechanical properties (greatly brittle) and have high porosity.

Binder Jetting Characteristics

Parameters for the printer

A machine manufacturer sets most of the process parameters in Binder Jetting.

In general, the layer height varies with the material: full color models typically have 100 microns of layer height, metal parts typically have 50 microns of layer height, and sand casting mold materials typically have 200-400 microns of layer height.

Bonding occurs at room temperature, making Binder Jetting unique among other 3D printing technologies. Binder Jetting is not prone to thermal distortions (such as warping, DMSL/SLM, or curling) that result from thermal effects.

Therefore, Binder Jetting machines have the largest build volume of any 3D printing technology (up to 2200 x 1200 x 600 mm). Molds for sand casting are generally produced by these large machines. A metal binder jetting system has a larger build volume than a DMSL/SLM system (up to 800 x 500 x 400 mm), permitting the parallel manufacturing of multiple parts at once. Due to the post-processing step involved, the maximum part size is limited to 50 mm.

Additionally, Binder Jetting does not require support structures: the powder surrounding the part provides all the necessary support (like SLS). Binder Jetting differs from other metal 3D printing processes in that it does not require extensive support structures, allowing for the creation of freeform metal structures with minimal geometric restrictions. As we will see in a later section, metal Binder Jetting is prone to geometric inaccuracies due to post-processing steps.

Because the parts in Binder Jetting do not need to be attached to the build platform, the entire volume of the build can be utilized. Therefore, Binder Jetting is suitable for small-to-medium-sized batches. The entire build volume of the machine (bin packing) must be filled effectively in order to use the full capabilities of Binder Jetting.

Binder jetting in full color

Like Material Jetting, Binder Jetting can produce full-color 3D printed parts. Due to its low cost, it is often used for 3D printing figurines and topographical maps.

The models are printed in full color using sandstone powder or PMMA powder. First, the main printhead jets the binding agent, then a secondary printhead jets a colored ink. In a similar way to a 2D inkjet printer, different colors of ink can be combined to produce a wide array of colors.

To enhance part strength and color vibrancy, the parts are coated with cyanoacrylate (super glue) or a different infiltrant after printing. Additionally, a secondary epoxy layer can be added to improve both strength and appearance. Even with these additional steps, full-color Binder Jetting parts are still very brittle and should not be used for functional applications.

A CAD model containing color information is required to produce full-color prints. You can apply color to CAD models in two ways: on a per-face basis or as a texture map. Adding color to each face is a quick and easy process, but using a texture map gives you greater control and detail. For specific instructions, consult your native CAD software.

The metal binder jetting process

Compared with other metal 3D printing processes (DMSL/SLM), Binder Jetting is up to 10x more economical. Binder Jetting’s build size is considerable, and the parts are produced without the need for support structures, allowing complex geometries to be created. Metal Binder Jetting is therefore a very attractive technology for low-to-medium metal production.

Metal Binder Jetting parts are not suitable for high-end applications due to their mechanical properties. Nevertheless, the material properties of the produced parts are the same as those of metal parts produced by Metal Injection Molding, which is one of the most widely used manufacturing methods for mass-producing metal components.

The process of infiltration and sintering

To achieve good mechanical properties, Metal Binder Jetting parts require a secondary process after printing, like infiltration or sintering, since the as-printed parts mostly consist of metal particles bound together with a polymer adhesive.

Following printing, the part is placed in a furnace, where the binder is burned out, leaving voids. Approximately 60% of the part is porous at this point. Using capillary action, bronze is then injected into voids, resulting in parts with low porosity and good strength.

When printing is complete, the parts are placed in a high-temperature furnace, where the binder is burned away and the metal particles are sintered together (bonded), resulting in parts with very low porosity.

Metal Binder Jetting Characteristics

Model accuracy and tolerance can vary greatly depending on the model and are difficult to predict because they are dependent on geometry. The shrinkage of parts between 25 and 75 mm is estimated to be between 0.8 and 2%, whereas the average shrinkage of larger parts is between 3% and 4%. During sintering, parts shrink by approximately 20%. Binder Jetting’s software compensates for shrinkage during the design stage, but non-uniform shrinkage may have to be accounted for when the machine operator operates the machine.

Inaccuracies can also occur during the post-processing step. The temperature of the part is raised during sintering, which makes the piece softer. An unsupported area may deform under its own weight when it is in this soft state. Further, as the part shrinks during sintering, there is friction between the furnace plate and the lower surface of the part, causing warping. To ensure optimal results here, communication with the Binder Jetting machine operator is key.

Sintered or infiltrated Binder Jetting metal parts will have an internal porosity (sintering produces 97% dense parts, while infiltration is approximately 90%). This affects the mechanical properties of metal Binder Jetting parts, as the voids can lead to crack initiation. Fatigue and fracture strength and elongation at break are the material properties that are most affected by internal porosity. Advanced metallurgical processes (like Hot isostatic pressing or HIP) can be applied to produce parts with almost no internal porosity. For applications where mechanical performance is critical though, DMLS or SLM are the recommended solutions.

The surface roughness of metal Binder Jetting parts is an advantage over DMLS/SLM. Metal Binder Jetted parts typically have a surface roughness of Ra 6 *m after post-processing, which can be reduced to Ra 3 *m if a bead-blasting step is used. Comparatively, the surface roughness of DMLS/SLM parts is approximately Ra 12-16 μm. This is particularly important for parts with internal geometries, such as internal channels, where post-processing is difficult.

Binder jetting: Benefits & Limitations

The key advantages and disadvantages of the technology are summarized below:

1. Binder Jetting produces metal parts and full-color prototypes at a fraction of the cost compared to DMLS/SLM and Material Jetting respectively.
2. Binder Jetting can manufacture very large parts and complex metal geometries, as it is not limited by any thermal effects (e.g. warping).
3. The manufacturing capabilities of Binder Jetting are excellent for low to medium batch production.
4. Metal Binder Jetting parts have lower mechanical properties than DMSL/SLM parts, due to their higher porosity.
5. Only rough details can be printed with Binder Jetting, as the parts are very brittle in their green state and may fracture during post-processing.
6. Compared to other 3D printing processes, Binder Jetting offers a limited material selection.

 

Guidelines

1. Use metal Binder Jetting to 3D print metal parts at a low cost, for applications that don’t require very high performance.
2. Binder Jetting provides more design freedom than DMLS/SLM for metal 3D printed parts, as thermal effects are not an issue during the manufacturing process.
3. It is only suitable for visual purposes, as Binder Jetting is very brittle.
4. Binder Jetting can be used to produce very large sand casting cores and molds.

One of the most promising fields for 3D printing applications is the medical industry, which requires customizable, biocompatible, and sterilizable plastic and metal components. Although additive manufacturing may seem like science fiction, a growing number of medical applications are being developed using this technology every year.

Using 3D printing, patients are able to obtain efficient and affordable custom implants, prosthetics, and devices; it gives doctors new tools to perform their jobs more effectively; and it enables medical device manufacturers to design better products more quickly. Research is even being conducted to print living tissues and organs in 3D!

3D printing for medical purposes has many advantages

Why is 3D printing so useful in the medical field? 3D printing aligns well with the capabilities of modern medicine in many ways.

It is necessary to design implants, prostheses, devices, anatomical models, and even tools according to the specific needs of each patient. The process of customization is time-consuming and expensive with traditional technology. As an alternative, 3D printing can produce small runs of custom parts at no extra cost and without any tooling or setup time. Human bodies are among the most customized of all products, and additive manufacturing excels in these applications.

It is common for medical devices to have complex designs, internal geometries, or organic shapes. Consider, for instance, the spirals and hollow spaces on a hearing aid or a heart! Traditionally, these shapes would be difficult or impossible to make.

With 3D printing, one piece geometries can be easily produced in plastic or metal with high accuracy. This can lead to improved designs as well as reduced costs and production times. In addition to facilitating easier sterilization, eliminating crevices and gaps between multiple parts makes devices more difficult to grow bacteria on.

A device’s materials are as important as its design when it comes to medical devices. The printing of 3D materials offers mechanical, chemical, and thermal properties that make them perfect for use in biocompatible and sterilizable material. You can print 3D printed components that are rigid or flexible and smooth or textured. Almost any application can benefit from 3D printed materials.

Compared to other technologies, 3D printing also offers unparalleled production speeds. The treatment of patients is no different. Because of the lengthy timeline for traditional manufacturing, patients often have to wait months to be able to begin their treatment program or go to multiple doctors and undergo multiple intrusive procedures to wear and rewear their medical devices. The patient is inconvenienced and may experience additional discomfort at best. The patient’s condition can worsen or even be fatal if there are delays in treatment.

As a final benefit, 3D printers have made it possible for medical professionals to eliminate plaster casts by using 3D scanning and x-rays to quickly create 3D models, eliminating the need to store countless physical casts. Besides saving space, this also reduces the potential for damage from mishandling or aging. A 3D model is an accurate, permanent model that can be accessed anywhere, saving time and money for medical professionals.

Using 3D printing in the medical field

3D Printed Prosthetics

Prosthetic medicine requires intense customization, which makes the fabrication of prostheses time-consuming and expensive. Since these devices and their sockets are subject to rigorous use, a perfect fit is critical in creating a reliable, comfortable and functional prosthesis for the patient. All of these reasons and more have contributed to the revolution in the field of 3D printed prostheses.

In general, multiple castings and follow-up appointments are necessary to fine-tune the fit of the prosthesis. Patients who may be sensitive about their condition often feel that this is more than just an inconvenience: Having a cast made can be uncomfortable, and the many fittings can be invasive. Not to mention that the time spent on fitting and re-fitting represents the time without a properly fitted prosthesis.

By using 3D printing, patients no longer have to wear a physical cast. As an alternative, technicians can use 3D scanners to quickly create a 3D model of the residual limb. Based on this 3D scan, a 3D-printed socket can be made that is both accurate and affordable, which typically only requires a single fitting to complete.

 

Devices and implants customized for each patient

Customization is not limited to the field of prosthetic medicine. Devices (like hearing aids) and implants (such as artificial joints, cranial plates, and even heart valves) are increasingly turning to 3D printing for its flexibility and speed.

The traditional way of adjusting hearing aids and heart valves has been extensive, handcrafted adjustments over a week or more. From casting to fitting, a hearing aid required nine steps before 3D printing. Hearing aids can now be scanned and printed in a single day with 3D scanning.

There are also design advantages: 3D printed silicone heart valves provide an exact fit that rigid, traditionally manufactured heart valves simply cannot. Implants such as titanium artificial joints or cranial plates can be printed with complex, porous surfaces that are less likely to be rejected by patients’ bodies.

 

Orthodontics and dentistry

Orthodontic devices and dental implants require extensive customization with high precision. Dentures, crowns, implants, and retainers must be durable, precise, and comfortable because our teeth stand up to heavy use day after day. Additionally, they need to be made of biocompatible materials such as cobalt chrome and porcelain.

Using 3D printing, dental and orthodontic professionals can accomplish all of that faster and at a lower cost than traditional methods like machining. Dental devices can be produced quickly and easily using 3D scans and x-rays rather than castings or setups.

In the case of devices such as braces or expanders that do not require 3D printed components, 3D printed models made from sterilizable plastics can be used to measure form and fit, eliminating the need for patient fittings or repeat visits.

 

Development of medical devices

Research, development, and certification of medical devices are extremely time-consuming and resource-intensive. Often, the high price of medical devices is not caused by manufacturing costs, but by expensive product development. Because 3D printing offers a variety of biocompatible and sterilizable materials, it allows medical device developers to produce and test functional prototypes in a fraction of the time, resulting in better products and lower costs.

The advantages of additive manufacturing for product development include its quick turn-around time, ease of alterations and low cost for very small volumes of parts. It can save businesses hundreds of thousands of dollars and months of time in product development. Medical devices must undergo a rigorous and lengthy certification process, so these time and cost savings are especially valuable.

 

 

Customized surgical instruments

Precision and efficiency are critical in the operating room. The unique challenges of each procedure cannot be overstated-each patient’s body is different, as are the hands of each surgeon. If fine control is essential, why should surgeons be restricted to one-size-fits-all tools?

By using 3D printing, personalized surgical tools can be produced quickly and affordably, tailored to the particular needs of each surgeon and each procedure. These tools are made of sterilizable and biocompatible plastics and metals. These tools can be made so quickly that hospitals don’t need to keep a large back stock of instruments, but instead can order them as necessary.

Instruments that are customized to the size and shape of each surgeon’s hands, along with customized features tailored to each application, can greatly improve outcomes and efficiency. Moreover, surgical guides made specifically for each patient can increase accuracy while decreasing the amount of time spent in the operating room by eliminating the need to consult diagrams and assistants.

 

 

Models of custom anatomy

Anatomical models are expensive, and even the best offer a limited range of options. Professionals and students regularly use models for education, training, surgery preparation, and to provide visual aids to patients.

3D printing can help medical professionals and educators create affordable custom anatomical models. Surgeons can practice difficult surgeries using patient-specific models that reproduce exactly what they will encounter during surgery.

 

 

Bioprinting

Wouldn’t it be interesting if 3D printers used cells and organic matter instead of plastic and metal? That’s the basic concept of bioprinting—the cutting edge of 3D printing in the medical industry.

Although most bioprinting technologies and applications are still in their infancy, researchers have successfully printed bones, skin, and cartilage. One day, we may even be able to 3D print functioning organs.

Bioprinting works similarly to other 3D printing techniques: material is deposited or solidified in successive layers to create 3D objects. In bioprinting, however, the cells are cultivated from tissue samples or stem cells. A binding gel or collagen scaffold holds the cells together.

Bio printed body parts and organs would allow the patient’s own tissue to grow over the 3D printed parts and eventually replace the cells with their own. While we’re unlikely to see functioning bio printed organs anytime soon, the technology is already helping researchers conduct research on living tissues without having to take them from a living organism.

 

 

3D-printed medical materials

Not all materials are created equal when it comes to medical products. As microorganisms can cause life-threatening infections, medical devices and implants must be sterilizable. A product that will come into contact with tissue must also be biocompatible, which means it will not produce harmful reactions if placed in a biological system. In particular, implants must be made of materials that are likely to be accepted by recipients’ bodies. Our bodies’ fluids are surprisingly corrosive over time, which is why corrosion-resistance is just as important. In order to withstand heavy long-term use, implants must be strong, durable, and lightweight.

Modern 3D printers are compatible with a range of plastics and metals that meet these requirements. We’ve outlined a few of the most commonly used 3D printed materials for the medical industry below.

 

Nylon PA-12

Plastics like this are lightweight, corrosion-resistant, durable, and can be sterilized with steam autoclaves. The nylon PA-12 is flexible and chemically resistant. Additionally, it is among the fastest and most affordable medical-grade materials to print, and it is compatible with Multi Jet Fusion printing and SLS. The nylon PA-12 is USP Class I-VI and ISO 10993 certified.

 

PC-ISO

FDM 3D printing uses PC-ISO, a biocompatible polycarbonate (PC) engineering thermoplastic. The material has a lower-quality finish than Nylon PA-12, but it is commonly used for surgical guides, prototypes, and molds. The PC-ISO can be gamma sterilized or EtO sterilized and is USP Class I-VI and ISO 10993 certified.

 

ABS M30i

ABS M30i is another biocompatible engineering thermoplastic for FDM, just like PC-ISO. Functional prototypes, form-fit tests, and end-use parts are perfect for FDM printing. ABS M30i can be gamma or EtO sterilized, and it is USP Class I-VI and ISO 10993 certified.

 

Titanium

The most popular material for medical implants is titanium, the king of biocompatible metals. All types of replacement joints, pacemakers, cranial plates, dental implants, and more are made of titanium. Titanium is a strong, lightweight, corrosion-resistant and non-reactive metal. DMLS, one of the most expensive 3D printing technologies, can be used to print it

 

Cobalt Chrome

Cobalt chrome also exhibits excellent corrosion resistance and biocompatibility, like titanium. It possesses additional strength and hardness over titanium and is commonly used for replacement teeth as well as heavy-use joints like hips, knees, and shoulders. DMLS is also used to 3D print cobalt chrome.

 

Stainless Steel

Steel is strong, sterilizable, and biocompatible; however, it does not offer the same long-term corrosion resistance as titanium or cobalt chrome. Therefore, stainless steel is used more often in surgical tools and temporary implants like bone screws. Direct material printing makes it possible to 3D print stainless steel parts at a much lower cost than other metals. The strength, rigidity, and chemical resistance of different types of stainless steel vary.

 

Silicone

Rubber materials such as silicone have a wide range of applications in the medical and food industries. For biocompatibility, it can be certified as Class V or Class IV. Silicone can be used for both short- and long-term implants. Silicone is commonly found in catheters, respiratory masks, medical tubing, and seals.

While silicone 3D printers are still in their infancy, silicone casting with 3D printed molds is a fast, affordable way to produce high-quality parts and products.

 

The Future of 3D Printing in Medicine

Due to the unique needs of each patient and body, medical devices often require the most customization of any product in any industry. Because of the high costs and long lead times of tooling for traditional manufacturing, these devices have historically been expensive and slow to produce. With its ability to produce small runs of highly customized parts, 3D printing is redefining what is possible in medicine.

Adapting medical solutions to patients and doctors improves outcomes and reduces costs and production times, which increases accessibility. Custom medical devices, implants, and tools are now more accessible than ever. As 3D printing technologies continue to advance, healthcare providers and researchers will continue to explore new applications from implants and surgical tools to tissues and functioning organs.

Choosing the best 3D printing filament is essential once you start 3D printing. The choice of the right filament must be based on an informed decision.

When choosing a filament, you might have to consider a few factors, for example, how strong should your printed part be? In terms of accuracy and precision, what do you want? What level of flexibility do you need for your product? And so on. Here are a few common 3d printing filaments that you may find helpful for choosing the right one for your project.

 

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PLA

 

3d printing products utilizing PLA are highly popular with consumers. In general, it is a very popular 3D printing filament. It comes in a variety of colors. Additionally, the material does not warp easily and is biodegradable.

Advantages

● Biodegradable

● Easily printable

● Available in translucent and glow-in-the-dark colors

● Has a pleasing, sweet smell

Disadvantages

● Brittle

● sometimes jams or clogs the printer nozzle

Applications

Polylactic acid is a common material for prototype parts, medical implants, food containers, low-wear toys, etc.

 

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ABS

 

A popular 3D printing filament, ABS has high impact resistance and toughness. It is an excellent material for extrusion since it is flexible and strong.

Advantages

● Durable and lightweight

● Affordable

● Flexible

● Suitable for both professionals and beginners

Disadvantages

● Unpleasant fumes

● Highly flammable Since it is petroleum-based, it is not biodegradable

● Warps easily

● Melts under high temperatures

Applications

ABS is most commonly used in toys, electronic components, and moving parts. Additionally, it is used in bicycle helmets, automotive components, wedding rings, phone cases, and car phone mounts.

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PETT (PETG, PET)

 

A common plastic type is PET (polyethylene terephthalate). This type of plastic is often used in food containers and plastic bottles. It is PETG, a variant of PET, that is used for 3d printing. Here, ‘G’ stands for ‘glycol-modified.’ This modification makes the filament easier to print and less brittle.

Advantages

● Flexible and strong

● with high impact and temperature resistance

● Easily printable

Disadvantages

● The product is hygroscopic (absorbs moisture from the air, so proper storage is necessary)

● The surface can be easily scratched.

Applications

In addition to phone cases, electronics, mechanical components, jewelry, and protective components, PET is also widely used in other items.

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PVA

 

Plastics made of polyvinyl alcohol are biodegradable and non-toxic. PVA is not only easily 3d printed, but it also works well as a support material during 3d printing.

Advantages

● Durable

● Water-soluble

● Non-toxic and biodegradable

● Easily printable 

Disadvantages

● Material that is relatively expensive compared to other materials

● Not easily available

● Hygroscopic (absorbs moisture from the air)

Applications

PVA is commonly found in packaging films, paper adhesive thickeners, and children’s toys.

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TPE

 

Plastics with rubber-like properties are thermoplastic elastomers (TPE). This makes them durable and flexible. Physical stress can be absorbed by TPE, since it is both stretchable and soft. It has the ability to withstand a considerable amount of wear as well as bending, compression, and stretching.

Advantages

● High flexibility

● Good bending and compression resistance

● Robust

Disadvantages

● Slow print speed

● Not easy to print

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Wood

It is actually PLA infused with wood fiber that is used in wood filaments. Combining these two allows you to print objects that feel and look like wood. It is possible to use willow, ebony, pine, birch, and so on, as PLA wood. Wood filaments can be used to make parts that are aesthetically superior to other materials, but they have lower strength and flexibility. In order to avoid damaging or burning wood, you’ll need to be cautious about the temperature. The nozzle of your printer can also wear down if the filament is wood.

In some cases, wood is better used with objects that are meant for good looks rather than complex functions. With wood filament, you can print decorations for tables, shelves, and desks. This filament can also be used to create scale models.

Advantages

● Stunningly beautiful. Suitable for models

● for cutting and painting

Disadvantages

● Weaker in strength

● Less flexibility

● The nozzle is more likely to wear out

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Metal

Bulky and lustrous models can be created using metal filament. A metal filament is made from a mixture of ABS/PLA and metal powder. Because metal blends are denser than PLA and ABS, the final model weighs and looks like pure metal.

Depending on your commercial needs, you may be able to find filaments made with brass, aluminum, copper, bronze, and stainless steel. Metallic powder grains can degrade your nozzle’s efficiency, as they are also abrasive. If you want visual appeal and functionality, metal filaments are a great choice. Metallic filament is suitable for manufacturing tools, toys, models, and finishing components.

Advantages

● Visual appeal, metallic look, and finish

● Minimal shrinkage and warping when cooled

● Durability

Disadvantages

● Too abrasive for nozzles

● Not easy to print

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Nylon

One of the most popular filaments for 3d printing is nylon, which is used in many industrial components. In terms of strength, durability, and flexibility, nylon makes sense as a material for 3D printing.

Another unique feature about nylon is its ability to be dyed before or after printing. Because of its strength and durability, Nylon is a great material to use when creating prototypes, tools, gears, buckles, hinges, etc.

Advantages

● Flexibility, durability, and strength

● Can be used after remelting

● Thermoplastic

● Less brittle than ABS and PLA

Disadvantages

● Hygroscopic

● Expensive

● When heated can emit toxic fumes

● High temperatures required for printing

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Conductive Filament

Electrical current can flow through conducting filaments, making them unique in their ability to conduct electricity. PLA and ABS filaments with conductive carbon particles are called conductive filaments. Small electronic projects work well with these filaments. For instance, this filament is commonly used in digital keyboards, circuit boards, and gaming controllers. 

 Advantages

● It does not require a heated bed

● Useful for projects involving electronics

Disadvantages

● Warps/shrinks during cooling

● Not flexible

● Not durable

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Clay/ceramic

A large portion of the materials used in this industry consist of plastic. Clay is a very popular non-plastic option. Copper and clay are typically used to make clay filaments. Faux pottery is often made with this extremely brittle filament. This material can be used to print items that need to look like they are handmade.

Advantages

● It has properties similar to clay.

● Can be fired in a kiln

Disadvantages

● Expensive

● Parts can shrink/warp during cooling

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Magnetic

A magnetic filament is created by mixing powdered iron with PLA or ABS. This material is ferromagnetically attracted to magnetic objects. There is also a gunmetal finish on the material. With this material, you can print toys and tools.

Advantages

● Aesthetically appealing

● Strong and durable

● Will adhere to magnets

Disadvantages

● Post-processing is a very specific process

● Expensive

● Needs a heated bed

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Carbon Fiber

The carbon fiber filament is made by reinforcing ABS, PLA, etc. with carbon fiber. It is relatively lightweight, rigid, and stiff. Printing carbon fiber materials frequently can wear down your printer’s nozzle since carbon fiber is widely used in structural applications.

Carbon fiber filaments can be printed in large quantities because of their low density and high structural strength.

Advantages

● Enhanced structural properties

● Lightweight

● Less shrinkage upon cooling

Disadvantages

● It causes wear and tear on the printer’s nozzle.

 

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Acetal(POM)

Often used in plastic parts that require high precision, Acetal is also known as POM (polyoxymethylene). Zippers, gears, bearings, and camera focusing mechanisms can also be made of Acetal. Acetal is highly preferred in these applications due to its strength and rigidity. Moreover, its low coefficient of friction makes it desirable as a 3D printing material. When toughness and low friction are required in parts, Acetal is a good material to use.

Advantages

● High strength and rigidity

● Resistant to chemicals and heat

● Perfect for functional uses 

Disadvantages

● The temperature of the print bed must be high.

● Adhesion of the first layer is difficult.

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polypropylene

There are many uses for polypropylene (PP) because of its many favorable properties. In addition to being chemically resistant, the material is lightweight, flexible, and tough. These materials are frequently used in the textile, engineering plastic, and food packaging industries.

A problem with PP is that it is not a very user-friendly material for 3d printing. Warping and poor layer adhesion are common problems. Despite having some of the best chemical and structural properties, PP falls short of ABS and PLA. As a general rule, PP is best used for printing lightweight and strong materials.

Advantages

1. High strength and durability
2. Resistant to chemicals 

Disadvantages

1. Poor layer adhesion
2. Not easy to print
3. Can warp considerably

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Wax

An investment casting material is wax. Metals such as tin, brass, and bronze can be represented using wax filaments. Compared to most other filaments, wax is softer. The extruder, however, needs some modification. Additionally, an adhesive may need to be applied to the print bed.

Advantages

1. Makes molds from your printer 

Disadvantages

1. Limited applications
2. require modification to your printer

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ASA

 

Acrylonitrile styrene acrylate is often considered as a weather-resistant material. This filament is easy to print and relatively rigid and strong. In addition to its chemical resistance, ASA is also resistant to heat and chemicals. When exposed to heat and sunlight, ASA models do not denature and turn yellow like ABS models.

Advantages

1. Compared to ABS, it warps less
2. Ideal for automotive parts

Disadvantages

1. Can crack during printing

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HIPS

 

The properties of HIPS (high impact polystyrene) combine the elasticity of rubber with the hardness of polystyrene. Often, it is used to produce protective packaging as it is a copolymer. Support materials are typically printed by using HIPS materials when printing 3D models. Overhang materials are held in place by supports.

Advantages

1. Stronger than PLA/ABS
2. Less shrinkage/warping than ABS
3. Can be painted easily

Disadvantages

1. Can only be used with ABS
2. It has adhesion and curling problems