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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.

For a piece to be 3D printed, software known as a slicer must be used. By using the slicer, you can convert a 3D model into a file that includes all of the instructions for printing to a 3D printer. David Braam developed Cura in 2014 for this purpose – it was later purchased by Ultimaker. In the Additive Manufacturing market, it is probably the most widely used open-source software. The company believes it processes 2 million print jobs each week with 600,000 users using Cura. How does Cura succeed in gaining such a large following?

Ultimaker Cura

Known for its open-source slicing application, Ultimaker Cura is the world’s most popular 3D printing software.

 

How does Ultimaker Cura differ from other 3D printing software?

● A single click on an intent profile generates specific applications

● The recommended profiles are tested over thousands of hours to ensure reliability

● There are over 400 settings for granular control in the Custom mode

● The experience of printing is constantly improved by regular updates​

Cura is a 3D printing software that is easy to use, supports a variety of file formats, and is compatible with a variety of 3D printers. 3MF and STL files are supported, as well as OBJ, X3D, and X3D. Cura is part of the Ultimaker ecosystem, but it can also be used with printers from other manufacturers. The software is available in 15 languages, allowing users around the world to access it as easily as possible. The program’s compatibility with most major operating systems, including Windows, Mac, and Linux, contributes to its popularity. The secure features and functions of Cura can be enjoyed by Windows and Mac users, too.

Is Cura a user-friendly software?

 

The option of choosing between the recommended and custom settings is immediately available in Cura’s simple interface. There is no need to manually change the settings when you use the recommended setting – you achieve maximum results with just a few clicks. Nevertheless, the software is capable of choosing the best orientation of the part to minimize time spent post-processing, as well as generating optimized supports to minimize post-processing and layer thickness for the user. The best option if you are just getting started!

Over 400 different option settings can be selected from the custom setting. Other options can be added easily in addition to the basics like the addition of support structures and the amount of filling needed. With Cura’s preview mode, users can also preview how the model will be cut out. The user experience is improved because it is ergonomic. Additionally, a filament can be selected as a profile before printing so that the parameters are automatically adjusted.

 

Cura’s digital fabrication extends beyond slicing

Having become a commonly used open-source software, Cura is constantly evolving. Through Cura’s cloud service, individuals can directly send printing instructions to printers without using traditional storage media such as USB sticks. In addition, users can access their projects from anywhere, as long as they have a free account. Additionally, you can create a Professional or Excellence profile that gives you access to additional features. This means that the user can now import CAD models into Cura via these two profiles, simplifying the process of preparing the model.

 

The Cura Connect service allows printing to be sent to several printers via a single connection, so they can all be used simultaneously. In addition, the tool allows you to plan and manage multiple 3D print jobs from different Ultimaker printers. The interface and its status overview give a quick glance at the current print jobs, possible maintenance operations, etc.

Several plug-ins are also available in the Cura Cloud. One of the most popular is probably the one in which you can upload CAD files directly into the slicer from programs such as SOLIDWORKS, AutoCAD, or Siemens NX. No other software is necessary, since everything is integrated into a single tool.

Also, the Material Alliance Program, launched in April 2018, allows Cura to integrate different 3D printing profiles depending on the chosen material. Ultimaker is currently working with more than 80 filament makers worldwide, testing their materials and offering pre-set profiles accordingly (more than 100 as of today). Cura comes with optimal settings for the French manufacturer Kimya: if you wish to use its ABS-ESD for 3D printing, Cura will suggest them. Obviously, you can modify these to suit your needs. As a final point, Cura has a great community of active users, which makes it possible to share recommendations and best practices regarding its use.

 

Layers.app has integrated Ultimaker Cura into its powerful instant quote software.

Our instant quotation service was designed with speed and accuracy in mind. The Layers software lets you start with a 3D model, quickly create an estimate, and create visually appealing instant quotes that are easy to track. Having access to critical information is now simple and accessible to your entire team.

Layers’ quoting and estimation software streamlines the quoting process so you can focus on other aspects of your business. Layers can unlock the true potential of your team.

Layers.app’s instant quotation service features allow customers to upload their files, select their preferred printing options, and receive price estimates within minutes.

How Instant Quote & Price Estimating Software Helps 3D Printing Service Businesses Compete

 For 3D businesses, now is the perfect time to attract new customers and maintain the efficiency of operations. Your customers will appreciate the ability to order online from you as a key solution. With an embedded ordering portal that uses 3D printing instant quotes, your quoting process can be simpler, faster, and cheaper. This allows you to convert more leads, increase customer satisfaction, and stay ahead of the competition – so you can focus on the more fundamental task of growing your business.

Typical challenges in 3D printing quoting

 

Manual pricing consumes most of your team’s time

In order to produce an accurate price estimate, a considerable amount of information must be collected from a potential customer. Gathering all of the necessary information can sometimes take a series of phone calls or email exchanges. In the next step, you will need to collect additional information, such as payment and shipping methods, when a customer is ready to place an order. A lot of this is done manually with spreadsheets and other disparate software. There could be a lot of duplicate work and confusion as project managers try to move work through the facility and maintain contact with customers.

Manual pricing is inaccurate 

Even though spreadsheets offer many benefits when calculating 3D printing costs, there is a risk of over-typing numbers or formulae, or incorrectly factoring in numbers. Although these errors are easily made and solved, they are often discovered after the quote has been submitted to the client. A spreadsheet mistake can cost your company thousands of dollars, impacting overall profitability.  Therefore, it’s crucial to find solutions that can reduce the need for manual entry during quotes and reduce the chance of human error.

The process of acquiring new customers

Attracting new customers and ensuring repeat business is among the top priorities of most 3D printing service providers. The outbreak of the pandemic has made it difficult to find new clients or even stay afloat. Although 3D printing has been widely used during the pandemic times, many businesses have reported revenue declines or have even closed. How you reach out to a potential customers is one of the most important aspects of acquiring them. Your website remains the key to enhancing your online presence, even with the help of social media, email marketing, and paid ads. Is your website optimized to make it easier for people to order from you online? You can increase revenue by using your website to generate more leads.

Enhancing service pricing

Price structures for 3D printing services can be tricky to develop. In some cases, companies copy their competitors’ pricing strategies or simply undercut their competitors. However, these approaches are often risky because they don’t take into account your business’s unique processes. Pricing formulas for 3D-printed parts and projects must consider various aspects of the business (human and machine time, machine depreciation, software, facility costs), the size of the job, and the specific requirements of the part. Your pricing strategy should also align with your business goals, whether these are to maximize profitability, ensure your business’s longevity, or grow your customer base.

Low-value orders are not processed efficiently

Many 3D printing service providers face the challenge of efficiently processing orders with different values. Many service bureaus spend a significant amount of time processing 3D printing orders and educating customers. Those costs are easier to absorb with larger jobs. Smaller orders require similar attention but provide less revenue. Sometimes, they cost more than they’re worth. However, service providers should consider how they can handle these lower volume jobs more efficiently despite their importance.

Increasing sales by converting missed opportunities

Take the following example: after a long discussion with a client, he or she requests a quote from you, so you spend some time putting it together and sending it to them. You thought the conversation went well, but it’s been a week and the client still hasn’t responded. There is always the option to send a follow-up email, but when you have multiple clients to follow up with, it is easy for those emails to slip through the cracks, especially if you didn’t track the process.

How instant quotation software can help you grow your 3D printing business

 

Automate processes to increase value

Using the ordering portal, you can easily configure the software for your pricing model and include information about your supported file types, machines, materials, and finishing options. You embed the portal into your website to enable customers to instantly quote and order their 3D printing projects, automating much of the process that was previously handled manually. Providing quotes instantly and automatically rather than manually saves your team countless hours of time in the process and allows them to devote more time to pursuing new leads and growing the business.

Increase conversions and reach new customers

A customer-facing 3D printing ordering portal with instant quotation capabilities makes all the difference when it comes to reaching new customers. Your potential customers will not only prefer to shop online, but they will also demand it. As customers search for the best prices on 3D printing services online, your business can use the search engine to locate new visitors to your ordering portal and convert them into customers.

Provide accurate quotes to customers

There is no room for error when it comes to quoting a price for 3D-printed parts. 3D printing instant quote software not only eliminates errors in price quoting but also offers integrated STL file repair tools, which automatically fix models for successful printing. This helps to ensure that you provide customers with better, more accurate quotes and verify their models for 3D printing faster.

Provide a better customer experience

The benefits of digital are now widely accepted – 24/7 availability, simplified purchasing, up-to-date product information, and transparent pricing. These benefits, as well as others, are provided by ordering portals for 3D printing. A web ordering portal, powered by instant pricing, can reduce quote turnaround time from hours to minutes, allowing you to build stronger customer relationships. Through their personalized dashboard, customers can also access their order history, tracking data, and reordering options. They will have more control over the entire ordering process, which not only enhances efficiency and transparency but eliminates the need to call someone in order to ask for an update on an order. They can also request a manual quote if they need personal assistance.

Put your brand on a professional level

Finally, offering your customers the ability to order parts online and receive 3D printing quotes instantly makes your brand appear more professional.

 

Regardless of how large or small, your operation is, there is specific information that you need to know in order to calculate the costs. These are the things you need to know:

Material

Let’s start by calculating your total cost per gram. What is your purchase unit? If you have a desktop machine, you’re likely to purchase it by kilogram. The item may be sold by the gram, the pound, or by the cubic inch, so make sure you double-check and have that information handy. How much does your material cost per unit? A 1-kilogram spool of PLA usually costs between $15 and $45 if you purchase it from Amazon or another reputable reseller. In grams per cubic centimeter, what is your material density? PLA typically has a density of 1.24 grams per cubic centimeter. Refer to the manufacturer’s material data sheet for details. With those values, you can calculate the total cost per gram.

Machine

Next, let’s examine a few aspects of your machine. How many does your machine cost? Using a mid-grade, prosumer level machine, you will probably spend between $5K and $6K, but it may be as high as $10K. What are your machine’s lifetime hours? You will want to know the usage time for your machine. It may seem difficult to determine, but in reality, it’s not so hard. You should be able to access some life testing data depending on the manufacturer. You may find that in the manual or you may need to contact the manufacturer. Alternatively, you can estimate this number based on your experience or when you expect to replace it. How much does your machine cost to maintain and service each year? With a desktop prosumer computer, you’re likely to spend at least 40 hours a year just maintaining the machine and buying consumables – how many does that cost you? You may have purchased a service package from a reseller, which for the example machine mentioned above can range between $500 and $1,000 per year.

Rate of fabrication and deposition of material

How long does it take you to fabricate one cubic centimeter of material? In our calculations, this factor is also referred to as the “material deposition rate”. How long does it take to produce one cubic centimeter of material? You can calculate this in several ways. Slice a 10x10x10mm cube at 100% density with your typical settings and refer to the output values. If you want to be even more accurate, you can use your phone or stopwatch to time the print from the moment the machine starts laying down the material to the moment it finishes. Material deposition rates vary depending on geometry, firmware, and other factors. The goal here is to establish an acceptable baseline average. To be even more precise, I recommend timing 10 prints with varying geometries and weighing the final prints. Divide the time in minutes by the weight of the prints in grams to determine how fast you can deposit a cubic centimeter of material. With this information, and with what we already know, you can calculate how much material you use in an hour, and therefore how much it costs you.

Facility, Human Time, and Software/Services

Now, let’s figure out your costs by incorporating the remaining ancillary points. What is your monthly rent and what are your utilities? These are your facility costs. Approximately how many people are required to operate the machine, and what is their hourly wage? When it comes to setting up and tearing down a machine after a print job, how long does that take you? That is your human cost per print job. How much does your CAD software, slicer, CAM, or ERP system cost? How about your accounting software, your email and internet providers, or any other software you use daily? Combining those costs with the number of working hours in a year, you get a comprehensive hourly cost for every job you print on your machine. Take a moment to think about how long it takes to print your average job. Is it maybe 12 to 18 hours? Can it take up to 48 hours? By calculating your cost, you can get an idea of how much it will cost you.

What is the true cost of 3D printing?

Let us now calculate how much it would cost to manufacture the entire kilo of PLA. Calculate how many print jobs you can get from all that material, then multiply that by your human costs. You will be shocked at how large this number is if you add your other calculated costs together. Using an average deposition rate of 12.5 grams per hour, we can estimate that the entire spool will take around 80 hours to construct. If on average your prints are 100g per print job, then on average you can fit roughly 10 print jobs within a spool. Multiply your total hourly costs by the number of hours that spool will last along with the human cost on the average of 10 print jobs per spool. If fabricating a spool costs more than $500, don’t get discouraged. This is totally normal and can exceed $1,000 depending on your machine and rent. How much should you charge? How much margin should you have? The answer depends on who your clients are and what you are working on. For example, if your clients are in the consumer electronics industry, you probably should charge a markup of 80-200%. But don’t be afraid to go even higher. Time and work are more valuable than you think. Once you have all these inputs, you can calculate the minimum hourly price for each hour of printing time. Add your total hourly cost, human time, and markup to get your price.

 

Layers instant quoting service

Our instant quotation service was designed with speed and accuracy in mind. The Layers software lets you start with a 3D model, quickly create an estimate, and create visually appealing quotes that are easy to track. Having access to critical information is now simple and accessible to your entire team.

Layers’ quoting and estimation software streamline the quoting process so you can focus on other aspects of your business. Layers can unlock the true potential of your team.

Layers.app‘s instant quotation service features allow customers to upload their files, select their preferred printing options, and receive price estimates within minutes.