Open Material 3D Printers: Unlimited Applications with Low to High Temperature Plastics

BigRep PRO 3D Printer Open Material System

Open 3D print material systems offer manufacturers freedom to choose any compatible filament that hits the market but closed material systems deliver predictable results. This raises the BIG question: Are open material systems truly open for innovation?

3D printing promises unparalleled freedom of production. Open material systems multiply that freedom tenfold.

The FFF continues to swell with an ever-growing range of 3D print filaments, and manufacturing sectors are wasting no time in discovering new applications with their 3D printers. For example, medical technology and the defense industry are increasingly seeing the use of Conductive Polymers such as PEDOT (Poly(3,4-ethylenedioxythiophene) in applications like organic electronics, sensors, and energy storage devices.

However, not all 3D printers support any compatible materials. There are two types of materials systems: open and closed. 3D printers with closed material systems allow you to print with specified proprietary materials whereas with open material systems, you can use any compatible filament.

If open material systems sound more open to innovation, what keeps industries within the walls of closed 3D material systems?

Open vs Closed 3D Print Material Systems

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With an open material system, you can experiment with different materials, create and edit print profiles (the print temperature, print speed, layer height, etc., in the 3D printer’s slicer software) to bring out desired properties and source them from different suppliers, which opens a world of possibilities.

On the other hand, closed material systems keep printing simple and consistent by limiting you to proprietary materials specified by your 3D printer manufacturer and locked print profiles. This can ensure reliability and consistency but might come with a hefty price tag (expensive proprietary materials, cost to unlock new print profiles etc.,) and limit innovation with other materials. While closed systems offer ease of use and predictability, open systems are all about flexibility.

Advantages of an Open Materials System

Flexibility and Freedom

Choice: You have access to a broad range of materials which allows you to select the perfect material based on the functionality and aesthetics you are looking for.

Customization: You can tailor material profiles of any compatible filament ensuring your 3D printer delivers successful prints and brings out desired properties.

Lower Material Costs: You can choose from different suppliers without being locked into expensive proprietary filament.

Budget Flexibility: With affordable access to a wide range of materials, you can go big or small on the budget.

Cost Efficiency

Innovation and Experimentation

Encourages Exploration: The freedom to experiment with new and advanced materials drives innovation in applications.

Facilitates R&D: Open systems support continuous product development with materials that fit specifications.

Diverse Sourcing: You can source materials from different suppliers, which reduces supply chain bottlenecks.

Enhanced Reliability: An open system makes it easier to maintain a steady flow of materials, reducing the risk of production downtime.

Supply Chain Benefits

Enhanced Performance

Optimized Material Profiles: Profiles can be tailored to bring out the best properties of any compatible material, whether it’s strength, flexibility, or heat resistance.

Adaptability: There is no restriction on a single set of materials which allows for the smooth and efficient scaling of your business as it grows and evolves.

Scalability

Choosing the Right 3D Print Material

With the plethora of materials available, which one would be the best fit for your part? The right filament depends on your project requirements. Are you looking for ease of use and biodegradability? PLA might be your best bet. Need something tougher with higher temperature resistance? Consider ABS or Polycarbonate. For extreme performance, PEEK could be the answer.

By understanding the properties and printing requirements of these materials, you can make informed decisions and achieve the best results for your 3D printing projects. Whether you're prototyping, producing functional parts, or exploring new applications, there's a 3D printing plastic that fits your needs.

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Exploring Low to High-Temperature 3D Print Plastics

One of the key considerations while choosing a plastic is the temperature range of the material and your 3D printer’s technical capabilities. From low to high-temperature filaments, each type has its own strengths and applications.

Standard & Bio-Based Plastic Filaments

BigRep ONE Sample 3D Print Prototype

PLA (Polylactic Acid): One of the most user-friendly and commonly used filaments, PLA is biodegradable and perfect for beginners. It prints at relatively low temperatures (around 190-230°C) and is great for prototypes, educational models, art installations, and interior decor.

PETG (Polyethylene Terephthalate Glycol): A step up from PLA, PETG offers better durability while still being easy to print with. It typically prints at around 220-250°C and is well-suited for functional parts that need impact resistance to a certain degree.

Engineering-Grade Plastic Filaments

ABS (Acrylonitrile Butadiene Styrene): Known for its excellent strength, ABS is a popular choice for more demanding applications. It requires a heated print bed and prints at around 220-250°C. It is ideal for parts that need to withstand higher temperatures and mechanical stress.

ASA (Acrylonitrile Styrene Acrylate): ASA is the weatherproof version of ABS. It prints at similar temperatures to ABS (230-270°C) but offers better UV resistance, making it perfect for automotive and parts exposed to outdoor elements.

CNHTC -Dr. Dong with a 3D print

High-Performance Plastic Filaments

CNHTC 3D printed parts with the BigRep PRO

Polyamide (PA): Highly durable and wear-resistant, Polyamide, also known as Nylon, is a bit trickier to print because of its tendency to absorb moisture. It prints between 240-300°C and is excellent for gears, bearings, and other high-stress components.

Polycarbonate (PC): Tough and transparent, Polycarbonate is one of the strongest 3D printing materials available. It prints at around 260-310°C and is great for applications that need high-impact resistance and clarity.

PEEK (Polyether Ether Ketone): At the top end of the temperature spectrum, PEEK is a high-performance plastic used in aerospace, medical, and industrial applications. It requires very high printing temperatures (around 350-450°C) and offers exceptional mechanical and chemical resistance.

Fiber-Reinforced Plastic Filaments

PA12 CF (Polyamide 12 Carbon Fiber): Durable and with great surface quality, PA12 CF is suitable for many industrial parts with daily usage under long-term stress. Its high strength-to-weight ratio makes PA12 CF a perfect solution for lightweight end-use parts.

PC CF (Polycarbonate Carbon Fiber): Its impact and heat resistance make PC CF an ideal choice for industries such as electronics, automotive, and aerospace. The addition of carbon fibers provides additional strength and toughness.

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Validated BigRep Filaments Compatible with All BigRep Machines

The heart of all BigRep machines is the material system that’s open for innovation. You can print with any compatible filament of your choice – BigRep’s or a 3rd party’s – and unlock new applications with our low to high-temperature machines.

We also have a portfolio of industrial-grade 3D printer filaments ranging from affordable, general-use materials to technical materials for demanding industrial applications. Each filament is rigorously tested to ensure reliable and even extrusion so have successful prints every time.

Our filaments are specifically designed for large-format 3D printing, helping you bring your big ideas to life.

Our Catalogue of Verified Filaments

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PA12 CF: Stiff and strong for industrial parts
HI-TEMP CF: High-temperature carbon fiber
ASA: UV-resistant and high-strength
ABS: Versatile and impact-resistant
PLX: Cost-effective and reliable
BVOH: Water-soluble support for dual extrusion
HI-TEMP: Stiff and eco-friendly
PA6/66: Lightweight and resistant
PRO HT: Easy printing and support removal
PETG: Durable and impact-resistant
PLA: Affordable and versatile
TPU 98A: Flexible and chemically resistant

BigRep BLADE: Custom Material Print Profiles Made Easy

As part of BigRep’s commitment to a lifetime partnership with our customers, we develop material profiles to ensure best printing quality so your prints come out right the first time, no matter your level of 3D printing experience.

Our slicing software, BLADE, offers a variety of pre-configured profiles for all BigRep materials. These profiles optimize the printing process, saving you valuable time and money by achieving faster print times, reducing material usage, creating lighter parts, and improving the aesthetics of your prints.

Have third-party materials you want to print on your BigRep machine? No problem. With BLADE, you can fully customize the printing parameters to perfect your parts. The intuitive interface makes it easy to create custom profiles and fine-tune print settings such as layer thickness, extrusion and build chamber temperature, and print speed to meet your material and application requirements.

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The Best of Both Worlds

When you opt for an open material system, you may not get custom printing profiles or materials that are developed for and tested on that specific 3D printer. With BigRep, you can reap the benefits of both worlds. We combine closed systems' reliability and consistency of our propriety materials and profiles with open systems' flexibility, competitive pricing, and broad material choice. This dual approach ensures businesses achieve maximum performance and best price-to-performance ratio, while maintaining the freedom to experiment and innovate.

Want to learn more about open material choice for 3D printing solutions?

Register to watch the webinar, FROM LOW TO HIGH TEMP FILAMENTS: How to Choose the Perfect Material for Any Application

Learn why all BigRep 3D printers are open material systems, meaning you are free to use any compatible material, whether its BigRep or otherwise. Gain insights about 3D printing materials across the temperature spectrum, from standard low-temperature polymers to high-temperature and high-performance materials.

FROM LOW TO HIGH TEMP FILAMENTS: HOW TO CHOOSE THE PERFECT MATERIAL FOR ANY APPLICATION

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

3D Printing in Education: The BigRep STUDIO Takes Learning Out of the Box

The BigRep STUDIO for Universities

Integrate 3D printing in education with the BigRep STUDIO, a large-scale machine that sets students and researchers up for success with its state-of-the-art technology trusted by industry leaders.

3D printing is rooted in hands-on learning, a pedagogical tool for ambitious students and researchers to take them from concepts to physical models, preparing them for real-world success. The technology is widely used to ensure promising research outcomes through high-accuracy parts in a wide range of materials for studies ranging from engineering to art and design. While most entry-level 3D printers in the market comfortably fit on a desk, the unrestricted freedom to explore new ideas manyfold as the build volume gets BIGger.

Built with a generous build volume of 1000 x 500 x 500 mm, the BigRep STUDIO is 10 times that of a standard desktop 3D printer. It is a massive, reliable, and education-ready 3D printer built to graduate students from desktop learning to a professional industrial-grade machine. Many leading universities around the world house the STUDIO and discover applications across almost all academic and research disciplines.

Join the Ranks of Top Universities by Integrating Large-Scale 3D Printing into Your Curriculum

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WHY THE STUDIO IS THE BEST-IN-CLASS
EDUCATIONAL TOOL

A Generous Build Volume

A 1000 x 500 x 500 mm build chamber for students and researchers to explore and test their ideas in full-scale.

BigRep STUDIO - Large build volume
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A Safe, Fully Enclosed Build Chamber

The temperature-controlled build envelope for consistent prints and safe access to the print bed.

Open Material Platform

Freedom to print with compatible 3rd party materials including carbon-fiber-reinforced plastics enabling the widest variety of applications in any academic field.

BigRep Filaments
BigRep STUDIO Dual Extruder

Uninterrupted Productivity

The STUDIO allows for around-the-clock non-stop printing so students can schedule print projects back-to-back and experiment efficiently even during the busiest periods.

Training and eLearning Platform

Students have complete access to online courses on the BigRep ACADEMY and in-person training from fundamentals to expert-level in 3D printing.

BigRep Academy eLearning Platform
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Space Conscious Machine Design

Built with a sleek body, the STUDIO is at home in any workspace. The machine runs on a convenient standard electrical outlet and has relatively low power consumption.

Intuitive 3D Print Software

Easy-to-use cutting-edge software suite gives students complete control over the print process, from design to print monitoring: BLADE, FLOW, and CONNECT.

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Large-Format 3D Printing Applications Across Different Academic Fields

The natural intersection between the STUDIO and education lies in the shared focus on large-scale experimentation, critical thinking, and creativity. The 3D printer imparts practical learning by being a testbed for experimentation, prototypes, physical models, and real-world applications.

The most common educational fields that benefit from the STUDIO’s large-scale capabilities are:

1. Engineering

The significant advantage of the STUDIO for engineering and advanced manufacturing students is its ability to effortlessly print large parts with complex geometries. Designs that would be challenging or even impossible to build with traditional manufacturing methods are second nature for the 3D printer.

Engineering students can quickly test, iterate, and refine their ideas and experiment with different filaments thanks to the open material system. They can gain insight into how material properties influence design and how manufacturing processes impact the final product. This experiential learning helps students develop an intuitive understanding of materials science and manufacturing principles, equipping them with valuable skills for their future careers.

Here are some of the use cases of Universities employing BigRep 3D printing systems in their research labs.

Helmut Schmidt University's Eleven-O-Six Racing Team 3D printed the steering wheel, entire bodywork, and a nose cone prototype.
Helmut Schmidt University's Eleven-O-Six Racing Team 3D printed the steering wheel, entire bodywork, and a nose cone prototype.
  • High-performance car production process
    Eleven-O-Six Racing Team, a motorsport team at Helmut Schmidt University in Hamburg, Germany uses a BigRep 3D printer to see what it could bring to their high-performance car production process.

    Prof. Dr.-Ing Jens Wulfsberg, the Chair of Production Engineering (LaFT) and leader of the project underlines a key advantage of their BigRep 3D printer:

"Using a BigRep 3D printer is a fast solution to produce a fast car because we have short cycles for optimizing the parts. In every iteration cycle, the car is better, and faster. This is one of the direct consequences of using the machine."

  • Rapid prototypes
    Dr. Mario Oertel and his team at the advanced hydraulics engineering lab at Helmut Schmidt University are transforming weir designs with BigRep 3D printing systems.
  • End-use parts
    Aalborg University Engineers 3D printed a functional bicycle frame in one go.
At Aalborg university, a fully functional bicycle frame was 3D printed, thanks to the BigRep 3D printer's large build volume.
At Aalborg university, a fully functional bicycle frame was 3D printed, thanks to the BigRep 3D printer's large build volume.
  • Aerospace engineering
    Aix-Marseille Université, one of the largest universities in France, developed a unique accredited degree program in aerospace engineering with BigRep 3D printing systems.
Mixed Reality Aerospace Program
Using their BigRep 3D printer, Aix-Marseille’s technical aeronautical training school, POLYAERO introduced 3D printed mockup parts for an ideal training solution.

2. Sciences

Thanks to the large-build volume, the STUDIO can create anatomically accurate representations for biology and medicine students ensuring a realistic and immersive learning experience. The 3D printer can play a crucial role in medical device development, allowing researchers to prototype and test cutting-edge healthcare solutions.

The other area that additive manufacturing contributes significantly is in the visualization of concepts. Beyond healthcare and biology, they support environmental studies and geoscience research by creating models for studying ecosystems, geological formations, and natural phenomena.

The STUDIO can easily create complex components and prototypes for advanced physics research projects tailored to specific objectives. Students can experience experimental design, data collection, and analysis. Be it fabricating models that are tested by being subjected to natural forces, or designing innovative sensors, students can leverage the capabilities of FFF 3D printing to push the boundaries of scientific exploration and discovery.

The 3D-printed rotor blades at TU Berlin designed by  Jörg Alber, and Laurin Assfalg with a BigRep machine.
The 3D-printed rotor blades at TU Berlin designed by Jörg Alber, and Laurin Assfalg with a BigRep machine.

TU Berlin’s Ph.D. student, Jörg Alber, and Master’s student, Laurin Assfalg, 3D printed a wind turbine rotor blade to experiment, evaluate, and improve its performance. By creating and optimizing rotor blades on a smaller scale with BigRep’s 3D printer, they could explore different infills, shapes, and materials and test them against simulated real-world conditions.

Laurin Assfalg:

"3d printing was a compelling option to produce the rotor blades as it can create complex forms and enhance performance. The idea was to come up with the science that can somehow be used for big rotor blades too."

3. Art

In art and design education, the STUDIO empowers aspiring artists with the freedom and practical skills needed to breathe life into their creative visions. Students can explore new techniques and experiment with materials, overcoming the limitations of traditional art mediums. Some of the areas where the 3D printers give the students a leg-up are with props and special effects, fine art creation, sculptures, installations, and art preservation.

The machine’s high level of precision helps students create intricate artwork, allowing them to delve into digital fabrication techniques and integrate technology into mixed-media art projects. Welly Fletcher, an Assistant Professor of Sculpture in the Department of Art at the University of New Mexico, built a bridge to prehistoric cave art with a massive 3D printed mixed-media lion-like figure with a BigRep printer.

Welly Fletcher’s sculpture ‘Trans Time’, an abstract depiction of a lion-like animal printed using a large-format BigRep 3D printer.
Welly Fletcher’s sculpture ‘Trans Time’, an abstract depiction of a lion-like animal printed using a large-format BigRep 3D printer.

4. Architecture and Construction

Studying architecture and construction at a university with access to a large-scale FFF 3D printer offers students the opportunity to prototype their designs at scale. This helps with a detailed analysis of spatial relationships, structural integrity, and design aesthetics of the building. The physical model can be quickly iterated to find the perfect solution to architectural challenges.

From complex architectural features to intricate building elements, integrating a STUDIO in the process fosters interdisciplinary collaboration and innovation. Architecture and construction students can collaborate on projects that combine architectural principles with engineering expertise.

The elaborate, contemporary “Ancora Villa” printed on a BigRep printer, is a complex architectural design with a fragile overall structure and many highly intricate details.

BigRep 3D Printed an elaborate architectural model, Villa Ancora, in 1:50 scale in just 5 days.
BigRep 3D Printed an elaborate architectural model, Villa Ancora, in 1:50 scale in just 5 days.

5. Archaeology and Paleontology

FFF 3D printing can turn back time by recreating lifeforms that have gone extinct and artifacts that have been damaged or lost forever. The physical models are profoundly engaging, offering an unparalleled experience by allowing students to learn about the past by holding it in their hands. Creating singular pieces of small to large scale parts comes easy for the STUDIO and students have a wide variety of materials to choose from. Post-processing techniques like painting and wrapping the part ensure a more realistic representation.

CDM STUDIOS in Australia 3D was commissioned to create sculptures and models of dinosaurs and extinct sharks on short notice. With a BigRep 3D printer, they were able to accurately recreate 110 models in just 9 months.

A shark model 3D printed on a BigRep 3D printer by CDM:Studio.
A shark model 3D printed on a BigRep 3D printer by CDM:Studio.

6. Product Design

The iterative nature of 3D printing allows students to test and refine their ideas, gaining valuable insights into form, function, and manufacturability. By experiencing the entire design cycle—from concept development to prototyping—students develop critical problem-solving skills and design thinking methodologies.

The STUDIO enables the intersection of design, engineering, and materials science by collaborating with peers from diverse backgrounds to tackle complex design challenges. Through this collaborative approach, students gain a deeper understanding of the multifaceted nature of product design and develop the ability to integrate technical, aesthetic, and user-centered considerations into their designs.

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Next-Gen AM Technology for Next-Gen Graduates

The STUDIO provides a solution for educational institutions that’s equal parts reliable and open for experimentation, engineered with state-of-the-art technology trusted by industry leaders. The 3D printer ensures successful research outcomes by printing high-accuracy parts with an open material platform rooted in a user-friendly, professional-grade full-solution AM eco-system.

In today's competitive job market, hands-on experience with professional 3D printers provides students with a valuable edge, offering a tangible representation of their ideas and enhancing the learning process. Prepare students for the real world and set them up for successful careers in any field, all within an accessible price range and unlimited experimental opportunities.

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Want to learn more about how Universities are upgrading education with 3D printing?

Register to watch the on-demand webinar, Inspire Students and Innovate Faster.

In this webinar, we discuss with some of the top universities, the projects and research they’ve conducted using large-scale 3D printing. 

REGISTER FOR THIS WEBINAR TO LEARN HOW 

  • 3D printers support scientists and students conducting research in universities 
  • AM is crucial in fast-paced experimentation and rapid iteration 
  • To unleash creativity through AM technologies 
  • 3D printers are an ideal tool in educational institutions to test new ideas. 

INSPIRE STUDENTS & INNOVATE FASTER: INTEGRATING LARGE-FORMAT 3D PRINTING IN UNIVERSITIES.

Graduate from Desktop. Get Industrial.

With 10 times the build volume compared to desktop 3D printers, the STUDIO is your gateway to large-scale industrial manufacturing.

Graduate from Desktop. Get Industrial.

With 10 times the build volume compared to desktop 3D printers, the STUDIO is your gateway to large-scale industrial manufacturing.

  • Enclosed 250 Liters Build Chamber: 1000 x 500 x 500 mm build volume for large 3D prints from a machine that easily fits in most work spaces.
  • Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 per hour.
  • Heated Print Bed (Up to 100 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
  • Large Parts with Fine Detail: Layer heights from 0.1 to 0.6 mm let you achieve small details on large prints, without compromising on printing speed.

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

3D Printed Spare Parts: On-Demand Solutions for Aerospace, Defense, and Industrial Manufacturing

A broken or defective part could mean a reduction or even a total halt in production while waiting for the replacement to arrive – an expensive inconvenience for manufacturers.

One of the areas where 3D printing has been most disruptive is in the fabrication of temporary spare parts. These printed components can often meet functional requirements until a longer-lasting solution can be sourced or produced. This allows industries to continue production, which increases machinery uptime and minimizes supply-chain uncertainties.

In this article, we'll examine some common challenges for aerospace, defense, and industrial manufacturers, and how 3D-printed temporary solutions enable a more seamless production workflow.

1. Emergency Repairs

Imagine the scenario: You’re an industrial manufacturer relying on a machine to complete a lucrative contract for a client. Suddenly, a crucial part of the machine breaks, and production grinds to a halt.

If the replacement part isn’t at hand, you’d have to contact external suppliers for troubleshooting, components, or services. Inevitably, the time spent waiting for the part to arrive introduces an element of uncertainty into what is already a stressful situation, with an added layer of potential delays and costs.

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Why 3D Printing is a Solution

With the introduction of an in-house 3D printer, on-demand production gives industrial manufacturers the ability to produce temporary spare parts or tooling as and when required, which buffers the wait time. The range of high-performance industrial-grade 3D print materials ensures the temporary spare parts are strong enough to bear the loads and stresses until the replacement part can be sourced.

3D printers such as the BigRep PRO enable aerospace and defense manufacturers to print with engineering-grade materials, such as carbon fiber reinforced polymers, and high-performance materials like flame-retardant Polyetherketoneketone (PEKK). These materials are better suited for parts that endure fluctuations in temperature or operational stress.

2. Unavailable Spare Parts

A spare part might be inaccessible for a number of reasons. For example, it could be out of stock or it may no longer be in production. In situations where defense or aerospace manufacturers are operating in remote locations or are deployed in field operations, they could be out of reach of the traditional supply chains.

In these scenarios, the manufacturer's hands are tied, with no immediate solution to getting that all-important spare part installed to get production back up and running.

How Large-Format is Changing the Way We Produce Parts

Why 3D Printing is a Solution

A spare part might be inaccessible for a number of reasons. For example, it could be out of stock or it may no longer be in production. In situations where defense or aerospace manufacturers are operating in remote locations or are deployed in field operations, they could be out of reach of the traditional supply chains.

In these scenarios, the manufacturer's hands are tied, with no immediate solution to getting that all-important spare part installed to get production back up and running.

3. Surrogate Parts for Training

The production timeline of complex machinery might be long and at times operators might require training to handle it. Stand-in parts replicating the original designs are needed for training before the final assembly arrives so the operations can start without delay. This scenario often arises in the aerospace industry where complicated equipment is often used and time is a crucial factor given the testing, validating, and certification process of the tightly regulated sector.

BigRep Academy

Why 3D Printing is a Solution

By fabricating components, these stand-in parts offer employees a hands-on approach to familiarize themselves with the procedures and intricacies of the final machinery. This ensures operators are well versed in the assembly and servicing of the machines and allows manufacturers to accurately implement operation timelines.

Several government aerospace agencies have successfully integrated 3D printing into their operations training programs, a fact that underlines the unique advantages associated with AM. Industrial manufacturers can also leverage 3D-printed surrogate parts for a smoother workflow transition ensuring employees are brought up to speed with potentially complex operations.

Advantages of 3D-Printed Temporary Spare Parts

1. Minimized Disruption in the Production Process

3D printing spare parts on-demand addresses equipment breakdowns or component failures immediately. Defective components can be swiftly replaced, reducing downtime and enhancing operational efficiency.

One of 3D printing’s biggest strengths, quick design iterations, allows for the customization of parts to meet specific requirements, ensuring optimal performance and compatibility. This in-house solution streamlines the production timeline by decreasing the wait time for the original part to arrive, enabling industrial, aerospace, and defense industries to meet their typically tight schedules and customer demands more effectively.

Full length portrait of engine and landing gear of passenger aircraft with pilot in the wing isolated on the sun background
<a style = "font-weight: bold; color: #E7E7E7"  href="/wp-content/uploads/2021/11/BigRep-PRO-2021_02-scaled.jpg" download><i class="fa fa-download"></i> Download </a>

2. Reduces Downtime thereby Saving Money

Simply put, the more time that elapses between a part breaking down and its replacement being fitted, the higher the financial implication.

In this sense, traditional methods for purchasing and sourcing spare parts from external sources for industrial machinery can lead to extended periods of equipment downtime and lost productivity. Stocking replacement parts might be the obvious solution, but it comes with increased costs and additional logistics to purchase, store, and maintain the parts.

3D printing on-demand minimizes the disruption of the production process by being an immediate stand-in. This decreases the downtime and keeps the machinery moving, adhering to operation timelines. This results in positive financial implications for manufacturers within the aerospace and manufacturing sectors, who are ultimately looking for reliable solutions to unforeseeable machinery breakdowns.

3. On-Site Manufacturing is the Only Viable Option in Remote Locations

The ability to manufacture replacement solutions in any location is particularly appealing within the fields of defense and aerospace. In scenarios where on-site production is the only viable solution, for example, mountainous terrains, deserts, or at sea, having the ability to print replacement parts in-house is a game-changer. These locations are typically far from areas under operational coverage for geographical reasons, and the time for the part to arrive might be unpredictable or the logistics might be impossible.

CNE Engineering with SAS Scandanavian Airlines
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4. Saves Time by Eliminating Traditional Production Steps

Where traditional manufacturing methods involve lengthy and often manual fabrication processes, 3D printing enables the direct production of parts from digital designs. This democratization of the manufacturing process skips the tooling process, reduces the dependency on skilled workers, and eliminates the maintenance of inventory and logistics. These steps in the time-consuming outdated process pile costs and 3D printing have the transformative power of directly printing on demand resulting in the economical production of spare parts.

5. Surrogate Tools for Operator Training

Time is money in most industries, and it rings particularly true in aerospace. The machinery, tools, and parts used in spacecraft and airplanes are often complicated, and operating or handling them requires training. With 3D-printed surrogate parts, they can learn how to effectively use machines before their arrival. This preemptive measure ensures accurate operational timelines, a crucial workflow addition to minimize the likelihood of inefficiencies during the production process.

3D Printed Mold for Jet Engine Cover
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6. Digital Inventory Replaces Physical Inventory

Managing a physical inventory involves stocking up the approximate number of parts in the right environmental conditions by anticipating future needs. This may not always be a feasible option for spare parts as there are a lot of components involved in the production process that may break down. With 3D printing, the part design files are digital and can be transferred to any corner of the world and produced with a 3D printer. This digital optimization of inventory minimizes the effects of supply chain bottlenecks and potentially costly storage solutions.

7. Large-Scale Singular Prints Requiring no Assembly

Massive parts in airplanes and other aircraft demand large-scale MRO equipment. Traditional manufacturing processes often relied on the fabrication and assembly of multiple separate components which increased production time and the risk of assembly errors or inconsistencies. With 3D printing, the production of large, complex components in a range of materials, in a seamless integrated unit is second nature. By drawing on advantages such as accuracy, precision, and repeatability, the production of spare parts as fully assembled entities aids swift and cost-effective solutions.

3D Printing Service PARTLAB
BigRep Materials

8. A Full-Spectrum of Industrial-Grade 3D Print Materials

From eco-friendly filaments made with recycled ocean waste to high-performing carbon fiber-reinforced materials suitable for aircraft components, there’s a wide range of materials that fit the bill for different spare parts and budgets. 3D printing offers the freedom to select the filament based on the specific function of the spare part. This allows for the choice of materials that best embody the physical, chemical, and structural properties needed for optimal performance. While not all industrial 3D printer manufacturers support 3rd party filaments, some of them like BigRep have open material platforms that cater to the user’s requirements, whether it is prioritizing high performance or cost-effectiveness.

Empowered In-House On-Demand Solutions

3D-printed spare parts have unlocked an agile, responsive, and adaptable localized production workflow which is vital for the aerospace and defense industries that demand highly individualized components that may not be readily available.

By printing spare parts on demand instead of storing them in inventory, these industries can significantly save time, reduce costs, and find reliable solutions internally till the permanent part is sourced. These developments have critical advantages for the day-to-day operation of machinery, especially in remote locations where self-sufficiency is essential.

Want to learn more about how Low-Volume Production Empowers the Aerospace and Defense Industry?

Register to download the eBook, From the Print Bed to the Sky: 3D Printing Aerospace-Grade Parts.

Discover how the aerospace and defense industry leverages 3D printing to deliver purpose-built, qualified tools to explore the skies and beyond.

In this eBook, we deep dive into:

  • How 3D printed parts are instrumental in transforming the aerospace industry.
  • The rigorous tests and certifications that validate the performance and safety of the 3D-printed parts.
  • FEA analysis that helps build robust aerospace-grade parts.
  • 3 use cases of aerospace industry giants that thought out of the box with 3D printing.

FROM THE PRINT BED TO THE SKY: 3D PRINTING AEROSPACE-GRADE PARTS

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you all the way from prototyping to production.

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you all the way from prototyping to production.

  • Enclosed 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
  • Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 grams per hour.
  • Removable Flexible Print Bed (Up to 100 °C): A heated bed with a flexible, magnetic, interchangeable surface that enhances print adhesion and minimizes warping.
  • Numerous Automation Features:  Print bed and extruder calibration for quick, easy set up and optimal print quality.

About the author:

Patrick McCumiskey <a style="color: #0077b5" href="https://www.linkedin.com/in/patrick-mccumiskey-%F0%9F%92%A1%F0%9F%96%8B%F0%9F%8F%9B-b41a2699/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Patrick McCumiskey

Author

Patrick has over a decade’s worth of experience writing about design and technology. After first encountering 3D printing on a project while studying a Masters Degree in design, he’s taken a keen interest in the development of 3D printing and its impact on the world of design and tech.

Finished to Perfection: Post Processing Techniques for 3D Printed Car Parts

aftermarket_blog_photo_1 (1)

From upgrading vintage cars to powering high-performance race cars, 3D printing caters to a range of automotive applications replete with professional-grade finishes. While some prints are good to go fresh off the print bed, some need finishing touches before reaching their final functional form.

3D printing builds parts by laying layer upon layer of melted plastic leaving pronounced ridges, especially with lower print resolutions. Also, support structure removal can leave behind a marred surface that needs to be further processed. Different post-processing techniques smoothen and treat the surface to make the final part not only visually stunning but also structurally robust blending form with function.

In this guide, we explore the 3 primary post-processing types - additive, subtractive, and property-changing methods and combinations of these techniques for the finishing of the 3D-printed car parts.

Post-Processing Methods

3D Print Post Processing Powder Coating

1. Additive post-processing

adds material onto the 3D printed parts to fill in the irregularities, smoothen the surface, and enhance mechanical and functional properties.

Examples: Filling, priming, brush coating, spray coating, foiling, dip coating, metal plating, powder coating, and ceramic finishes like Cerakote coating.

2. Subtractive post-processing

takes away part of the surface to create a uniform look and feel. It is the most common post-processing method used for 3D-printed car parts.

Examples: Sanding and polishing, tumbling, abrasive blasting (sand blasting), CNC machining (milling), and chemical dipping.

The dashboard is post processed.
3D Print Post Processing Local Melting

3. Property-changing post-processing

rearranges the molecules of a 3D print’s surface to improve the strength and evenness of the object. It doesn’t add or take away from the print resulting in cleaner and stronger parts achieved from thermal and chemical treatments.

Examples: Local melting, annealing, and vapor smoothing.

While each of these methods treats the surface in different ways, depending on the function, there are tried and tested combinations for different car parts that are advantageous for aesthetics and functionality.

Aesthetic and Functional Post-Processing Techniques for 3D Printed Car Parts

Automotive Customization with 3D Printed Car Parts

The 3d printed car parts can go through a combination of finishing techniques to achieve an enhanced surface finish, geometric accuracy, aesthetics, added mechanical properties, and improved usability. While some car components like dashboards might need only sanding and coating, other parts that are load-bearing such as a wheel accessory might require sequential finishing treatments for optimal performance. Apart from the improved look and feel, the post-processing steps have added benefits such as strengthening, UV resistance, tolerance towards higher temperatures, and protecting the part from regular wear and tear like bumps and scratches.

Some of the key advantages are:

  • Smoothing the surface of printed parts to achieve roughness values acceptable for end-use parts.
  • Certain post-processing methods strengthen the prints so that they may withstand increased stress and pressure.
  • Specific additive post-processing methods can change the material properties of the surface (e.g. waterproofing, UV resistance, corrosion resistance).

1. Coating or Filling, Sanding, Painting, and Sealing

This process employs coating or filling to address surface imperfections, sanding to refine the texture, painting to add color and protection, and sealing to ensure durability.

Some of the 3D-printed car parts that are post-processed with this method are console elements, custom brackets and mounts, plate covers, fenders, and speaker covers.

3d-print-post-processing-sanding-polishing

THE PROCESS

1. Coating or Filling
The coating or filler depends on the type of 3D printing filament used as they differ in surface texture, porosity, and adhesion properties. Fill the visible layer lines, gaps, or imperfections, and allow enough time for the coating or filler to cure.

2. Sanding
Start with a coarse grit such as the 220-grit sandpaper and progressively move to finer grits. Sand the entire surface and focus on areas that are particularly notched, ensuring they are smoothened.

3. Priming
A primer adds a protective layer and preps the surface for paint adherence while also ensuring the durability of the coating. Make sure the primer is compatible with additional layers you might add later.

4. Painting
Choose automotive-grade paints for the specific 3D printing material and apply multiple coats spaced between sufficient drying time. You can explore painting techniques such as fades, gradients, or stencils to detail the part.

5. Sealing
Pick a clear automotive sealant to protect the painted surface creating an additional layer of defense against moisture, UV rays, and other environmental factors.

THE ADVANTAGES

Surface Quality

Coating and filling smoothen visible layer lines and blemishes resulting in a print with an even, aesthetic surface.

The painting process enables designers to customize the appearance, match the vehicle's aesthetic, or even integrate branding elements.

Customizable Design

Enhanced Durability

Most 3D printing materials such as PLA can degrade when exposed to elements over time. The sealant serves as a protective layer against environmental factors, maintaining its visual appeal over the long run.

A sealant creates a barrier against moisture, especially for the 3D-printed exterior car components.

Water Resistance

2. Gluing and Upholstery

Upholstering is the quickest way to make a vehicle’s interior look incredible and make a world of difference in the comfort level.  Different types of upholstery such as fabric, leather, or other materials not only protect the surface but also add softness, comfort, and warmth. Depending on what the part is used for, a layer of padding or cushion is inserted in between and glued, stitched, or stapled to reinforce the parts together. This process creates a durable bond that can withstand loads and stressors while also offering customization, durability, and tactile comfort.

Some of the car parts that are upholstered are usually interior panels on the door, dashboards, central consoles, and other parts such as car trunks.

FDM 3D Printed Car Interior

THE PROCESS

1. Select the Material
Choose a high-quality upholstery depending on the 3D-printed car part. Leather, vinyl, or Alcantara are commonly used for door panels and consoles, and polyester felt roll for the headliner or trunk of the car.

2. Adhere the Foam or Cushion to the 3D Printed Part (optional)
Measure and cut the foam or padding and use compatible glue while considering the properties of both the foam and the 3D printed part. Foam and padding are usually used for door panels and seats as they make them soft to the touch.

3. Measure and Cut the Upholstery
Trace a 2–3-inch gap on the material around the part and cut it so that there’s enough room for the material to stretch and adhere snugly to the part.

4. Apply the Adhesive
Glue the upholstery with the foam or the 3D print by applying adhesive to both parts.

5. Reinforce the Adhesion by Stapling and/or Sewing a French Seam
Stapling and stitching are other techniques that secure the material in place while also creating visual interest.

6. Trim the Excess Material
Carefully cut off any leftover upholstery, paying close attention to the corners and edges.

Types of Upholstery

The finished dashboard is installed in the car.
  1. Leather wrapped around 3D-printed parts upgrades the overall aesthetic and tactile comfort of the part.
  2. Vinyl is a popular choice as it is highly abrasion, water, and UV resistant. It mimics the look and feel of leather and is a popular choice for upholstery as it’s affordable and easy to maintain.
  3. Alcantara is a synthetic suede-like material, it's soft, durable, and frequently used for interior surfaces such as seats, door panels, and steering wheel covers.
  4. Fabrics such as cloth, microfiber, mesh, and nylon come in a wide range of textures, patterns, and colors. They are known for their comfort and abrasion resistance properties making them a good fit for interior car parts.
  5. Polyester fabrics also come in a wide range of patterns and colors and their biggest strength is that they don’t wrinkle easily.
  6. Polyester Felt Roll is made from polyester fibers that are entangled and compressed to form a non-woven fabric and are commonly used in car trunks.

THE ADVANTAGES

Tactile Comfort

Upholstery like leather or Alcantara has a texture that makes the car part soft and ergonomic, improving the user experience.

Upholstering brings different components together applying the same look and feel to the car interior creating a unified design language.

Visually Cohesive

Protection and Durability

Quality upholstery materials form a protective layer that can withstand regular usage, and resist stains, fading, and damage, ensuring a lasting visual aesthetic.

Upholstery can be designed with logos, labels, or a color scheme and tie the vehicle together visually.

Branded Customization

3. Foiling or Wrapping

Wrapping or foiling is typically for exterior parts of the car, or the entire vehicle adhered with a thin, adhesive-backed material such as vinyl. Foiling can change the vehicle's color, add graphics, or create a protective layer. If you are looking to automate the process, vacuum foiling produces quicker, precise results ensuring the material wraps around the part as perfectly as possible.

3D-printed car parts that are commonly foiled and wrapped are spoilers, fenders, side skirts, grilles, and mirror covers, as well as interior parts like the dashboard and center console.

3D Print Post Processing Foiling

THE PROCESS

1. Prepare the Surface
Ensure the surface of the 3D-printed part is clean and free of any dust, debris, or contaminants so it doesn’t come in the way of adhesion.

2. Pick the Material
Choose your foiling or wrapping material based on the finish, color, or texture you are going for.

3. Measure and Cut the Foil
Similar to the upholstering method, trace a 2–3-inch gap on the wrap around the part and cut it so that there’s enough room for the foil to be wrapped around and adhered to the part.

4. Apply it to the Part
Starting from one edge and working towards the opposite side, smooth out the wrap with a squeegee onto the 3D-printed part to avoid air bubbles or wrinkles.

5. Use a Hot Air Dryer (Optional)
Complex shapes are more difficult to foil, and it might be easier to conform the material using a heat gun or a hot air dryer set to around 70 to 85 degrees. The heat makes the wrap more flexible and bends into little nooks and crevices.

6. Trim the Excess
Once the material is applied, trim off the excess using a cutter knife, paying close attention to corners and edges for a clean finish.

Types of Wraps and Foils

  1. Carbon Fiber Wrap mimics the appearance of real carbon fiber and is often used for interior trims, exterior accents, and spoilers. While they don’t have the structural benefits of real carbon fiber, these wraps are a lightweight and cost-effective alternative.
  2. Vinyl Wraps are thin and adhesive-backed, offering flexibility and durability. They are available in a multitude of colors and finishes making them one of the most commonly applied treatments for customized car parts.
  3. Paint Protection Films (PPF) are transparent, self-healing urethane film that protects against chips and scratches while preserving the original paint color.
  4. Hydrographics or Water Transfer Printing transfers designs or patterns onto 3D printed parts by immersing them in water.
  5. Brushed Metal Wraps exude the appearance of a brushed metal surface delivering an industrial finish to the 3D-printed car part.
  6. Reflective Wraps enhance visibility in low-light conditions and make it safer to drive in the dark.
  7. Chrome Wraps are reflective, and mirror-like having a highly shiny surface. They are used to accent certain parts or at times wrap the whole car.

THE ADVANTAGES

Quick Installation

Wraps can be treated onto the car part relatively quickly compared to other post-processing methods as they involve fewer steps.

If the wrap gets damaged or the client has a change of heart, it can easily be swapped out within a short time and at a low cost.

Reversible Customization

Lack of Downtime

Unlike traditional painting, wrapping does not need extended periods in the workshop, allowing it to be on the road sooner.

Wraps are easy to clean and maintain, simplifying the process of keeping the vehicle looking fresh.

Easy Maintenance

4.  Sanding and Epoxy Coating

This technique pairs a subtractive post-processing method with an additive one to finish a part that requires a short downtime before taking its final form. The 3D-printed part’s surface is sanded to a uniform base to build upon. Epoxy, especially self-leveling epoxy, is particularly easy to use as it strikes a balance—neither too drippy nor too thick—resulting in parts with a reflective aesthetic finish and also a reliable grip.

3D-printed car parts that are sanded, and epoxy coated are mirror housings, door handles, dashboard elements, and control panels.

THE PROCESS

1. Sand the Surface
Lightly sand the surface to refine and create a gritty base the epoxy can easily adhere to.

2. Sit the Part on an Elevated Level
Using a sacrificial block or a similar tool, set the part at an elevated height so it can be painted from all sides.

3. Prepare the Epoxy Mixture
Mix the resin and the hardener in a plastic container and take care not to let the mixture sit too long before the application.

4. Apply with a Brush
With a right-sized brush, coat the epoxy evenly onto the part to a consistent finish.

5. Allow it to Cure
Give the finish enough time to become tacky before applying additional layers. As epoxy cure times can vary widely, the curing time between layers or after a final coat should be checked in the technical data sheet for the epoxy you use. Keep in mind that epoxy will cure faster in warm environments or may not cure at all if the temperature is too low. Room temperature is usually recommended for proper curing.

THE ADVANTAGES

Straightforward Process

The process of sanding and epoxy coating doesn’t require an array of tools, intricate techniques, or a high level of skill making it an easy process to execute.

The epoxy coating enhances the grip on the surface of the car part, giving you a secure and tactile surface while using it.

Improved Grip

Durable & Glossy Finish

The finish lends a long life to the coated part and imparts a glossy finish, enhancing the overall aesthetic.

This post-processing method forms a protective barrier, guarding the 3D-printed car part against wear, abrasion, and external elements. It also can penetrate porous substrates making the car parts more waterproof.

Guards Against Wear & Tear

5.  Post Processing Molds for Car Parts

3D-printed molds for car parts are produced for materials like fiberglass or carbon fiber. While post-processing them, the main goals are to have a high-quality surface finish on the final molded part and to make it easier to release the molded part. For this, the finishing process follows a sequence of steps such as filling, sanding, and sealing.

Commonly 3D-printed molds post-processed for car parts are bumpers, body panels, spoilers, side skirts, grills, and air vents.

The final carbon fibre part created with a 3D printed mold.
The final carbon fibre part created with a 3D printed mold.

THE PROCESS

1. Filling
Filling or coating smoothens out any imperfections or layer lines and creates a uniform surface on the mold. It is essential for the inside of the mold to have an even surface as any irregularities will reflect on the molded part.

2. Sanding
The mold surface is further refined by sanding with coarse grit such as the 220-grit sandpaper and you can achieve smoother finishes by advancing to finer grits.

3. Sealing
A sealant wraps up the process forming a protective layer ensuring durability, keeping moisture away, and creating a polished surface that makes it easy to release the molded part.

THE ADVANTAGES

Enhanced Surface Quality

The post-processed molds result in a smooth and refined surface delivering a higher quality impression onto the molded parts.

Sealants and coatings enhance the durability of the mold, protecting it from regular use.

Improved Mold Durability

Easy Part Removal

The smooth interior of the mold along with a mold release agent makes it easy to release the part. This safeguards the mold and the part during the removal stage.

Sealants act as a barrier against elements, preventing distortion or degradation of the mold which is particularly important when using materials sensitive to humidity.

Prevents Moisture Absorption

Time and Cost Efficiency

Investing time in post-processing molds pays off in the long run by extending mold life and reducing the need for frequent replacements.

Perfection to the Finish Line

Automotive-industry-3d-printing-Bigrep

Post-processing parts are more than just the surface level.

They are no longer an afterthought but a strategy to stay ahead of the curve and deliver top-notch aftermarket services by producing quality end-use car parts with professional-grade finishes. Leveraging finishing techniques improves functionality, saves time and money, strengthens parts, and ensures superior 3D printed products and services for the automotive car aftermarket.

Want to learn more about Post-Processing 3D-Printed Car Parts?

Register to watch the webinar, Ideation to Installation: 3D Printed Parts for Aftermarket Car Customization

From fabricating carbon fiber molds to perfectly finished speaker enclosures, the automotive aftermarket explores all avenues of 3D printing applications. Hear from JT Torres, owner of Automotive Entertainment, about how 3D printing takes the front seat in delivering bespoke interior door panels, center consoles, and a range of custom car parts.

IDEATION TO INSTALLATION: 3D PRINTED PARTS FOR AFTERMARKET CAR CUSTOMIZATION

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

The Definitive Guide to 3D Printing: The Past, Present, and Future

Professional 3D Printer - Large-Format 3D Printer

From its humble beginnings as a niche technology for rapid prototyping to its current spectrum of capabilities to create forms that are virtually impossible to build any other way, 3D printing has spawned a brand-new generation of manufacturing.

In this article, we’ll take a look at the origins of 3D printing, its big moments in history, applications, and explore the future it holds.

1. The Basics of 3D Printing

What Is 3D Printing and How It Works

3D printing, also known as additive manufacturing, is a process of building a physical object from a three-dimensional digital model. It creates an object by laying down successive thin layers of a material such as plastic, metal, resin, or even biomaterials—based on a digital design created using computer-aided design (CAD) software.

3D Print Speed

The process begins with the digital 3D model sliced into numerous thin layers. The 3D printer then follows these instructions, precisely depositing material layer upon layer, gradually constructing the physical object. This technology has found applications across a gamut of industries, including aerospace, healthcare, automotive, fashion, architecture, and more.

Types of 3D Printing Materials

3D printing materials can be categorized under:

  1. Plastics (PLA, ABS, PETG, nylon)
  2. Metals (stainless steel, titanium, aluminum, copper)
  3. Resins (standard, flexible, tough, castable)
  4. Ceramics (porcelain, stoneware, earthenware)
  5. Wood pulp with a binding polymer (Bamboo, Birch, Maple, Cherry)
  6. Composites (carbon fiber, fiberglass)
  7. Paper-based (cardboard and paper)
  8. Food-based (chocolate, dough, sugar)
  9. Bio-based (living cells and tissue)

The History

Evolution and history of 3D printing

The roots of 3D printing go back to the 1980s when visionaries like Hideo Kodama proposed methods for fabricating three-dimensional models using photopolymers solidified by UV light. Around the same time, Charles Hull pioneered stereolithography, patenting the concept in 1986. This technique employed UV light to solidify layers of liquid photopolymer resin, laying the groundwork for additive manufacturing. Subsequent decades saw the evolution of various printing methods like Selective Laser Sintering (SLS) and Fused Filament Fabrication (FFF), expanding material options and applications.

By the 2010s, 3D printing had become more accessible, integrating into industries such as aerospace, healthcare, and automotive manufacturing. Bioprinting also made strides, enabling the printing of living tissues and organs. Today, 3D printing stands as a transformative force, reshaping manufacturing, rapid prototyping, and medical advancements through its capability to produce intricate designs with precision and speed.

The advantages

Benefits of 3d printing Across Industries

Rapid Prototyping

3D printing enables quick and cost-effective prototyping, allowing designers and engineers to iterate designs swiftly, reducing time-to-market for new products.

Highly individualized products can easily be produced catering to specific needs and preferences without significantly increasing production costs.

Customization

Complex Geometry

Unlike traditional manufacturing methods, 3D printing can create intricate geometries and complex designs that would be challenging or impossible to achieve otherwise.

Additive manufacturing is inherently more efficient, as it typically uses only the materials necessary for the object being printed, minimizing waste.

Reduced Material Waste

Supply Chain Efficiency

On-demand production enabled by 3D printing reduces the need for large inventories and streamlines the supply chain by producing parts as needed.

For small batches or low-volume production, 3D printing can be more cost-effective than traditional manufacturing methods due to lower setup costs.

Cost-Effectiveness

Innovation in Medicine

Creating patient-specific implants, prosthetics, and medical models for surgical planning requires precision and customization which 3D printing delivers effortlessly.

3D printing has become an invaluable tool allowing students and researchers to visualize concepts and create prototypes to test theories in various fields.

Education and Research

2. Common Types of 3D Printing Technologies

BigRep One - Amir & Bea

Fused Filament Fabrication (FFF)

FFF is one of the most common 3D printing methods. It works by melting a thermoplastic filament and depositing it layer by layer through a heated nozzle onto a build platform. As each layer cools, it solidifies, gradually building the object. FFF is known for its simplicity, affordability, and versatility, making it popular for hobbyists and prototyping.

Stereolithography (SLA)

SLA employs a vat of liquid photopolymer resin and uses a UV laser to solidify the resin layer by layer, building the object from the bottom up. The UV laser traces the shape of each layer onto the surface of the liquid resin, solidifying it. SLA is known for producing high-resolution, detailed prints, making it suitable for applications requiring precision, such as dental and medical prototypes.

SELECTIVE LASER SINTERING (SLS)

SLS uses a high-powered laser to selectively fuse powdered material, typically nylon or other polymers, into a solid structure layer by layer. Unlike SLA or FFF, SLS doesn't require support structures as the unsintered powder acts as a support. SLS offers design flexibility and can produce complex geometries and functional prototypes with robust strength, making it common in the aerospace and automotive industries.

POLYJET PRINTING

PolyJet technology operates similarly to inkjet printing but with layers of liquid photopolymer cured by UV light. Tiny droplets of liquid photopolymer are instantly cured by UV light, solidifying it, layer by layer, onto a build tray. PolyJet printers can produce multicolor, multi-material parts with high accuracy and fine details. It's often used in industries requiring high-resolution models, such as product design and architectural prototyping.

3. Real-World Applications Across Industries

Advancing-Additive-Manufacturing-in-Aerospace_Hero

1. Aerospace and Defense

Lightweight yet durable components are the lifeblood of the aerospace and defense industry. Components like turbine blades, fuel nozzles, brackets, and even entire rocket engines can be 3D printed. This results in reduced component weight, improved fuel efficiency, and enables rapid prototyping for testing different designs.

2. Automotive

In the automotive industry, 3D printing is used for rapid prototyping, and creating functional prototypes for testing and validation before mass production. Additionally, it's utilized for manufacturing parts like engine components, interior elements, custom tooling, and even entire vehicle bodies. The technology allows for quicker design iterations and the production of complex parts, enhancing overall efficiency in the automotive manufacturing process.

Car Restoration: 3D Printed Center Console
FDM vs SLS Healthcare: 3D Printed Wheelchair

3. Medical and Dental

3D printing has transformed the medical and dental fields by enabling the production of patient-specific implants, prosthetics, and surgical tools. In dentistry, it's used to create crowns, bridges, and dental models tailored to individual patient needs. In medicine, it's utilized for creating anatomical models for surgical planning, prosthetic limbs, customized orthopedic implants, and even bioprinting tissues and organs for transplantation and research purposes. These offerings deliver personalized solutions and improve patient outcomes.

4.  Consumer goods

Embraced by leading companies across sectors like consumer electronics and sportswear, 3D printing has democratized manufacturing processes with the accessibility of industrial 3D printers. This accessibility empowers designers and engineers to delve into its immense potential. Its benefits include expediting product development through rapid prototyping, accelerating time-to-market, and enabling mass customization by efficiently catering to individual consumer preferences.

BigRep ONE 3D-Druck-Service
3D Printed Jigs and Fixtures Ebook

5. Industrial Applications

The industrial goods sector, pivotal in machinery and equipment production, grapples with the need for agility and cost-effectiveness amid escalating costs and digital advancements. To address these challenges, manufacturers turn to 3D printing for its agility, responsiveness, and innovation. Its advantages lie in rapid prototyping, on-demand production, slashing design change times, and cutting lead times by eliminating tooling requirements.

4. Seven Steps to Find the Right 3D Printer

Building on the foundation of 3D printing basics, types, and applications, you can now quickly narrow down the vast choice of 3D printers by considering factors like:

1. Type of Printer

Consider various technologies such as FFF (also called FDM), SLA, and SLS. Inexpensive desktop FFF printers may suit hobbyists, while SLA and SLS offer higher accuracy at a higher cost.

2. Cost of the Printer

Entry-level printers cost less than $500, while industrial-grade printers can go up to hundreds of thousands of dollars. Also, factor in maintenance and filament costs.

3. Printer Size and Volume

Evaluate available space and print size needs. Beginners may opt for smaller, faster printers while for industries it’s recommended to invest in large-format 3D printers.

4. Print Quality and Speed

Take resolution, layer height, and print speed into consideration. Higher resolution often means slower speed and vice versa.

5. Ease of Use

Look for user-friendly interfaces, easy calibration, automation, and reliable performance. Consider reviews for insights into reliability.

6. Support and Maintenance

Check for maintenance instructions, available replacement parts, and technical support. Some companies offer less expensive, build-your-own 3D printers while others offer a full-service package. Also look for community support as it can be a holy grail in troubleshooting your 3D printer.

7. Additional Features

Consider extras like multiple extruders for varied prints, auto-calibration, built-in cameras, touchscreen displays, proprietary 3D software, and internet connectivity based on personal needs and budget considerations.

5. The Future Of 3D Printing

BigRep PRO on MARS

3D printing holds vast unexplored potential to reshape our everyday lives by offering innovation, customization, sustainability, and efficiency through:

  1. Diverse Use of Material
    Expect a widening array of printable materials, including advanced polymers, metals, ceramics, and bio-compatible substances, expanding the scope of applications.
  2. Accessibility
    As technology progresses, 3D printing might become more accessible, affordable, and user-friendly, potentially integrating into everyday homes and workplaces.
  3. Sustainable Manufacturing
    Efforts towards eco-friendly printing using recyclable materials and reducing waste during the printing process are gaining traction, contributing to sustainable manufacturing practices.
  4. Bioprinting and Healthcare
    Advancements in bioprinting may revolutionize healthcare by facilitating the creation of tissues, organs, and medical implants, leading to personalized healthcare solutions.
  5. Integration with AI and Robotics
    The fusion of 3D printing with AI and robotics could streamline and automate the entire printing process, enhancing efficiency and precision.
  6. Space Exploration
    3D printing's potential for on-site construction using locally available materials might revolutionize space missions and support off-world colonization.

Past production advancements were typically gradual, building upon iterations by refining production lines and inventory systems. In contrast, 3D printing reimagines production at a fundamental level. It simplifies, accelerates, and streamlines the creation process using a single machine, deviating from the reliance on a string of machines.

This paradigm shift is why most industries invest in this technology, firmly believing in the promise 3D printing holds in exploring untapped industrial applications in the manufacturing sector. From the invention of the telephone to the personal computer, there have been milestones in human history when a technology has completely transformed society. Now is one of those times.

Want to learn more about Large-format Additive Manufacturing?

Download the eBook Guide to Integrate Large-Format Additive Manufacturing.

Explore how increasing the build size increases the possibilities for builds, why size matters, how to integrate, 4 applications that benefit from large-format additive, case studies from industry-leading companies like Ford, Steel Case, and more.

GUIDE TO INTEGRATE LARGE-FORMAT ADDITIVE MANUFACTURING

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you all the way from prototyping to production.

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you all the way from prototyping to production.

  • Enclosed 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
  • Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 grams per hour.
  • Removable Flexible Print Bed (Up to 100 °C): A heated bed with a flexible, magnetic, interchangeable surface that enhances print adhesion and minimizes warping.
  • Numerous Automation Features:  Print bed and extruder calibration for quick, easy set up and optimal print quality.

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

AM in Low Volume Production: High Speed, Quality, And Cost Efficiencies

While developing a new product, the leap from design to production is one of the biggest hurdles to overcome. And with low volume production of 100-1000 parts, the cost and time sink of getting to market are multiplied exponentially and might be prohibitive.

In recent years, there’s been a growing focus on additive manufacturing as not just a prototyping technology but a full-fledged tool for low volume production, customization, and mass customization. Embracing large-format additive manufacturing for small-scale production has created a paradigm shift in fostering innovation, streamlining operations, and delivering significant cost reductions through cutting-edge 3D technology.

Ultimately, the crux of leveraging 3D printing is contributing to a single bottom line – operational efficiency.

What is Low Volume Production?

Also known as low-volume manufacturing (LVM), is as the name implies - the production of parts on a smaller scale. Low volume production lies halfway between prototyping and mass production. This offers manufacturers a space where they can blend the flexibility of the former with the precision and repeatability of the latter.

Production of precise tooling, functional prototypes, custom parts, jigs and fixtures, and spare parts in limited quantities are some examples of low volume production scenarios. LVM is particularly advantageous when it comes down to cost-efficiency, customization capabilities, and rapid prototyping while gaining faster market access.

Big 3D Print Batch Printing

What Drives the Demand for Low Volume Production?

Small quantities of parts needed for:

1. Customization

The growing demand for personalized products and components has surged low volume manufacturing. Customization production relies on an automated, efficient, and lean supply chain set-up that requires a great deal of flexibility making 3D printing an ideal fit.

Low volume production also encompasses mass customization as businesses need variations of concepts to realize which features can be customized, and how to best implement them in their product lines.

2. Niche Markets

Many industries require short production runs with specific requirements for niche markets. Low-volume 3D printing is well-suited for these scenarios, as it enables the cost-effective production of limited quantities of specialized products that would otherwise be hard to serve. This includes specialty vehicles, one-off products, or nonstandard designs.

3. R&D and Innovation

Low-volume manufacturing helps in making real strides by responding to market demand and introducing new features and products at a faster pace. It enables rapid prototyping and production of units for testing, validating, and refining new designs and components. This capacity for rapid innovation is crucial in creating groundbreaking ideas by introducing new products and technologies ahead of competitors.

omni-platform-web

4. Sustainability

As environmental concerns grow, low-volume manufacturing reinforced by 3D printing underlines efforts for sustainable production methods. 3D printing's additive nature, which builds up material layer by layer, reduces material waste and energy consumption compared to traditional subtractive manufacturing methods. By producing only what is needed and minimizing waste, it aligns with sustainable manufacturing practices.

Low Volume Production Scenarios

1. Tooling

It’s hard to overstate the impact of tooling in the production process, especially in the automotive industry. With traditional methods, tooling lead times can take months and costs run high.

By incorporating additive manufacturing, the production of tools like molds, jigs, assembly, and inspection fixtures is economical and time-effective resulting in shorter lead times. Thereby expediting design and raw materials validation before transitioning to production.

low-volume-production tooling
Canyon_inspection

2. Rapid Prototyping

It’s a given that initial designs are prone to imperfections, so prototyping allows engineering to try out parts and explore possibilities. The ability to swiftly implement changes is advantageous in such scenarios as low volume production offers the flexibility for making real-time adjustments.

Originally 3D printing was developed for rapid prototyping, so it’s no surprise that it’s a natural choice for low volume production processes.

3. Temporary Parts

When manufacturers need a part for a machine or a prototype, it might take a while for the replacement to arrive, leading them to seek out alternative methods to avoid delays.

Low volume production encourages uptime by being a stand-in until the ordered part comes through. With an in-house 3D printer, the part can be produced with materials like BigRep’s TPU that’s flexible yet strong. 

Ford jigs and fixtures low volume production
Audi Breathe Chair 3D print on BigRep ONE

4. Bridge Production

Low volume runs of a part might be required between the interim stage of product development and full-scale production. These units are samples for testing, fit checks, verifying the design, checking conformance quality, and eliminating foreseeable defects.

This is vital for newly developed products or components to avoid any risks before mass production.

5. Small-Quantity Production

Low or sporadic demand, initial pilots of a new product or market, parts produced in limited editions, and specialized components raise the need for small-quantity production.

Reliance on outsourcing production might not be the most cost and time-effective as typically there’s a minimum order quantity and no flexibility in changing the order size. Also, the limited window to make iterations to products before hitting the market encourages manufacturers to create in-house low volume production workflows.

BigRep-Application-Batch_4
Professional 3D Printer - Large-Format 3D Printer

6. Produce on Demand

When there isn’t predictable demand, the production of units as and when needed helps with avoiding the high costs. This just-in-time manufacturing approach in low quantities is an alternative to maintaining inventory management in warehouses.

Parts can be 3D printed on-demand, eliminating logistical challenges, minimizing the risk of overstocking, and reducing the time it takes to fulfill and respond to changing requirements.

7. Fabrication of Obsolete or Discontinued Parts

In some cases, especially with legacy systems or machines, certain components may become obsolete or discontinued. Low volume 3D printing can provide a cost-effective solution by reverse engineering and fabricating replacement parts, extending the life of equipment that might otherwise be rendered unusable.

LVM is particularly valuable in building a spare inventory of replacement components where production volumes are low.

Airbus

Why 3D Printing is the Answer

1. Growing Acceptance and Versatility

Factors like design freedom, reliable quality prints, prototyping capabilities, repeatability, low cost, and a hands-off approach have created a surge in the adoption of LVM 3D printing. Industries are taking the printing process into their own hands, ensuring their products are leading the market in innovation by introducing new designs and features before competitors.

BigRep PRO 3D Printer

Also when it comes to the range of materials, 3D printers such as the BigRep PRO have a diverse engineering-grade filament portfolio and are open to third-party materials enabling flexible applications.

2. Automated for Peace of Mind

Automation enables lights-out manufacturing minimizing the dependence on highly skilled workers, furthering peace of mind in the production process.

Safi Barqawi, the owner of AVI Boston, an Automotive Custom Fabrication company talks about about how the BigRep Studio is like an extra pair of hands in his workshop.

"Finding skilled fabricators and installers are a challenge, but with our 3D printer, it's like having a full-time employee building parts. We design, press print, go away for the weekend and all the parts are ready by Monday morning."

BigRep Fiber-Ready PEX (Power Extruders)

3D printing software such as BigRep’s, aids material handling, remote print monitoring, data analytics, auto calibration, batch production, automated design, and workflows. This results in closer ties and predictable workflow timelines across the length of the print process. The best part of using these softwares is that it requires no prior experience in 3D printing or CAD software skills reducing the learning curve for operators.

3. Excellent Part Accuracy and Build Volume

3D printing technology excels in ensuring the accurate production of large to small sized parts, a critical aspect in maintaining product quality. The exceptional tolerances ensure the creation of complex geometries with precision, making it a reliable choice for manufacturing high-quality, sizable parts.

“The biggest advantage of large-scale 3D printing is getting rid of assemblies. When we can produce bigger parts in one piece, this gives us a huge advantage.”

Lars Bognar, a research engineer for additive manufacturing at Ford Engineering Europe.

BigRep-One-printing

The large build volume enables the efficient batch production of multiple parts or larger components in one go. This reduces the need for assembly, streamlines the manufacturing process, and is cost-effective.

4. Low-Risk Investment, Offering Time and Cost Savings

Unlike traditional methods that involve cutting parts from large chunks of non-recyclable materials, 3D printing uses only uses what’s required, drastically reducing waste and material costs. This resource-efficient approach aligns with sustainability goals while simultaneously offering financial savings. The option of printing parts as needed also brings down costs associated with inventory and logistics.

WAT Berlin, an automotive manufacturer specializing in the production of vehicle frames is dramatically improving workflows in their facilities with custom 3D printed parts. André Lenz, an engineer at the Berlin facility elaborates on how the BigRep ONE has been enabling the production of light-weight, durable components.

“If we had made them out of steel or aluminum, for example, it would have been incredibly expensive and above all heavy and made from multiple parts.”

3D printing simplifies manufacturing by serving as a one-step process, eliminating the need for multiple machines, thus saving valuable time and reducing associated costs. The process is also easily automated, allowing for unmanned operation and further cost reductions.

Airbus

5. Other Benefits

  • Strong and Lightweight Parts The use of material like carbon fiber which has an excellent strength-to-weight ratio, leads to lighter, more robust parts with lesser printing time.
  • Flexible Use of 3D Printers Businesses invest in a 3D printer for a particular project but explore other applications and printing materials giving them more return on investment.
  • Parts Fit Right the First Time Fast, precise, and inexpensive 3D printing iterations ensure that components, especially steel parts where accuracy is paramount, are a perfect fit at the first go.

Go Big With Low Volume Production

Low-volume production thrives in scenarios that are fast-paced, innovative, and cost-efficient. 3D printing's versatility, automation, precision, and efficiency make it a perfect choice. An Ecosystem such as BigRep’s creates a unique environment with innovative 3D printing technology and solutions for low volume production and beyond.

Want to learn more about low volume production empowered by additive manufacturing?

Register to download the eBook, 7 Ways BigRep 3D Printers Unlock Profit Instantly.

Discover how investing in large format additive manufacturing (AM) can revolutionize your industrial business, driving innovation, efficiency and significant cost savings with BigRep’s advanced technology.

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you all the way from prototyping to production.

Industrial Quality Meets Cost Efficiency.
Complex Parts in Large Scale.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you all the way from prototyping to production.

  • Enclosed 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
  • Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 grams per hour.
  • Removable Flexible Print Bed (Up to 100 °C): A heated bed with a flexible, magnetic, interchangeable surface that enhances print adhesion and minimizes warping.
  • Numerous Automation Features:  Print bed and extruder calibration for quick, easy set up and optimal print quality.

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

How To Pick A 3D Scanner For The Automotive Aftermarket

3D scanner for car customization - feature image

In the realm of aftermarket car customization, automotive 3D scanners can be the overlooked workhorse that brings physical objects into the virtual space. While some car components might have readily available 3D models, designing individualized or original 3D prints needs 3D scanners to recreate an object’s geometry accurately in a simulated environment. The 3D scanner does this by capturing millions of data points from all angles of the part and in minutes you have a complete digital clone of it. This virtual version serves as a three-dimensional test bed to build and iterate concepts swiftly before going into prototyping and production.

3D Scanner car customization

 

Typically, large-format 3D printers come into the picture when printing car parts or bespoke components like dashboards, consoles, and door panels. Coupled with 3D scanning technology, you get visually aesthetic and highly functional parts. 3D scans seamlessly integrate with large-format 3D printers and streamline the process from the outset saving time, effort and money, resulting in exceptional print quality with fewer failed prints.

So How Do You Pick A 3D Scanner That’s A Good Fit For Your Workshop?

To get to the bottom of this, we will explore:

1. Why Is 3D Scanning Important?

3D scanning offers endless possibilities for customization with which you can design and produce components quickly with a high level of precision and accuracy.

Quality Control

The virtual 3D model can be evaluated to make sure every aspect of the part is precisely measured and is within the specified tolerances.

Reverse Engineering

A 3D scanner captures complex geometries with high-quality CAD files when none are available, improving project results by removing the guesswork.

Simpler Prototyping

Modifying and optimizing prototypes digitally before printing them ensures accuracy in producing complex shapes.

Quicker Design Cycles

Scanning the object that the 3D part is being designed for reduces production time and ensures a perfect fit of the 3D-printed part.

Accurate Measurements

Measuring the component, including details in narrow and hard-to-reach spaces, can be scanned for precise dimensions.

Cost-Effective

With 3D scanning, virtual testing reduces the need for physical prototypes. Also, the chances of fewer failed prints bring down costs significantly.

2. How Does 3D Scanning Work?

3D scanners create high fidelity, visual, three-dimensional virtual models by capturing 3D surface data from an object. It uses technologies such as Laser Triangulation, Structured Light Scanning, Photogrammetry, and Time-of-Flight Scanning to recreate the shape, color, and texture of a component digitally. Apart from bringing physical objects into the digital world, you can use the 3D data for inspection, dimensional analysis, reverse engineering, remote part replication, and CAD model validation for 3D printing.

Time-of-Flight Scanners

3. What Are the Different Types Of 3D Scanners?

There are a range of technologies for 3D scanners, and each comes with its advantages, limitations, and cost. The compatibility of different types of 3D scanners with large-format 3D printing depends on factors like scanning range, resolution, scanning speed, and the level of detail necessary for printing the vehicle’s part. Here are the different types of 3D scanners and their potential to integrate with large-format 3D printing:

3D Scanner For The Automotive Aftermarket

1. Laser Triangulation Scanner

This scanner projects a laser line or dot pattern onto the object and captures its reflection angle with sensors to replicate the shape. It is usually used for smaller objects, but it also scans the geometry of larger formats.

2. Structured Light Scanner

A Structured Light Scanner projects light in the form of lines onto the object and analyzes the field of view to generate a 3D model. It works well with large objects as it can capture complex shapes and details and has a large scanning range.

Laser Triangulation Scanners
Time of flight 3D scanner

3. Photogrammetry Scanner

Instead of using active light sources, the Photogrammetry Scanner reconstructs a 3D model digitally with multiple photographs taken from different angles. Photogrammetry is commonly used in large-scale applications like architecture and landscape scanning.

4. Time-of-Flight Scanner

The name "Time-of-Flight" may seem somewhat arbitrary for a camera-like scanner, but it gets its name from the underlying principle it is based on. This scanner emits light and measures the time it takes for the light to bounce back from the object's surface. It can capture large objects easily and is used for large-format 3D printing projects.

Time of flight scanner

4. What Is The Scan-To-Print Workflow?

Scan-to-print workflow is exactly what it says - it’s the steps involved in transforming a 3D scan into a printable model. After capturing the object using a 3D scanner, the 3D data is processed and cleaned with a specialized software. Next, the scanned model is converted into a 3D printable format like an STL file. Finally, the model is prepared for large-format 3D printing by optimizing the orientation, adding support structures, and slicing the model into layers.

STEPS FOR A 3D SCAN-TO-PRINT WORKFLOW

1. Scan the Object

With a high-precision scanner of 100 microns± accuracy, scan the object.

2. Refine the Mesh

Clean up the scan data with scanner software that’ll repair small gaps and simplify the scan.

3. Edit the Model

Refine the 3D model using CAD software by combining multiple scans if necessary.

4. Slice the
File

Translate the 3D model into instructions for the 3D printer with slicing software.

5. Prepare for Print

Set up the printer with the printing filament and configure the device's parameters.

6. Get 3D
Printing

Print the part with an industrial printer perfect for automotive customization like the BigRep STUDIO.

7. Post-Process the Part

Wrap up the process by removing support or excess material, sanding or polishing the part.

STEPS FOR A 3D SCAN-TO-PRINT WORKFLOW

1. Scan the Object

With a high-precision scanner of 100 microns± accuracy, scan the object.

2. Refine the Mesh

Clean up the scan data with scanner software that’ll repair small gaps and simplify the scan.

3. Edit the Model

Refine the 3D model using CAD software by combining multiple scans if necessary.

4. Slice the File

Translate the 3D model into instructions for the 3D printer with slicing software.

5. Prepare for Print

Set up the printer with the printing filament and configure the device's parameters.

6. Get 3D Printing

Print the part with an industrial printer perfect for automotive customization like the BigRep STUDIO.

7. Post-Process the Part

Wrap up the process by removing support or excess material, sanding or polishing the part.

5. What Type of 3D Scanner Is Best for Aftermarket Automotive Customization?

3D scanner for car- structured light

For aftermarket car customization and large-format 3D printing workflows, two commonly used 3D scanning technologies are Structured Light Scanning and Laser Triangulation Scanning. Structured Light gives you high accuracy, making it the perfect choice for capturing intricate car details. While Laser Triangulation captures the overall shape and geometry of larger subjects like car bodies.

A handheld 3D scanner using Structured Light or Laser Triangulation would be the answer for your automotive scanning needs. Handheld 3D scanners offer mobility and flexibility, allowing you to scan objects directly from the car or at any location the vehicle is at. This comes in handy for on-site customizations or restoration projects.

When selecting a handheld 3D scanner, consider factors like scanning accuracy, resolution, ease of use, compatibility with different surface types (reflective or transparent surfaces), and the software used for data processing.

Print Your 3D Scans to Life

2019-10-19_BigRep-Studio-G2_DSC8837_2000px_sRGB

Now it’s time for your design to come to life layer by layer.

This is where BigRep 3D Printers come in. Learn how our 3D printers can give you the transformative power of creating custom car parts that were once concept in your garage. Contact our team today, let us help you THINK BIG!

Graduate from Desktop. Get Industrial.

With 10 times the build volume compared to desktop 3D printers, the STUDIO is your gateway to large-scale industrial manufacturing.

Graduate from Desktop. Get Industrial.

With 10 times the build volume compared to desktop 3D printers, the STUDIO is your gateway to large-scale industrial manufacturing.

  • Enclosed 250 Liters Build Chamber: 1000 x 500 x 500 mm build volume for large 3D prints from a machine that easily fits in most work spaces.
  • Dual Extrusion (Up to 280°C, 130 g/h): Multi-material printing capability with a dual-extrusion system, supporting high-temperature materials and a print rate of up to 130 per hour.
  • Heated Print Bed (Up to 100 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
  • Large Parts with Fine Detail: Layer heights from 0.1 to 0.6 mm let you achieve small details on large prints, without compromising on printing speed.

About the author:

Natasha Mathew <a style="color: #0077b5" href="https://www.linkedin.com/in/natasha-mathew/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Natasha Mathew

Copywriter

Natasha Mathew enjoys trying new things and one of them she’s currently obsessed with is 3D printing. Her passion for explaining complex concepts in simple terms and her knack for storytelling led her to be a writer. In her 7 years of experience, she has covered just about any topic under the sun. When she’s not carefully weighing her words, she’s reading, crafting, spinning, and adventuring. And when asked about herself, she writes in the third person.

Massive Benchy 3D Print as a Benchmark for Large-Format 3D Printers

The most frequently 3D-printed object in the world, 3D Benchy, is a 3D model in the shape of a boat that was designed as a benchmark to test all sorts of 3D printing parameters. BigRep put its large-format 3D printers to the test by producing the world's largest Benchy, measuring at 816 mm tall. Let's have a close look at this giant Benchy and what its features can show about BigRep 3D printers' capabilities.

What is a 3D Benchy?

A 3D Benchy is a computer model that is specifically designed to test the capabilities of a 3D printer. Its name derives from "benchmark," which reflects its relevance in 3D printing. The Benchy was first released as an STL file in 2015 and is often the first thing one prints with a new 3D printer it has a set of features that determine the printer's capabilities and possible limitations.

benchy_timelapse_short332_x

Benchy Features

The most common Benchy features include overhangs, bridges, surface finish, and dimensional accuracy. These features are all important in 3D printing, and help evaluate the printer's ability to produce intricate designs, handle complex geometries, and maintain precise measurements. By looking closely at the quality of Benchy prints, one can identify issues or limitations with their 3D printer and make necessary adjustments for better results.

overhang dfam

Overhangs

Overhangs are horizontal or inclined surfaces extending beyond more vertically oriented parts of a 3D print. Successful overhangs showcase the printer's ability to handle complex geometries and maintain structural integrity without supports.

Bridging - Design for Additive Manufacturing

Dimensional Accuracy

The 3D printed Benchy's dimensions can be compared to the 3D model's original specifications. Accurate dimensional reproduction is an important indicator of a printer's ability to maintain precise measurements and avoid scaling issues.

Bridging front view - Design for Additive Manufacturing

Bridges

Bridges are horizontal gaps between two vertical structures. Bridges demonstrates the printer's ability to create even and sturdy horizontal spans, without sagging or drooping in the middle. The length of possible bridges depends on a printer's capabilities, slicing settings, and material used.

Part Orientation - DfAM

Surface Finish

The surface finish of the Benchy model is an essential feature to evaluate. The smoothness, texture, and overall appearance of the 3D printed Benchy can be examined for any imperfections such as layer lines, warping, or inconsistent extrusion, which can affect the final print quality.

Benchy in BigRep PRO

Advantages and Challenges of Printing 3D Benchy

The Benchy is widely recognized in the 3D printing community for its successes and challenges. One of its major strengths is its ability to assess various 3D printing technologies and how they work with various materials. This versatility allows users to evaluate the capabilities and performance of different printers and materials, providing a first-hand understanding of their strengths and weaknesses. Another advantage of using the Benchy is its focus on evaluating print quality and accuracy. By using it as a test model, users can assess the level of detail, dimensional accuracy, and surface finish achieved by their 3D printers. This information is crucial for ensuring the desired level of quality in the final printed objects.

However, where there are opportunities, there are also challenges. One of the major challenges is the time-consuming nature of the test. The benchmark requires printing a complex model, which can be lengthy, resource-intensive, and particularly demanding for users who need quick results or have limited resources at their disposal.

Another limitation of the Benchy is that it may not fully represent real-world printing scenarios. While it is designed to incorporate various features and geometries to challenge printers, it may not capture all the complexities and nuances of real-world objects, potentially leading to limitations in its usefulness as a benchmark for real-world applications.

Benchy in BigRep BLADE
Giant BigRep Benchy

BigRep Benchy Specs

The world's largest Benchy was printed at the BigRep headquarters in Berlin. And while it is definitely a huge 3D print, it was not BigRep's biggest, heaviest, or longest running print.

Here are the printing specs for the BigRep Benchy:

  • Printer: BigRep ONE
  • Material: BigRep PLA
  • Nozzle Diameter: 1.0 mm
  • Layer Height: 0.6 mm
  • Dimensions: 864 x 864 x 816 mm (x, y, z)
  • Printing Time: 121 hours
  • Material Weight: 11.1 kg
Giant_Benchy_Nika_ONE

How Does the BigRep Benchy Measure Up?

While it's a beloved and whimsical 3D model, Benchy does also function as a useful benchmark to evaluate a wide range of 3D printing parameters. Let's have a closer look at the giant Benchy results.

Giant BigRep Benchy Overhangs

Overhangs

The layer height, nozzle diameter, and overall 3D print dimensions greatly effects the quality of overhangs. This gigantic Benchy has large overhangs spanning ranges up to 50 mm long. They were not printed with support to help demonstrate the limits of the printer's capabilities. The BigRep ONE achieved an even, consistent quality with minimal deviations in layer appearance.

Giant BigRep Benchy Dimensional Accuracy

Dimensional Accuracy

Accuracy is highly dependent on what tolerances are required for a part to be acceptable for its use case. There is no noticeable warping of this giant Benchy and only small deviations in layer quality in the most challenging aspects of the print. For a real-world accuracy analysis, a 3D scan of the print can be compared to the original design to determine tolerance.

Giant BigRep Benchy Bridging

Bridges

Some of the bridges in Benchy are too long - in this case, up to 180 mm - to be printed without sagging, and therefore required support. The image above shows the top section of some circular cutouts which were printed without support. There are some slight imperfections, but the overall quality is surprisingly good at such a large scale.

Giant BigRep Benchy Surface Finish

Surface Finish

The more vertically oriented the surface, the smoother the appearance of the layer lines. As a surface is more horizontal, the layers become more pronounced with the appearance of the staircase effect. With a relatively large layer height of 0.6 mm, the differences between vertically and horizontally oriented surfaces is visually apparent.

Conclusion

The Benchy 3D model has become a cornerstone in the world of 3D printing, serving as a reliable benchmark for evaluating the capabilities and limitations of different 3D printers. Its various features, such as overhangs, bridges, surface finish, and dimensional accuracy, provide valuable insights into the printer's ability to handle complex geometries and produce high-quality prints. By closely examining the quality of Benchy prints, users can identify issues with their 3D printers and make necessary adjustments to achieve better results.

However, it is important to acknowledge possible challenges with using the Benchy. The test can be time-consuming and resource-intensive, which may not be ideal for users who require results very quickly or have limited resources, such as filaments. Moreover, the model may not fully capture the complexities and nuances of real-world printing scenarios, potentially limiting its usefulness in certain applications.

Nevertheless, the Benchy remains a valuable evaluation tool within the 3D printing community. It provides a comprehensive assessment of printer capabilities, highlights potential areas for improvement, and allows users to make informed decisions when selecting printers and materials for their projects. By understanding its strengths and limitations and using it with other evaluation methods, users can maximize the benefits of the Benchy for their specific printing needs and applications.

Want to learn more about large-format additive manufacturing?

Register to download the eBook, Guide to Integrate Large-Format Additive Manufacturing.

Learn how Increasing the build size increases the possibilities for builds: users can create larger parts, removing the constraints of more standard sizes of build envelopes. 3D printing a large part all at once means less time is spent designing around multiple print jobs, less time assembling multiple parts, and more time getting those parts to work for you. Don't miss out, download the eBook today:

GUIDE TO INTEGRATE LARGE-FORMAT ADDITIVE MANUFACTURING

Large-Scale Innovation. Limitless Creativity.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. It's the trusted tool of designers, innovators, and manufacturers alike.

Large-Scale Innovation. Limitless Creativity.

The BigRep ONE is an award-winning, large-format 3D printer at an accessible price point. It's the trusted tool of designers, innovators, and manufacturers alike.

  • Open 1000 Liters Build Chamber: Large 1 cubic meter build volume for creating big, complex objects in a single print.
  • Dual Extrusion (Up to 250°C, 72 g/h): Multi-material printing capability with a dual-extrusion system, supporting a wide range of materials and a print rate of up to 72 grams per hour.
  • Heated Print Bed (Up to 80 °C): A heated bed with a polyimide surface that enhances print adhesion for a range of materials and minimizes warping.
  • Fine Detail or Fastest Printing: Layer heights from 0.3 to 1.0 mm let you achieve fine detail on large prints or extra fast prints when surface texture is less important.

About the author:

Nika Music <a style="color: #0077b5" href="https://www.linkedin.com/in/nika-music-2301/" target="_blank" rel="noopener"><i class="fab fa-linkedin"></i></a>

Nika Music

Digital Marketing Specialist

Nika is a Social Media Manager with a background in the philosophy of technology. After obtaining their MA, Nika's passion and expertise in this field naturally guided them towards the exciting world of 3D printing. Currently, Nika is thriving at BigRep, enhancing the company's social media presence and creating brand awareness.

How to Overcome Six Common Manufacturing Challenges

Whether you are an experienced manufacturer or a new entrepreneur, the business landscape is continually evolving with greater acceleration and more significant changes.

In this article, we will consider six common challenges for manufacturers and how they can be overcome with smart solutions that really work. By anticipating these issues rather than firefighting problems as they arise, you can secure a more sustainable business model to scale your business and grow revenue.

Let’s explore six manufacturing challenges producers face and how you can ensure success for your business.

1. Lack of Skilled Workers

CHALLENGE

A troubling trend is steadily rising around the globe: the lack of skilled workers in the manufacturing sector. This is the product of lower employment rates in many countries, an aging workforce, a lack of tech-savvy labor, and the effects of the COVID-19 pandemic, just to name a few factors. A report by The Manufacturing Institute and Deloitte Consulting concludes that 22% of workers in U.S. manufacturing will be retiring in the next ten years. Additionally, they predict that the manufacturing skills gap could result in 2.1 million unfilled jobs by 2030. A report by Eurofound in 2019 found that Europe is not exempt from these struggles, as 39% of European manufacturing companies reported that their production was limited by labor shortages. This year, the German Chambers of Commerce and Industry (DIHK) explained that more than half of Germany's companies struggle to fill vacancies due to a lack of skilled workers.

SOLUTION

The accessibility of 3D printing technology, also known as additive manufacturing, allows a broader range of workers, including those with limited traditional manufacturing skills, to aid in product development, low-volume production, and full-scale manufacturing. 3D printing simplifies the production process by creating complex parts and prototypes directly from digital designs, carrying out intricate manufacturing processes with minimal human intervention. This reduces the need for highly skilled labor to operate machinery and perform manual tasks.

One solution to simplify the digital design process is scanning an existing part to create a 3D model, which can be 3D printed. Another option is using a design configurator to customize and adapt 3D-printable designs without needing in-depth design expertise. To learn more about design configuration, have a look at BigRep FLOW configurator apps.

BigRep PRO 3D Printer

2. Inventory Management

CHALLENGE

Inventory management can be a real puzzle for manufacturers. Picture this: You've got to predict what customers want, but their desires are like a roller coaster, up and down. Plus, suppliers might send things late, putting your production on hold. Holding onto too much inventory costs you money, but running out is a disaster. And don't forget about products that can go bad or become outdated fast. It gets even trickier when you have many different products to handle, and deciding which ones to keep or drop is no simple task. Then there's the balancing act between having just enough inventory when you need it and keeping extra in case things go unexpectedly.

Forbes reports that today’s average manufacturing company carries thirty days more inventory than at the beginning of 2007. While adequate inventory is a crucial buffer for supply chain issues, it is also the primary source of waste for companies. Holding excess inventory ties up capital and incurs costs such as storage, insurance, and depreciation. In a world where everything is always changing, figuring out how to handle your inventory is like playing a game of strategy to stay ahead in the manufacturing world.

SOLUTION

As a means of rapid production, 3D printing allows for just-in-time manufacturing, where parts are produced precisely when they are needed. Thanks to significantly reduce lead times compared to traditional manufacturing methods, you can quickly respond to changes in customer demand to deliver on time. Often called the digital warehouse, 3D designs can be stored on a cloud or server to be 3D printed once an order is placed. This also reduces the risk of overproduction and minimizes the cost of holding excess inventory. The number of business 3D printing components, products, and spare parts on demand is steadily increasing with early adopters such as Deutsche Bahn, Bentley, Miele, and Shell, leading the way. If you want to learn more about 3D printed spare parts on demand, read the eBook Deutsche Bahn Goes Additive with BigRep.

3d-printer-prediction

3. Supply Chain Dependency and Transparency

CHALLENGE

As a manufacturer, you always depend on suppliers for materials, components, and services. However, each supply chain dependency introduces a potential risk of delays, lack of availability, or price increases. As your business grows, so do the potential risks of supply chain failures along with the complexity of logistics. And as we saw with the global supply chain gridlock during COVID-19, one issue can have massively far-reaching repercussions.

In addition to these practical supply chain concerns, consumers increasingly demand greater manufacturing transparency from companies. Today's customers prioritize quality and ethically produced items, plus they're willing to spend more for those products. A study conducted by researchers at the MIT Sloan School of Management revealed that consumers may be willing to pay an additional 2% to 10% for products with greater supply chain transparency. So, not only do manufacturers need to manage their supply chains to keep their business running, but they must also consider how those supplier choices will affect consumer confidence. 

SOLUTION

With additive manufacturing, companies can produce locally, reducing dependence on distant suppliers and minimizing the impact of global disruptions. By using a digital warehouse, you can even produce locally with distributed manufacturing from afar: send your 3D file to be printed on location wherever the part is needed, With greater control of your supply chain, you also have more influence over lead times and fewer unexpected or increased costs. 

By implementing 3D printing for in-house production, tracking and controlling your supply chain is much easier, allowing you to satisfy consumers' growing demand for transparency. You own your own production process, plus fewer steps and logistics require oversight. Localized manufacturing can allow more environmentally friendly production with reduced shipping and other logistics. For more information about how 3D printing can reduce supply chain dependency, read the eBook How to Reduce Lead Times with In-House Supply Chains.

Design for Additive Manufacturing (DfAM)

4. Mass Customization

CHALLENGE

An increasing number of industries and businesses are embracing the trend of mass customization. This movement encompasses well-established brands that have introduced customization features to expand their product offerings and boost their sales. It also includes niche manufacturers and startups, which benefit from not having costly legacy factories and intricate supply chains. Forbes claims that custom products are the future of small and medium-sized businesses, and The Deloitte Consumer Review reported that more than 50% of consumers showed interest in purchasing personalized products.

Customers are willing to pay more for unique products, and traditionally, manufacturers also spend more to produce them. For example, many plastic products are produced using expensive CNC-milled molds. This is cost-effective at scale, but the costs skyrocket for low-volume and unique production. Manufacturers are faced with the challenge of how to produce customized products at scale in a cost-effective way.

SOLUTION

With additive manufacturing, there are no added costs in unique and low-volume production. That means you can print identical or modified products, and the only factors changing the manufacturing costs are material usage and printing time variations. You have the greatest freedom of customization without added costs when 3D printing end-use parts and products. While traditional tooling, such as CNC-milled molds, is durable and long-lasting, the cost is prohibitive for single or limited use. 3D printed tooling may be less durable but can be the perfect solution for limited production and robust enough to get the job done. Read this blog to learn more about mass customization and the power of 3D printing.

Airbus

5. Scaling Your Business

CHALLENGE

One of the most unexpected challenges that manufacturers encounter is choosing the right time to scale your business.  Scale up too early and you risk financial strain, operational challenges, and loss of quality. Scale too late and risk market saturation, missed opportunities, and a competitive disadvantage to more established companies. To decide when the time is right, you need to ask yourself the right questions. Is your product ready for market? If your product is not performing well, do you need to pivot the product offering or redesign it? Do you have the capacity to meet production requirements if demand increases? 

SOLUTION

To ensure adequate quality, good product-market fit, and best product offering, you need to iterate your product design. With traditional production methods, this typically requires outsourcing and/or hand-made prototypes, and unfortunately, both of these are expensive and slow to produce. 3D printing is widely accepted as the best solution for rapid prototyping, so much so that the two are practically synonymous. Additive manufacturing lets you quickly produce a design or functional prototype, make changes as needed, and reprint until your product is perfect.

Large-format 3D printing also allows you to produce larger prototypes in full scale. If you find that your product is not performing well after you launch, you can repeat the iteration cycle to change the product as needed. And what if your product is perfect and demand is high? 3D printing can help you meet those demands with in-house production, simplified logistics, and reduced supply chains.

In short, additive manufacturing lets you get to market faster, plus it helps you ramp up production. To see some success stories of how 3D printing helped companies iterate fast, produce faster, and get to market faster, see the webinar Improve Time To Market for Commercial Vehicles.

Nowlab BigRep Gripper 3d printed

6. Keeping Up With Automation

CHALLENGE

New technological advancements seemingly occur every day, increasing demand and putting pressure on manufacturers to fulfill larger orders. Automation boosts productivity, increases quality, saves costs, and perhaps most importantly, it can collect and analyze data to influence decision-making for continually improved outcomes. The robotic process automation market was valued at $2.3 billion in 2022 and is expected to grow at a CAGR of nearly 40% from 2023 to 2030. This is concerning for small and medium businesses as they compete with large corporations that can afford to use AI to make their production lines more efficient. As automation has taken a foothold, it simply cannot be ignored as the future of manufacturing. 

SOLUTION

A digitized workflow can help your business catch up to the automation super trend, and 3D printing can play a huge part in that. The key is choosing what processes and technologies need updating and how to integrate those within an existing workflow to become more agile and efficient.

Consider digitizing your prototyping process to iterate faster with more data-driven design iterations. Once in full production mode, you might produce 3D printed tooling to streamline your production process. Perhaps you choose to scan components to create perfectly customized 3D printed tools. Maybe you want to embed technology like sensors into those custom tools to provide valuable feedback during production. With an industrial 3D printer, you can expect reliable results with automation across the calibration and printing phases. You might incorporate 3D printing with robotics, milling, or AI so that the strengths of each technology can truly shine as part of an intelligent, automated solution.

Conclusion

3D printing is a transformative solution for manufacturing challenges. It simplifies complex processes, reducing the need for highly skilled workers. It also enhances supply chain resilience through localized, on-demand production, streamlines inventory management by minimizing stock needs, and enables cost-effective mass customization. With 3D printing, scaling your business becomes flexible and efficient, and automation seamlessly integrates into production, boosting productivity while cutting labor costs. Embrace 3D printing for a more agile, efficient, and future-ready manufacturing approach.

Want to learn more about manufacturing challenges overcome by adopting additive?

Watch the on-demand webinar Maximize Efficiency for Localized Production.

Learn how additive manufacturing can make a huge impact to reduce production costs and speed up manufacturing times. Particularly for low-volume and custom parts, highly skilled labor and outsourcing can massively inflate costs and lead times. Learn how large-format 3D printing can streamline processes, simplify logistics, and minimize supply chain risks to deliver the biggest business impact. Don't miss out, register for the webinar:

MAXIMIZE EFFICIENCY FOR LOCALIZED PRODUCTION