Layers Blog

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

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

 

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

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

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

 

What Are the Benefits of 3D Printing in Manufacturing?

 

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

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

 

3D printing uses a variety of techniques

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

 

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

 

FFF (Fused Filament Fabrication)

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

 

Continuous Fiber Reinforcement (CFR)

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

 

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

 

In the end, It’s all about

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

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

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

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

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

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

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

 

 

 

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

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

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

 

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

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

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

Composite 3D printing

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

 

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

 

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

 

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

 

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

 

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

 

SLA (stereolithography)

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

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

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

FFF (fused filament fabrication)

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

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

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

LFS (low force stereolithography)

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

Metal 3D printing

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

 

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

 

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

 

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

 

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

 

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

 

Final thoughts

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

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

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

 

What is Artificial Intelligence?

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

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

Using AI with 3D printing

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

 

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

3D printing workflow automation

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

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

 

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

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

 

Where does AI come in?

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

A process for optimizing 3D printing

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

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

What are the implications of artificial intelligence and additive manufacturing?

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

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

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

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

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

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

 

What are the functions of a slicer? 

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

 

Layers Slicing Software offers many advantages

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

 

Layers slicer is online

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

 

Updates in real-time

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

 

Security

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

 

Cost

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

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

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

 

How do STL files work?

 

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

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

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

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

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

 

The importance of STL 3D printing

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

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

How should I handle my STL files?

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

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

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

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

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

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

Measuring mesh quality in relation to file size

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

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

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

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

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

How does the Printability Check work?

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

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

● Size

● Width

● Depth

● Height

● Volume

● Area

 

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

 

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

● Wall thickness

● Bounding Box Size

● Model Density

● Model Integrity

● Orientation

● Holes

● Area

● Strength (based on material properties)

● Other variables

 

 

Preparation of 3D prints automatically

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

 

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

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