3D Printer Speed: What You Need to Know

December 9, 2022December 6, 2022

In additive manufacturing, if you want to succeed, then you need high speeds. The crucial question remains: how can you maintain quality while significantly ramping up production speeds?

It helps to have a better understanding of how 3D printing speeds are defined, what they mean for your prints, and tried and tested ways of producing parts faster. To learn more, read our thorough guide below.

Defining 3D Printer Speed

Oftentimes 3D printer speed is equated with the speed of the print head: the faster the printhead moves and deposits filament, the faster a part is built. But that’s only part of the picture.

While the speed of the print head influences the deposition rate of filament on the print bed, it does not reflect the overall length of the 3D printing process. It is far from the only print setting to influence overall printing time. It’s worth taking a broader look at 3D printing speeds for the FFF process, considering the 3D printing process from beginning (pre-processing) to end (post-processing).

Each step in the FFF 3D printing process adds time, contributing to how long it takes to get from 3D model to finished product. Fortunately, this means that the end-to-end 3D print speed can be accelerated by optimizing certain elements of the print process and tweaking certain settings. We propose a slightly more encompassing metric of speed that takes into account the time and labor spent before and after printing, as well as the printing time itself.

What Influences 3D Print Speed?

To accelerate and optimize the speed of the 3D printing process, it is important to understand what factors come into play across the pre-processing, build, and post-processing stages.

A batch of 3D prints are sliced with BigRep BLADE.

Pre-Processing

Pre-processing encompasses the time it takes to prepare the 3D model and the 3D printer for the printing process. Three pre-processing stages determine how long a 3D print will take.

3D Model Preparation

3D model preparation is itself a category that includes parameter selection and printing preferences. Decisions made in 3D model preparation have a massive influence on overall printing times. For example, choosing the right orientation for the 3D print on the build platform can reduce or even eliminate the need for support, cutting back on printing time. Some slicing programs, such as BigRep BLADE, offer automatic settings—like auto-orientation—that optimize these features so you don’t have to spend time figuring out the right parameters.

Slicing

Slicing software translates 3D models into a language that 3D printers understand. This process takes time, especially if your 3D model is particularly complex or the STL file is too large. Adjusting the resolution of your 3D model as well as layer heights and infill densities can alter slicing times. Keeping your slicer software updated can also eliminate bugs that slow processing times.

3D Printer Calibration

Calibration is a necessary step that ensures your 3D printer is properly positioned and all components, such as the extruder, motors, and axes, are aligned. Manual calibration can be time-consuming and take hours, but many FFF 3D printers offer automatic calibration that can be done in mere minutes.

A sensor measures the printed structures to calibrate the extruders for dual extrusion before printing.

3D Print Time

The print time refers to how long the 3D printer spends creating an object. As you might expect, it is typically the most time-intensive element of the 3D printing process. Different print settings and hardware features can increase or decrease printing times.

3D Print Speed

Print speed refers to the rate at which the 3D printer extrusion system moves when extruding filament. Print speed is measured in millimeters per second (mm/s), and most FFF 3D printers have the capacity to print at speeds in the range of 40 mm/s to 150 mm/s. This setting can also influence print quality: the faster the extruder, the less precise the print becomes.

Travel Speed

Travel speed indicates how fast the print head moves when not extruding filament. The travel speed can often be faster than the print speed without affecting quality. However, if it is too fast, it can lead to 3D printing defects like less precise prints or even layer shifts.

The sustainable travel speed you can achieve, depends a lot on the mechanical structure of your 3D printer. A sturdier frame and portal allow for higher travel speeds without the risk of vibrations showing in your part.

Two 3D prints with different layer heights: 0.2mm and 0.6mm.

Layer Height

This measurement determines how thick each printed layer will be and thus has a direct influence on printer speed. The thicker the layer height, the fewer layers will be needed to complete a print and the faster your part will be built. As the layer height increases, however, the resolution of the print decreases.

Nozzle Diameter

The nozzle diameter is a hardware selection that can unlock faster printing rates. The bigger the nozzle diameter, the wider each printed line will be. This can eliminate the need for multiple perimeter layers to achieve a certain wall thickness. A wider nozzle diameter also allows for increased layer height.

Two 3D prints are sliced with different infill percentages and wall thicknesses.

Infill Density

The percentage of infill density—the internal structure that supports the outer shell of a 3D print—can have a big impact on print speeds. The lower the infill density, the less material is required, which can reduce print times.

You should note that lower infill densities also provide less strength than a higher infill, so it’s about finding the right balance between speed and quality.

Support Structures

Generated to reinforce overhangs and bridges, support structures can also increase the time it takes to 3D print a model. Support patterns, densities, and other settings will influence support printing time. Orienting your model on the print bed to minimize supports can also speed up print times.

The white material is BigRep's BVOH filament, a water soluble support for easy removal.

Post-Processing

Once the 3D print is removed from the print bed, a certain level of post-processing is required. For prototypes and hobbyist-grade components, post-processing times can be minimal. For end-use parts or visual prototypes, however, post-processing can be demanding.

Support Removal

If your 3D model was printed with supports, removal is an obligatory step. The ease of removal is highly dependent on the type and number of supports.

Some supports can be removed manually in just seconds, while others require special cutting tools to avoid damaging the 3D print. The easiest and often fastest support removal can be achieved by using a dual extrusion 3D printer and a soluble support material that simply dissolves away.

Support structures are designed to break away easily after 3D printing.

Sanding and Polishing

Sanding and polishing are necessary steps for 3D prints that need a fine surface finish. Since both these steps are manual—requiring the use of sandpaper, polishing paste, or cloth—they can be very time-consuming, especially for larger prints.

Mechanical methods like tumbling and sandblasting are more complex yet speedier options for larger batches.

Priming and Coating

Other optional post-processing steps are priming, painting, and coating. The time each of these steps takes depends entirely on the technique used (for example spray coating, dip coating, or hand painting) as well as the scale of the 3D print and batch size.

For example, dip coating can accelerate post-processing for batches of parts, while spray coating can be more efficient for large prints.

A 3D print is post-processed with a brush-on coating to smooth and protect the surface.

Conclusion

3D printing speed is not as simple as knowing the mm/s rate of the print head: many other factors influence how long it will take to complete a 3D print job. In the pre-processing stage, model prep, slicing, and parameter selection can be optimized for faster processing.

In the build stage, various settings and hardware choices directly influence the speed and quality of a 3D print. Finally, the degree of post-processing required for an FFF 3D print can greatly influence how long it takes to get from a 3D model to the finished part.

By optimizing these various steps and understanding the correlation between print speed and part quality, you can achieve faster print rates and a more efficient printing process overall.

Want to learn more? Watch this webinar to see how to save time with the BigRep PRO 3D printer!

Dominik Stürzer

SEO Manager

Dominik is a mechanical engineer whose passion to share knowledge turned him to content creation. His first 3D prints started in university. Back then the 3D printers were big on the outside and small on the inside. With BigRep the machines are finally big in their possibilities.

3D Printer Cost of Ownership: What You Need to Consider

April 7, 2022May 26, 2021

The Additive Manufacturing market continues to grow at an exponential rate. This includes a significant increase in adoption from industrial manufacturers while the 3D printing industry itself welcomes new hardware, software and material companies everyday.

There are many factors to consider when purchasing a 3D printer, such as material capabilities, build size, purpose and future intention. However, one conversation that OEMs are afraid to have with prospects and clients is the true cost of ownership.

What are the upfront costs associated with my machinery? Where can I purchase consumables, resin or filament? When will my equipment become obsolete? This article will address all these questions and more.

The goal is to provide you, the end user, with enough information so that you can be prepared to present solutions to your management. Unexpected costs or limited financial transparency will become quite problematic, especially if your organization is budget sensitive.

The 3D printing market is vast. There are hobbyist-level 3D printers available for amateur enthusiasts, and then there is industrial additive manufacturing equipment used by engineers and professionals.

How much is a 3D printer?

Hobbyist-level 3D printer prices range between $200 - $7,500 with basic printing capabilities and materials. The industrial-grade 3D printing equipment has a much broader price range, $25,000 - $500,000, that is much more technologically advanced.

The price of a 3D printer rises with high resolution, bigger size and higher print speed.

But there is much more to it than just the purchasing price of a 3D printer.

BigRep Industrial 3D Printers at Ford

The purpose of this article is to understand the professional-grade equipment and assess the costs associated. If you wish to learn more about the entry level 3D printing market, you can find more in this article at allthat3d.com as a resource.

Part One: Capital Equipment Expenditures + Purpose

Regardless of company size or department budget, capital equipment expenditures over $50,000 will always be scrutinized. If it doesn’t fit on a corporate card then you will most likely be required to justify the purchase. And let’s be honest, your name will forever be connected to that piece of machinery once it’s installed—so it’s important to do the homework and make a good decision. In Part One, we will dissect the cost of AM equipment, and its purpose.

Industrial additive manufacturing equipment (operating with thermoplastic materials) can range from $25,000 to $500,000 depending on a variety of factors. This includes the size of the machinery, capability, reliability, ease of use, material compatibility and even brand name recognition. That’s a lot to keep track of.

For example, larger platform printers require robust servo motors and high-performance components to remain reliable and repeatable for users. Additionally, printers with advanced material capabilities operate with controlled heating chambers that will undoubtedly raise the cost of ownership and may be unnecessary for your application. You may be asking yourself, how do I determine which printer is the right one for me?

Is your department purchasing AM equipment for prototyping or production applications? What does your current process look like from a time and cost perspective? Who will be managing the machine? Analyze your current prototyping/production process and identify AM ready parts -- meaning which parts are too expensive to outsource or are too complicated with traditional machining. AM provides inherent values when it comes to designing, so understanding the intention and purpose of your equipment will help determine the return on investment.

For example, assembly line facilities have historically used metal parts for jigs and CMM fixtures simply because that was the only material available to them at the time. 3D printing with PLA plastic has become a viable alternative because it’s less expensive and lighter weight. Understanding the costs associated with traditional processes or parts helps determine the savings with 3D printing and ultimately, justify the ROI. The industry standard for equipment ROI is typically 18-24 months.

Kawasaki experienced a positive ROI after just 6 months.
Read this eBook to see how Kawasaki uses their large format 3D printer.

Part Two: Service Contracts, Consumables, + Post Processing

The equipment cost is just one piece to the printer acquisition puzzle. Purchasing a service contract for an expensive piece of machinery is commonplace in every industry, but AM is unique when it comes to consumables and post processing technologies. Almost every 3D printing technology comes with proprietary materials and a recommended solution for support removal.

The best estimate for an equipment service contract is between 15-20% of the overall cost. Indicating that $100,000 3D printer may require a $20,000 annual service contract. Much of this is dependent on equipment reliability and complexity. However, the alternative of no service contract is having to purchaseing replacement parts at a much higher cost so you’re left with trying to decide what makes the most sense for your business. It’s possible that your business has separate budgets for equipment and service so we recommend speaking to your finance team first.

Every 3D printer OEM offers proprietary consumables in resin, filament or pellet form. The question is compatibility and control. Some OEMs restrict users from using 3rd party materials and consider it a breach of service contract if they do. Those OEMs tend to charge more for their materials while suggesting that the printer is more reliable because of that. However, the industry is transitioning to an open platform concept that enables end users to operate printers with third party materials.

BigRep’s approach is unique because it makes both options available. Be confident to use our suggested filaments with predefined settings embedded in the slicing software or feel free to experiment with other material providers. We simply recommend to our users to reach out and ask about the options. Oftentimes, we have experience with many materials and can point you in the right direction.

Historically, support removal and post processing equipment in 3D printing wasn’t discussed. Yes, it’s the less attractive part of the industry but it’s impossible to ignore if your AM technology requires it. For example, many thermoplastic technologies use soluble support materials which typically requires an ultrasonic bath for removal. The size of your parts justifies the size of the support removal system, which increases the cost accordingly. Alternatively, some AM technologies use breakaway support structures which require manual removal and sanding. Ultimately, it depends on your application and what type of finish your part requires. It’s not uncommon for designers and engineers to paint, weld, bond, sand or coat parts for optimal look and feel. With each process comes costs—whether automated equipment or manual labor.

These air duct fittings from Boyce didn't require any post-processing before they went into the Verizon Kiosk they produce.

3D Printing Lower Cost with less Post Processing

Part Three: Intangibles + Obsolescence

Okay, if you’ve come this far then it’s time to talk about the future of your 3D printer and how to maximize your investment. As previously mentioned, the AM marketplace is complicated and it’s challenging to discern which technology is right for you. After you have determined the purpose of your 3D printer and analyzed the cost of ownership, it’s likely that you will have several options to consider. There are so many competing technologies that exist; so which company, brand or product are you willing to commit to?

How long has this company been in existence? Who are the major investors? What are the equipment reviews and will the company provide access to users and references? There is no need to work in a bubble when there is a world of resources available. When it comes to intangibles like company reputation or service standards, never underestimate the user testimonial. The industry is constantly evolving, and it’s very common to see major partnerships between OEMs, material providers, research institutes, and industrial leaders. In 2021, we have seen several AM companies go public and multiple mergers. Take time to learn about the company you wish to invest in. After all, your name is going to be attached to the decision.

Obsolescence is a much trickier conversation, and is one of the major reasons why some companies are hesitant to adopt 3D printing. Technology is advancing faster than ever before, and no one wants to be left holding the keys to outdated equipment. How can your department proactively prepare for obsolescence? First, determine a realistic ROI and try to stay under a 24 month payback schedule, which will improve the printer’s profitability. Second, ask the OEM if they have upgrade paths or buyback programs — most organizations do and are willing to drive customer loyalty. Finally, build an internal or external network of users, customers and research institutes that want access to your equipment and would pay to do so. These are just a few examples of building purpose for your 3D printer and monetizing it as quickly as possible.

Industrial 3D Printer Price Customer Nikola Corp.

What advice would you give to someone just getting started?

"Talk to someone that has one of these. It's guys like me that are operating the machine that can really tell you. Learn from their successes and failures."

Riley Gillman,
Nikola Corporation

Conclusion

The industrial AM market is complicated and expansive. The technology exists to enable engineers to rapidly produce prototypes, increase new product development, and identify new methods or materials for production purposes so the cost is justified. The question is, what exactly are you trying to accomplish? There is an alternative mindset in the market to purchase equipment now and identify ways to use this machinery in the future. These businesses typically have the financial resources to make such acquisitions and the luxury to wait and see. For the rest of us, we must develop ways to justify equipment purchases and truly understand the costs associated. Every 3D printer available on the market was originally designed to solve a problem but now every printer is the ultimate solution—one size does not fit all.

We recommend taking the time to develop an ROI calculation and truly assess every aspect of a 3D printer purchase. How expensive is the annual service contract? If we find less expensive materials, can we run them through our equipment? Will my printer be reliable enough to become profitable for my business? We invite you to speak with our team of experts to learn more, and find out how BigRep can be profitable for you.

Talk to a 3D Printing Expert to help you calculate your ROI with a BigRep 3D Printer

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4 Things to Consider Before Buying a Self-Assembled Large-Format 3D Printer

November 4, 2021April 23, 2021

Industrial 3D Printer vs Self-Assembled / DIY

Would a self-assembled large-format 3D printer be worth the price tag savings?

The answer depends on a variety of factors.

The reality is there are an array of options when choosing a 3D printer, and the right system for you is going to depend on several factors, ranging from your knowledge of 3D printers, budget, and what you want to accomplish with the printer.

How much experience do you have working with 3D printers? Are you comfortably knowledgeable of every component? Can you troubleshoot most problems yourself or do you often depend on services? Even if you can troubleshoot your own printer, how large is your margin for error?

In the right situation, self-assembled 3D printers can be an affordable option. Highly experienced users who understand 3D printer construction, maintenance, and modification with a wealth of time to build and troubleshoot their new 3D printer can make use of self-assembled offerings. Unfortunately, DIY 3D printers are too often treated as a cost-saving solution and purchased without fully understanding the expertise and time they’ll likely require.

It’s important to understand what each offering includes, and weigh them against your expectations. So, in this article we’ll go over 4 key considerations when deciding if a self-assembled (DIY) 3D printer is right for you, and why we believe premium offerings like BigRep’s 3D printers are a better choice.

Assembly Time

Time is money and your time is extremely valuable. Assembly is one of the clearest reasons to buy a premium 3D printer, so we’ll get it out of the way first.

Many businesses invest in technologies like 3D printers with specific goals in mind. They may want to reduce the lead time on parts and tooling or decrease outsourcing expenditures. Others may need a resource for agile product development to create prototypes on demand. It’s important to consider when you want to start progressing through these goals if you’re considering a self-assembled 3D printer.

Just assembling a DIY 3D printer takes time. How much time exactly will vary from user to user depending on pre-existing knowledge and clear instructions and labeling but could take a few days up to a month or more depending on labor availability, parts and any issues that could arise.

Additive manufacturing requires high precision to function effectively. Even small imperfections – in the wrong place – can render a part useless for many applications. During self-assembly it’s easy to misalign or mistakenly construct a printer that can cause excess vibrations or other inaccuracies during operation. Experienced users may know how to troubleshoot and repair these issues if they aren’t simply the result of low-quality hardware. Less experienced users may be unable to properly assemble their new 3D printer at all. In this case, and if the manufacturer doesn’t offer onsite servicing, you would need to hire a technician for assembly – likely bridging the cost gap. Either situation, requires significant time investment to ensure a system is operating properly.

With premium 3D printers like offerings from BigRep, a highly skilled technician can install your system onsite and validate its performance in as little as one day. They’ll introduce you to your new printer, train you on typical 3D printer troubleshooting, and help you to understand large-format best practices. Better yet, should unexpected problems arise, a BigRep service technician can come onsite or through a virtual service call to remedy the problem and ensure as little productivity is lost as possible.

Costs

At first glance, the price of a DIY system might seem too good to pass up. However, what many don’t realize is the price you see for many self-assembly 3D printers are “barebone” packages. These price points offer the most basic system, and a few upgrades are usually required to bring the system to an industrial standard.

Barebone systems are typically packaged en masse straight out of an affordable manufacturer, usually in China, and come with hardware of minimal quality – depending on the specific offer. If you don’t purchase upgrades before assembly, it’s likely that you’ll feel the need to once you’re using the system regularly.

When choosing upgrades, integrations are important features to pay mind. Is your build volume’s heating integrated with the 3D printer control board? If not, you might have to manually switch the heating off before the print bed can cool down. Limitations like this can severely restrict the flexibility of large-format 3D printing, like running prints overnight.

Aside from these big quality of life upgrades, there are a lot of smaller parts – like ware components – where quality will be very important.

Industrial 3D printers come fully equipped so they are ready to perform out of the box, no upgrade costs required. So yes the price tag will be more but it also comes with the assurance there are no hidden costs or components needed to bring it up to an industrial standard for printing.

Down Time

You purchase a printer to do a job. So when the printer is down, it effects the bottom line. Most users will compare a 3D printer’s key components out the gate and upgrade self-assembly systems where they feel necessary – hot ends, filament detection, and control systems are common in the first pass. While easier to ignore, it’s essential to also examine the quality of ware components. Check various gears, bearings, and straps for quality.

All moving parts are essential to replace early on cheaper systems to ensure consistency and reliability throughout operation. Low-quality parts will ware much faster than premium industrial parts or otherwise require additional intervention when compared to parts and systems that come standard with premium industrial 3D printers like BigRep’s.

Experienced users will either upgrade low-quality moving parts from the start or when they’re skilled troubleshooters, replace them as needed. It may be difficult for less experienced users to locate these smaller components when they begin to fail and overlooking these parts can lead to serious downtime and lost business if you’re not prepared.

Keep in mind that cost-cutting doesn’t stop with the quality of a system’s parts: many DIY 3D printer manufacturers maintain their low prices by offering limited support or none at all; meaning you’ll need to hire a third-party technician if you can’t fix it yourself. That’s not a slight against the companies, their systems are made to be routinely customized and upgraded by users with extensive 3D printer knowledge and familiarity. However, given to less experienced users or placed in demanding industrial environments these concessions could mean large maintenance down times and easily bridge premium cost.

Quality Assurance

You buy a printer to produce parts – prototypes, jigs, fixtures, molds or end use parts. One expectation when producing them is that they will meet your quality expectation. The quality of parts coming off your 3D printer will be directly determined by the quality of your printer in many ways. In most cases this will be obvious parts – high-quality control boards or gantries will be pivotal to high-quality parts. Even upgrading these core components can eliminate your initial savings from many self-assembled 3D printers, but it’s important that you consider the overall quality of the system you’re purchasing.

In the wrong place even a degraded nut or bolt can lead to excess vibrations that heavily impact your production quality. While replacements for these flawed support components may be very affordable, they can be far more difficult to identify as the source of a problem. In industrial settings, those issues directly impact future revenues.

Mass manufacturing is all about cost efficiency, so many DIY 3D printer manufacturers will take advantage of these hidden concessions so they can compete better with visible features. Unfortunately, even these small components have a significant impact of the quality of your parts. If your business will be negatively impacted by reduced print quality or printer downtime, it’s vital that you consider your supplier’s commitment to their product over its lifetime. A robust service offering like BigRep’s shows that corners won’t be cut on manufacturing and assembly so your business can operate smoothly with consistent quality.

Conclusion

So the question “are they worth it?” is really up to your needs, time allowance, and expectations. If you have a dedicated technician who wants to know their machine inside and out, modify heavily, has endless time and is confident they can handle all servicing, a DIY 3D printer may be an option for you – even in large-scale. However, without the right staff, available labor, and 3D printing knowledge, they have the potential to cause more problems than they’re worth.

With an industrial large-format 3D printer like one of BigRep’s, uncertainties are taken out of the equation. Our products are carefully designed to balance cost with the performance and long-term reliability expected by industrial users. With German-engineered and validated systems installed onsite by a specialized technician, you’ll waste no time getting your 3D printer up and running with every assurance of its quality and reliability.

Not sure which solution is best for you? Talk to one of our experts and we’ll help you uncover which type of 3D printer could help you.

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Dual Extruder 3D Printer – Two Heads Are Better

January 6, 2023April 15, 2021

The old adage, two heads are better than one, simply indicates that two people can solve a problem better than an individual can. This is certainly the case when it comes to 3D printing, and why dual extruder technology is must-have for any engineer, designer, architect or artist. Single extruder technology that is available on the market today is incredibly limited and actually defeats the true purpose of a 3D printer, the ability to transform complex, digital designs into tangible, physical items. If you’re a serious designer with aspirations to bring your ideas to life, then you should never underestimate the value of a professional 3D printer. First, let’s understand the basics of 3D printing.

Limitations of Single Extruder 3D Printers

The vast majority of 3D printers available today operate with FDM (Fused Deposition Modeling) or FFF (Fused Filament Fabrication) technology. Essentially, thermoplastic material is fed through a heated nozzle that melts the material and simultaneously deposits it on the build platform. It’s arguably the simplest and most effective 3D printer technology that has been adopted by consumers and professionals in every industry imaginable.

With single extruder printing, you are able to 3D print very basic parts and shapes. For example, it’s possible to print a small pyramid or a six-sided box, because the geometries are not challenging and do not require additional design or rework. But 3D printers are supposed to enable the impossible. Instead of trying to fit a square peg in a round hole, why not redesign the peg? Why not customize the hole and create new functionality for the whole system? Adding a second material extruder enables this and so much more.

The Value of Dual Extruder 3D Printers

Advancements in 3D printing materials are enabling new applications across several different industries. What we are experiencing today will look very different tomorrow with the current rate of technology improvements and adoption. Dual extruder 3D printing is the primary mechanism fostering the next generation of industrialization because it allows engineers to design with freedom and without constraints. Compared to conventional manufacturing methods or single extruder 3D printers, multi-material 3D printers will equip product development teams to enhance functionality, aesthetics and other critical requirements.

“A man will be imprisoned in a room with a door that’s unlocked and opens inwards; as long as it does not occur to him to pull rather than push.”

Ludwig Wittgenstein - Referenced in Aaron Council’s 3D Printing: Rise of the Third Industrial Revolution

A dual extruder 3D printer goes beyond design & print applications. Instead, it’s a mind-opening technology that can influence so much more. For example, single extruder 3D printers rely on the basic principles of fabrication and will simply print parts layer-by-layer with one material. This eliminates the ability to create complex parts, internal channels, or working gears which leads to a lack of functionality or purpose. Most engineers and designers operate with CAD (computer aided design) software that allows them to digitally design prototypes and products in a 3-dimensional space that doesn’t adhere to natural forces (i.e. gravity). Therefore, designs can become quite complicated and require a technology that is sophisticated and advanced enough to produce these parts.

That’s what dual extruder technology brings to the table for designers and engineers. From inexplicable art to impossible prototypes, this further supports why 3D printing is becoming the primary tool for so many different industries. To further paint the picture, or build the masterpiece, let’s dive deeper into several different dual extrusion use cases and how different industries are applying it today.

Dual Extruder 3D Printer - Support Material

Impossible Parts

The true beauty of a dual extruder 3D printer is the ability to combine model (M) and support (S) materials. Essentially, you are able to 3D print your model in a PLA thermoplastic material and simultaneously print water soluble support structures out of BVOH. This is the science that enables true design freedom and flexibility. You can design and print in a 3-dimensional space that goes way beyond surface level. Now, it’s possible to create interlocking features for workable gears or internal channels for fluid and air passageways. This is only possible with the use of support structures that are literally washed away once the 3D print is finished.

Tips for Users: Different support materials eliminate post processing nightmares or enhanced aesthetics. Contact our Engineering team today to learn more.

Enhanced Mechanical Properties

Let’s take it a step further and instead of Model +Support, why not Model 1 + Model 2? Yes, that is completely possible with dual extruder 3D printers and will provide improvements to the mechanical properties of your part. Combining Model 1 + Model 2 can be a strategic and helpful feature for those product development teams that wish to take functionality to the next level.

For example, lightweighting is a common tactic used by many transportation, automotive and aerospace companies that wish to reduce costs through design. Eliminating weight = less energy costs. A door, table or chair must retain the same strength capabilities but instead of a fully dense part, engineers can create honeycomb internal structures with lighter weight plastics. M1 is a PLA Shell and M2 is a PVA Ultralight infill material that ultimately prints a part with the same strength characteristics, but with less weight associated.

Dual Extruder 3D Printer - Multi-Material Print

Ergonomic Improvements

Ergonomics is the study of human and product (or machine) interaction. Those who design consumer products are constantly iterating prototypes to test ergonomics and user satisfaction (i.e. how to make user friendly, comfortable products). You’ll notice that the majority of consumer products and electronics are designed and built with soft touch overmolds, rubber or TPU materials to enhance comfort. Think of a grip on a power tool. With dual extruder 3D printers, engineers can combine rigid plastics with soft touch flexible materials to produce overmolds. Material 1 is a Pro-HT plastic with enhanced strength properties combined with Material 2, a TPU categorized as a Shore 98 A flexible material.

Tips for Users: Using PLA as a support material for TPU printed singularly will enhance aesthetic features. Contact our Engineering team today to learn more.

Improve Aesthetics

We have discussed functionality, now let’s turn to the possibilities for artistic features with multicolored 3D printing. We do not live in a monochromatic world, so we do not expect you to design for one. Oftentimes, prototypers will present their products to focus groups or potential customers for invaluable feedback to validate a design. It’s important to provide parts that are aesthetically pleasing and match a color scheme for the end product. Having multi colored parts is valuable for other applications - such as color coded safety fixtures on assembly lines, diagram models used in healthcare communications or other research, education or artistic purposes.

Dual Extruder 3D Printer - Multi-Color Print

True Mass Production

Unique to BigRep is that ability to print Tandem mode, which splits the printing platform in half and enables the production of parts in twice the time. The dual extruders are separated by distance, but connected by advanced software so that they mimic each other and print identical parts on the platform. This is ideal if you wish to begin batch production and want to bypass tooling, machining and other costly manufacturing methods. BigRep already offers one of the largest build platforms in the industrial market, and Tandem mode enables manufacturers to react immediately and produce parts on demand. This is unheard of in the marketplace today, and provides a significant time and cost savings advantage to users.

Tips for Users: If you have a print bigger than 8 kilos with the same material, split the STL, and print the first 8 kilos with Extruder 1. Use Extruder 2 with the remaining material which will allow you to print 16 kilos with the same filament.

Learn more about Tandem Mode by talking to our 3D printing experts today.

This is only a small collection of advantages awarded by a dual extruder 3D printer. It’s important to remember that new materials drive applications, and the book of 3D printing continues to write itself. Single extruder technology is a toy made for tinkerers and hobbyists. In order to produce parts that are functional and reliable, dual extruder 3D printers are a necessity.

The Future of Dual Extruder 3D Printers

To summarize the benefits: Industrial 3D printers and dual extruder technology with BigRep enables you to produce impossible parts with support material. It exceeds a variety of functional requirements such as mechanical property improvements or soft touch overmold applications. Dual extruders provide a pathway for artists, architects and creatives to think outside of conventional fabrication methods and bring color, realism and life to their designs.

Where does dual extruder technology go from here? Are three heads better than two? Maybe, but the evidence isn’t there to support it quite yet. In the meantime dual material printing continues to be such a major advantage for industrial engineers and designers. We recommend staying in touch with us, since we are constantly evolving our technology and materials to further the adoption of 3D printing.

Do you have a new application you want to bring to life? We want to hear from you!

Dual Extruder 3D Printers in Short

What is dual extrusion 3D printing?

Do dual extruders print faster?

What is the purpose of dual extruder 3D printer?

What is dual extrusion in 3D printing?

What is the benefit of having two extruders?

What is an extruder and how does it work?

What are the types of extruders?

What does an extruder do in a 3D printer?

About the author:

Dominik Stürzer

Head of Growth Marketing

What is Vacuum Forming & Thermoforming? How to 3D Print Molds Easily

April 14, 2023December 6, 2020

Vacuum forming has been used for nearly a century to make many of the products we see and use daily. From grocery store items to car parts, vacuum formed components are all around us. But how are they made - and how is 3D printing making them better?

What is Vacuum Forming & Thermoforming?

Vacuum forming is a type of thermoforming: heat used to form a design. Thermoforming processes include vacuum forming, pressure forming, and twin sheet forming. Each of these processes uses a mold or molds to shape heated sheets of plastic into the desired form.

Pressure forming methods require that the plastic sheet be pressed between two molds and then heated to assume the shape. In twin sheet forming, two plastic sheets are heated and fused together to form double-walled or hollow parts.

Vacuum forming is the simplest of the thermoforming methods, using only one mold at a time. As the name might indicate, vacuum forming relies on a vacuum, as suction applied to the heated plastic sheet will draw it around the mold to create the appropriate contouring.

How Does Vacuum Forming Work?

The vacuum forming process comprises a few relatively straightforward steps:

Clamp a plastic sheet in a frame
Heat the plastic sheet to the point the plastic is workable - soft enough to take on a new shape, but not heated to the point of melting or losing its integrity.
Apply vacuum to pull the plastic around the mold, shaping the heated sheet to the desired contours.
Allow the plastic to cool before removing from the mold. This may be expedited for large pieces, using fans or cool mists.
Trim excess plastic and smooth edges to final part quality.

See how the process works on a Formech vacuum forming machine:

Types of Plastic for Vacuum Forming

The ultimate result of a successful vacuum forming operation is creating a shaped plastic part. But what type of plastic should be used? That depends on what you want from the product; different plastics are applicable for different uses. For a clear plastic salad box, you wouldn’t need the same high impact strength as you would for an outdoor sign, for example, while a car bumper needs still more durability.

When choosing a plastic, considerations that should come into play include:

Strength
- Rigidity
- Chemical/impact/UV resistance
Specific gravity
Formability
Colours
Hygroscopicity
Temperature range for pliability
Availability/cost

Further, you’ll need to take into account the look and feel of the plastic for the end-use application you have in mind. A strong plastic may not be usable if it offgasses volatile organic compounds (VOCs) when subjected to high temperatures, for instance.

Among the most popular plastics used in vacuum forming are:

ABS - acrylonitrile butadiene styrene)
Acrylic - PMMA - Poly(methyl methacrylate)
HDPE - high density polyethylene
HIPS - high impact polystyrene
PC - polycarbonate
PET - polyethylene terephthalate
PETG - polyethylene terephthalate glycol
PP - polypropylene
PS - polystyrene
PVC - polyvinyl chloride

Each option has its pros and cons. As with any end-use material choice, you’ll need to weigh the cost and ease-of-working of a given material with its strength and performance.

How to Create Molds for Vacuum Forming

The molds used for vacuum forming are critical to the process: they form the basis of the actual shape for the end product. How you choose to create your molds will depend on the precision, complexity, and timing of your project.

While wood, aluminium, and structural foam are among the conventional options for mold making, 3D printed molds are becoming more popular. These newer options enable more complex geometries to be made and can significantly speed up the process of mold making.

3D Printed Molds

The benefits of 3D printing are many. 3D printing can reduce the time and costs needed to make items like vacuum forming molds, as well as improve the geometric complexities possible. Faster turnaround and lower costs can be a major incentive when it comes to adopting a new way to create molds, forms, and rapid tooling.

In-house 3D printing can substantially shorten timelines when it comes to producing new molds and tooling. Without the need to outsource mold production, wait for turnaround is limited only to how fast a 3D printer can bring a CAD design to life - which can be as short as a matter of hours. Only the material needed to produce a given design need be used, eliminating waste and additional material costs. Furthermore, small features - think textures or even text - can be added without increasing the cost of a design. Customization and rapid prototyping of designs are also big benefits, getting unique designs to customers who need them quickly and for lower cost.

Working with the right 3D printing equipment is of course key to producing the best results. Industrial equipment offers professional quality, as well as the opportunity to work with heat-resistant materials like carbon fiber 3D printing filament. Furthermore, large-format 3D printers enable faster production of either large parts or several small parts in a single build job.

3D Printed Mold for Vacuum Forming

Wood, Aluminium and Structural Foam Molds

Traditional vacuum forming molds are formed by subtractive processes, such as carved wood or structural foam, or by metal casting processes. While each of these processes when leveraged appropriately will produce workable molds, their use is subject to the wait times of casting and high costs of milling.

Wooden molds are well-known to be durable for vacuum forming. Strong wood choices can lead to molds that can be used for hundreds, if not thousands, of vacuum forming runs. Eventually, though, most wood molds will splinter or warp. The best usage of wooden molds is when little detail is required or a thicker mold is desirable.

Cast aluminum molds are among the most durable types, best-suited for scale production of 100,000+ parts. Costs of both material and production -- which can take up to a few months -- make aluminum molds infeasible for shorter production runs.

Structural foam molds are durable and can also be used for larger production runs. These molds are lightweight yet extremely durable, and are often a lower-cost alternative to aluminum options. Many plastics are viable, as a chemical blowing agent is used to makes the plastic’s internal walls thicker for longer-lasting molds.

Applications for Vacuum Forming

Vacuum forming is often used to create parts we interact with every day. Lightweight packaging, securely fit coffee cup lids, and car parts are just a few of the places we often encounter vacuum formed parts.

Aerospace

Aerospace applications for vacuum forming can range from specialty packaging to keep tools in one place to massive parts. Cabin components like large bulkhead dividers and seating needs like arm rests, footwell trays, seat backs, and tray tables are increasingly produced via vacuum forming.

Thermoforming Application: Aircraft Interior

Automotive

In the automotive industry, both internal and external components are often vacuum formed. From relatively small cabin structures like the grate on an air conditioning vent to a full bumper, shaped plastics help to shape our automotive experiences.

Packaging

Salad containers or sushi boxes, razor packaging, and sterilized medical device packages are just a few of the packaging uses for vacuum forming. The plastic sheets used in this process can be shaped to precisely house a premium product or made more generally to hold whatever we need to carry.

Consumer Goods

Toys, musical instrument cases, helmets, luggage, barware -- you name it and the plastics we use every day often come about through vacuum forming. From the outer housing on a bicycle helmet to the body of an RC car, vacuum formed products keep us all rolling.

Conclusion

When it comes to vacuum forming, the sky is the limit. Heated plastic can be exactly shaped to match a custom mold for one or thousands of parts. When the molds are 3D printed, they can be made with more complexity, more detail, more options -- and less cost.

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Vacuum Forming and Thermoforming FAQs

What is thermoforming molding?

Is thermoforming and vacuum forming the same?

What are the advantages of vacuum forming?

What is the vacuum forming process?

Thermo or 'Vacuum forming' is one of the oldest and most common methods of processing plastic materials. The process involves heating a plastic sheet until soft and then draping it over a mould. A vacuum is applied sucking the sheet into the mould. The sheet is then ejected from the mould. In its advanced form, the vacuum forming process utilizes sophisticated pneumatic, hydraulic and heat controls thus enabling higher production speeds and more detailed vacuum formed applications.

What products are made using vacuum forming?

In recent years, vacuum forming has also started to be used for creative purposes, particularly within the retail and marketing industry. Numerous household items are made from vacuum forming plastic. The plastic bathtub in the bathroom, the plastic utensils, and appliances that can found in the kitchen, the garden equipment that is stored in the shed. These are all common products found in the home environment, things that are used on a day-to-day basis, created via the vacuum forming process.

What are the materials used in making thermoforming mold?

How are thermoforming molds made?

Thermoforming mold is usually made of cheaper aluminium. Injection molds are made of steel, thick aluminium or strong alloys to maintain large production runs.

Thermoforming is using a single-singe tool and injection molding is using a double-sided mold. The initial cost for thermoforming is lower than injection molding. But thermoforming mold is not as durable as injection molds so it can be used only for small volume and not repeat production.

Which type of molds are used in thermoforming?

Both ferrous and non-ferrous metals have been used extensively for this purpose, with advantages and disadvantages of different types well balanced depending on the nature of the part to be formed, the volume of production, type of equipment and numerous other variables.

Generally, wood and plaster are the most used materials. Cast phenolic and epoxy resin molds works well in short to medium runs. In long production runs generally require a metal mold.

How 3D Printing works with the vacuum forming technique?

When it comes to vacuum forming, the sky is the limit and when the molds are 3D printed, they can be made with more complexity, more detail, more options – and less cost. Heated plastic can be exactly shaped to match a custom mold for one or thousands of parts.

Today, Made in Space has announced that such a feat has now been proven possible through a series of tests performed here on Earth. This ability is an exciting one, but the true goal of NASA and Made in Space has been to 3D print in vacuum of space itself.

About the author:

Dominik Stürzer

Head of Growth Marketing

Rapid Prototyping: A Comprehensive Guide

November 14, 2023October 12, 2020

In the competitive arena of product development, rapid prototyping is the cornerstone of innovation. 3D printing is at the forefront of this process, transforming ideas into tangible realities with unprecedented speed and precision. This synergy of technology and creativity not only enhances the design process, it redefines it.

Engineers and designers now have a powerful ally in 3D printing that streamlines the path from concept to prototype.

Find out how this rapid prototyping not only accelerates development cycles, but opens up new ways to design and excel.

Understanding Rapid Prototyping

Before delving into the benefits and challenges of rapid prototyping, it is important to first define what it is. Rapid prototyping is a methodology that involves creating physical models of designs or concepts using computer-aided design (CAD) software and usually 3D printing. The goal is to produce a tangible representation of an idea that can be tested and refined before committing to large-scale production.

What is Rapid Prototyping?

Rapid prototyping, also known as additive manufacturing or 3D printing, is a process that builds up layers of material to create a three-dimensional object. It has revolutionized the product development cycle by significantly reducing the time and cost traditionally associated with creating prototypes.

Is Rapid Prototyping the Same as 3D Printing?

When the technology was first developed, 3D printing was so synonymous with rapid prototyping that the two terms were interchangeable. Whether referencing “3D printing,” “rapid prototyping,” or “RP,” the conversation generally all referred to the same thing. Today, 3D printing has developed into end-use production capabilities as well and is more commonly synonymous with “additive manufacturing.”

Still, rapid prototyping was the first and remains the largest application for 3D printing. Iterations from proof-of-concept through to functional prototype can all be 3D printed. Whether outsourced or in-house, using 3D printers speeds up the rapid prototyping significantly through removing traditional bottlenecks in tooling and/or shipping. Rapid prototyping can also increasingly be done using the same 3D printing technology as will be used for the final product.

The Importance of Rapid Prototyping in Innovation

One of the main reasons why rapid prototyping is vital in the innovation process is its ability to accelerate the design cycle. In the past, creating physical prototypes required specialized equipment and often took weeks or even months to complete. With rapid prototyping, businesses can quickly produce multiple iterations of a design and test their feasibility in a matter of days.

Rapid prototyping not only speeds up the design process but also allows for more creativity and experimentation. Designers and engineers can easily explore different ideas and concepts by quickly producing physical prototypes. This iterative approach encourages innovation and pushes the boundaries of what is possible.

Also, rapid prototyping enables effective communication and collaboration among team members. Instead of relying solely on 2D drawings or verbal descriptions, stakeholders can interact with a physical prototype, providing valuable feedback and insights. This enhances the decision-making process and ensures that everyone involved is on the same page.

In addition to its role in the design and development phase, rapid prototyping also plays a crucial role in marketing and sales. By creating realistic and visually appealing prototypes, businesses can showcase their products to potential investors, customers, and partners. This helps in securing funding, generating interest, and gaining a competitive edge in the market.

Rapid prototyping allows for early detection of design flaws and technical issues. By physically testing a prototype, engineers can identify and address any potential problems before moving forward with production. This saves time, resources, and prevents costly mistakes down the line.

Another advantage of rapid prototyping is its ability to facilitate customization and personalization. With the flexibility of additive manufacturing, products can be easily tailored to meet individual customer requirements. This opens up new opportunities for mass customization and niche markets.

Overall, rapid prototyping is a game-changer in the world of product development. Its speed, cost-effectiveness, and ability to foster innovation make it an indispensable tool for businesses across various industries. By embracing rapid prototyping, companies can stay ahead of the competition, deliver better products, and drive continuous improvement.

The Process of Rapid Prototyping

Now that we understand the concept of rapid prototyping, let's explore the steps involved in the process and the tools and techniques used to bring ideas to life.

Steps Involved in Rapid Prototyping

Rapid prototyping typically involves the following steps:

Design: The first step is to create a digital 3D model of the idea using CAD software. This model serves as the blueprint for the physical prototype.
Printing: Once the design is finalized, it is sent to a 3D printer. The printer uses a variety of materials, such as plastic or metal, to build up the prototype layer by layer.
Post-processing: After the printing process is complete, the prototype may require some post-processing, such as sanding or polishing, to achieve the desired finish.
Testing and Iteration: The final step involves testing the prototype to evaluate its functionality and gather feedback. Based on the results, the design can be refined and further prototypes can be created.

Design is a crucial step in the rapid prototyping process. It involves translating an idea into a digital 3D model using computer-aided design (CAD) software. This step requires careful consideration of the desired functionality, aesthetics, and manufacturability of the prototype. Designers must ensure that the model accurately represents the intended product, allowing for a realistic evaluation of its feasibility and potential improvements.

Once the design is complete, the next step is printing the prototype. This is where the magic happens! The digital model is sent to a 3D printer, which brings it to life layer by layer. The 3D printer uses various materials, such as plastic or metal, depending on the requirements of the prototype. The choice of material can greatly impact the final product's strength, durability, and appearance.

After the printing process is finished, the prototype may undergo post-processing. This step involves refining the prototype's surface finish and texture to achieve the desired look and feel. Techniques such as sanding, polishing, or applying a protective coating may be employed to enhance the prototype's aesthetics and functionality. Post-processing is crucial for creating prototypes that closely resemble the final product, allowing for a more accurate evaluation and feedback.

Testing and iteration are vital components of the rapid prototyping process. Once the prototype is complete, it is subjected to rigorous testing to evaluate its functionality, performance, and user experience. This step helps identify any design flaws or areas for improvement. Feedback from testing is then used to refine the design and create further iterations of the prototype. This iterative process allows for continuous improvement and optimization of the product, ensuring that it meets the desired requirements and objectives.

Tools and Techniques for Rapid Prototyping

Several tools and techniques are used in rapid prototyping, each with its own advantages and limitations. Some of the most commonly used methods include:

Fused Deposition Modeling (FDM): This technique involves extruding thermoplastic material through a heated nozzle to build up the prototype layer by layer. FDM is known for its affordability and versatility. It is widely used in various industries, including product development, engineering, and architecture.
Stereolithography (SLA): SLA uses a laser to solidify liquid resin, creating the prototype layer by layer. This method provides high levels of detail and accuracy, making it suitable for creating intricate and complex prototypes. SLA is commonly used in industries such as jewelry, dentistry, and automotive.
Selective Laser Sintering (SLS): SLS utilizes a laser to fuse powdered material together to form the prototype. This technique is particularly suitable for creating prototypes with complex geometries and functional parts. SLS is widely used in industries such as aerospace, automotive, and medical.

There are various other tools and technologies available for prototyping, such as CNC machining, vacuum casting, and laser cutting, but rapid prototyping always refers to 3D printing. The choice of tool or technique depends on factors such as the desired material properties, level of detail required, and budget constraints.

Rapid prototyping has revolutionized the product development process, enabling faster and more efficient iteration and innovation. By allowing designers and engineers to quickly transform ideas into tangible prototypes, it accelerates the development timeline and reduces the risk of costly errors. With the continuous advancements in technology and materials, the possibilities for rapid prototyping are expanding, opening up new avenues for creativity and problem-solving.

The Benefits of Rapid Prototyping for Businesses

Rapid prototyping offers numerous benefits that contribute to accelerated innovation. Let's take a closer look at two key advantages: time and cost efficiency, and enhanced design and functionality.

Time and Cost Efficiency

In traditional product development cycles, creating physical prototypes can be time-consuming and expensive. The process typically involves multiple iterations, which can lead to delays and increased costs. However, with rapid prototyping, businesses can significantly reduce both the time and cost associated with developing new products.

One of the main reasons for the time and cost efficiency of rapid prototyping is the ability to quickly iterate and test designs. Unlike traditional methods, where each iteration requires significant time and resources, rapid prototyping allows for rapid design changes and modifications. Designers can quickly create a new prototype, test it, and make necessary adjustments in a matter of hours or days, rather than weeks or months.

This accelerated iteration process not only saves time but also reduces costs. By identifying and addressing any potential issues early in the process, companies can avoid costly mistakes and rework later on. This proactive approach helps streamline the overall product development cycle, leading to faster time-to-market and increased competitiveness in the industry.

Decrease Time to Market

The time it takes an idea to move from concept to deliverable should be as short as possible. Replacing months or years of traditional wait times in the iterative prototyping process with days or weeks is an easily apparent benefit of rapid prototyping. A 3D printer can precisely create the next iteration from a slightly tweaked design file much faster than could any traditional tooling-based prototyping process. Speeding the design cycle inherently improves time-to-market for a new product.

Enhancing Design and Functionality

Rapid prototyping enables designers and engineers to explore complex designs and functionalities that may be difficult or costly to achieve with traditional manufacturing methods. By creating physical prototypes, they can test the design's functionality, ergonomics, and aesthetics, and make necessary improvements before moving forward with production.

With rapid prototyping, designers have the freedom to experiment and push the boundaries of what is possible. They can easily create multiple iterations of a design, allowing them to explore different concepts and variations. This flexibility not only leads to better design outcomes but also encourages innovation and creativity.

Furthermore, rapid prototyping allows for a more iterative and collaborative design process. Designers can share physical prototypes with stakeholders, such as clients, investors, or end-users, to gather feedback and make informed design decisions. This iterative feedback loop ensures that the final product meets the needs and expectations of all stakeholders, resulting in a more successful and marketable product.

In addition to design improvements, rapid prototyping also enables the testing of functionality. Engineers can simulate real-world conditions and evaluate how the product performs under different scenarios. This testing phase helps identify any flaws or limitations in the design, allowing for necessary adjustments and refinements.

Improve Effective Communication

The fast turnaround of rapid prototyping eases communication gaps by opening up the conversation. It’s much easier if every engineer on your team has the same understanding of a process, and quickly getting a next physical prototype in hand offers a clear point of reference. As each prototype becomes closer to the feel and performance of the final design, small tweaks and large adjustments both become easier to understand for your entire team.

Overall, rapid prototyping enhances both the design and functionality of products. It empowers designers and engineers to create innovative and user-centric solutions, while also reducing the risk of costly design errors and production issues.

How to Use Rapid Prototyping in the Engineering Process

Rapid prototyping sounds great, but where can it be used in the engineering process? The answer may not be wholly surprising at this point: from initial proof-of-concept to final-look-and-feel prototype, rapid prototyping can come into play across the entire process.

Concept Prototypes

The earliest prototypes are often conceptual. Proof-of-concept prototypes serve as physical validation of the ideas that may have emerged as a sketch on a napkin. Taking an idea into the three-dimensional real world is the best way to prove viability. Getting hands-on with a concept model can help your engineering team understand their next steps at the same time as it may encourage management to simply move forward with a project.

These early prototypes are often the roughest, as they are the lowest-risk representations made in the rapid prototyping cycle. These prototypes are made quickly and generally in different materials and colors than later-stage prototypes, much less final designs.

Aesthetic or Industrial Design Prototypes

Once a design is validated in its roughest form, it moves next into an aesthetic or industrial design step. These next prototypes begin to hone in on how the design should look and feel, with the thought process beginning to turn toward usability and functionality -- without necessarily being fully functional quite yet. To ensure a new part will fit into a greater whole, or a new product will fit with your brand’s existing aesthetic or functional line, these prototypes more accurately look like something that is moving toward a final design. These prototypes also enable engineers to consider how exactly to best manufacture the eventual final design.

Especially when working with life-sized, larger designs like furniture, having life-sized prototypes to fit to spaces and users becomes ever more important as designs move through the prototyping cycle. Large-scale 3D printing can bring these large-scale designs to life, allowing for a full iteration to be made and tested in less than the time it would take for a traditional tool to be made. Furniture maker Steelcase experienced this benefit first-hand as they use their large-format BigRep 3D printer to create new furniture designs:

Functional Prototypes

A functional prototype does just that: it functions. These later-stage prototypes are often made of materials similar to what will be used in a final product, to validate that everything will work as intended. Engineers at this stage pay attention to performance: does it fit, does it function, do load-bearing parts bear loads?

Attention must be paid to detail, to how the final part will be manufactured (especially if this will be done in a different process than the prototype; for example, 3D printing a prototype for a part that will ultimately be injection molded) as well as how the final part will be post-processed/finished.

Test Serial Production

Many products bound for the mass market are bound for mass production, and this may mean in a different manufacturing process. While 3D printing may be the right technology for both rapid prototyping and serial production of the final part - consider, for example, cases of mass customization - this will not always be the case.

Prototyping must take into account the eventual manufacturing process to be used, and later-stage prototypes should use the same materials and fit into the appropriate manufacturing parameters as the final parts will be. Consideration for traditional production processes comes more into play here, for example for tooling, jigs and fixtures, or any other necessary implements. Design for additive manufacturing (DfAM) may move toward traditional design for manufacturing (DFM) thinking.

Demonstration or Presentation Model Prototypes

The final look is the final stage in prototyping, the last step before full production begins. At this stage, a prototype should not only feel and operate like the final product, but needs to look like it, too. This prototype can be used for marketing materials while production ramps up, for convincing investors of final viability and feasibility, for final field testing, or for any other demonstration or presentation needs. The goal of rapid prototyping is to reach this stage faster than ever before using conventional prototyping workflows.

Challenges in Rapid Prototyping

While rapid prototyping offers many advantages, it is not without its challenges. Let's discuss potential limitations and risks, as well as strategies for overcoming obstacles in the rapid prototyping process.

Rapid prototyping, also known as 3D printing, has revolutionized the manufacturing industry. It allows for the quick and cost-effective production of prototypes, enabling designers and engineers to iterate and refine their designs at a much faster pace. However, there are certain limitations and risks associated with this process that need to be addressed.

Potential Limitations and Risks

One of the main limitations of rapid prototyping is the material selection. While rapid prototyping supports a wide range of materials, including plastics, metals, and ceramics, the selection may not be as extensive as with traditional manufacturing methods. This can be a constraint when trying to replicate the exact properties and characteristics of the final product.

Additionally, the strength and durability of prototyped parts may not match those of the final manufactured product. This can be a limitation when testing for functionality and reliability. It is crucial to keep in mind that prototypes are not always a perfect representation of the end product, and adjustments may need to be made during the manufacturing process.

Another risk associated with rapid prototyping is the potential for design flaws to go unnoticed until the final product is manufactured. Since the prototyping process is relatively fast, there may not be enough time for thorough testing and evaluation. This can result in costly rework and delays in production.

Overcoming Obstacles in Rapid Prototyping

To overcome these challenges, it is important to carefully consider material selection during the design phase. By understanding the limitations of the available materials and their properties, designers can make informed decisions and choose the most suitable material for their specific application.

Additionally, testing the prototypes under realistic conditions and conducting thorough performance evaluations can help identify and mitigate any potential issues before production. This includes subjecting the prototypes to various stress tests, simulating real-world scenarios, and gathering feedback from end-users. By thoroughly evaluating the prototypes, designers can gain valuable insights and make necessary improvements to ensure the final product meets the desired standards.

Furthermore, collaboration between designers, engineers, and manufacturers is crucial in overcoming obstacles in rapid prototyping. By working together and leveraging each other's expertise, it becomes easier to address any challenges that arise during the prototyping process. Regular communication and feedback loops can help streamline the process and ensure that all parties are aligned towards achieving the desired outcome.

In conclusion, while rapid prototyping offers numerous benefits, it is important to be aware of the potential limitations and risks associated with the process. By understanding these challenges and implementing strategies to overcome them, designers and engineers can maximize the potential of rapid prototyping and accelerate the innovation and development of new products.

3D printed drone eVTOL by Airflight for crane and hoisting applications

Future of Rapid Prototyping

Rapid prototyping continues to evolve, presenting exciting opportunities for the future of innovation. Let's explore some of the emerging trends in rapid prototyping and its role in shaping the future of the industry.

Emerging Trends in Rapid Prototyping

One key trend is the integration of rapid prototyping with other advanced technologies, such as artificial intelligence (AI) and virtual reality (VR). This combination allows for even faster and more accurate prototyping, as well as enhanced visualization and user experience.

With the integration of AI, rapid prototyping can now generate intelligent designs based on user requirements and preferences. This not only speeds up the prototyping process but also ensures that the final product meets the specific needs of the target audience. Additionally, AI-powered rapid prototyping can analyze vast amounts of data to identify potential design flaws or areas for improvement, leading to more refined and successful prototypes.

Virtual reality is another technology that is revolutionizing rapid prototyping. By creating virtual environments, designers and engineers can test and experience their prototypes in a simulated setting, allowing for better evaluation of form, fit, and functionality. This immersive experience enables early identification of design flaws and facilitates iterative improvements, ultimately resulting in more robust and user-friendly products.

The Role of Rapid Prototyping in the Future of Innovation

Rapid prototyping will play a crucial role in the future of innovation by enabling businesses to swiftly adapt to changing customer demands and market dynamics. As the technology continues to advance, we can expect to see even greater speed, precision, and customization in the prototyping process, further empowering businesses to bring their innovative ideas to life.

One industry that is benefiting from rapid prototyping is aerospace. With the ability to rapidly produce and test complex components, engineers can iterate designs and optimize performance, leading to lighter and more fuel-efficient aircraft. Rapid prototyping also enables the production of intricate and customized parts that would be difficult or costly to manufacture using traditional methods.

In the consumer electronics sector, rapid prototyping allows companies to quickly bring innovative products to market. By rapidly iterating designs and incorporating user feedback, businesses can stay ahead of the competition and meet the ever-changing demands of consumers. This agility in product development is crucial in an industry where trends and technologies evolve rapidly.

Conclusion

In conclusion, rapid prototyping is a powerful tool that accelerates innovation by allowing businesses to quickly iterate, test, and refine new ideas. Through the use of advanced technologies and manufacturing processes, companies can bring innovative products and services to market faster than ever before. While there are challenges in the rapid prototyping process, the benefits far outweigh the limitations. As we look to the future, rapid prototyping will continue to redefine the way we bring ideas to life and shape the landscape of innovation.

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About the author:

Dominik Stürzer

Head of Growth Marketing

Mass Customization and the Power of 3D Printing

February 23, 2023September 14, 2020

Mass Customization and the Power of 3D Printing

One of the major selling points of adopting 3D printing technology into operations is the ability to mass customize.

But what exactly is mass customization, why would anyone want it, and how does 3D printing enable it?

What is mass customization?

At its simplest, mass customization is exactly what it sounds like: customization on a large scale.

Customization is typically thought of as more one-of-a-kind than one-size-fits-all, which can make it difficult to achieve on a large scale. The major benefit here is in combining the low cost-per-unit of mass manufacturing with the appeal and flexibility of individual design.

Mass customization can be simple or complex, depending on the manufacturer and application. Selecting a different color or size of a design, for example, is a relatively simple way of customizing a mass-produced product. Upping the complexity, the shell of a certain system may look the same, such as in the case of a computer, while the internal components may be swapped out to affect speed or power, to create many potential configurations of customization within a single product.

In many cases, the ultimate assembled product may thus be customized, even if the individual components themselves are still subject to standard mass production. In different applications, though, a single order of many of the same object may require slight variations between each item in the run. This inherently changes the plan for manufacturing, as a single mold for injection molding can only create the same geometry time after time.

Why is mass customization useful?

From shoes to computers to widgets, there are myriad reasons why a customer might want to offer variances within a single production run. Let’s look to an example in the medical industry to easily understand why customizing on a larger scale might be helpful to a manufacturer.

One of the earliest wide adopters of 3D printing technology was the hearing aid industry. Another more recent example is the orthodontic aligner business. In both these cases, a manufacturer must make an individually fitted device for the unique anatomy of a single person. No two ear canals, nor two sets of teeth, are quite the same. When it comes to dental aligners, even a single person’s needs will change as the teeth are shifted through wearing these and new aligners will be required on a fairly regular basis.

In both hearing aids and aligners, it’s clear to see why each design must be unique to its eventual wearer. But getting there with mass production technology can be a trickier proposition.

For a manufacturer, good business sense dictates that every effort should be made to create the best possible product at the lowest cost, using the least material, time, and labor possible. That generally means producing on a larger scale, as price-per-unit can be reduced through the concept of mass production. Combining that capability with the needs of products that are customized in at least some aspect is where the idea of mass customization begins to make strategic sense.

Mass customization examples

Beyond the medical industry, mass customization comes into play across many application areas.

One of the most interactive ways to access mass customization is through co-creation, which is a collaborative effort working closely with a partner or customer. Both parties’ expertise, whether of technology or end-user experience, comes into play to together design a solution that can be tweaked as needed to individualize the ultimate experience.

Sizing and color are among the primary aspects of many designs, from furniture to clothing, that can be customized, but by no means are they the only facets.

Mass Customization: 3D printed part for special needs car

German automotive company Paravan, for example, is the market leader in producing wheelchair-accessible vehicles. The company has turned to large-format 3D printing to customize vehicles for drivers and passengers with disabilities or special needs. While a base car may be similar, each individual’s needs are different; some may need a modified steering mechanism while another may need an adapted braking system.

Comfort, style, safety, adaptability, personality, luxury -- the reasons for wanting mass customization are many, though ultimately all boil down to the need to satisfy the end user.

mass-customization-adaptive-customization-example

Different approaches to customization

Just as the goals of customization differ case by case, so do the approaches to achieving it. Among the major approaches are collaborative, adaptive, transparent, and cosmetic customization.

Collaborative customization

When it comes to collaborative customization, co-creation is the key. Working closely together with your customer to identify exactly what needs must be met, and what may need to be adjusted to meet individuals’ unique needs from a base design, the co-creators are able to determine the whats and the whys to then develop the hows of appropriate mass customization.

Adaptive customization

Focused more on the end user, adaptive collaboration enables, well, adaptation. Allowing a few options to customize a product, a customer can select the fit or style that best suits them. When making products like water sports mobility devices, for example, ensuring the right fit for the rider is not only practical, but a safety measure. Large-format 3D printing is enabling just that for JAMADE’s AMAZEA underwater scooter.

Transparent customization

Sometimes customization seems obvious - and when needs are apparent, transparent customization can come into play. Here, individuals’ products are customized from the back end as the producer can reliably predict and then discreetly create designs that suit those needs. The goal with transparent customization is to make workflow easier for the client, removing the need for ongoing back-and-forth discussion.

Cosmetic customization

Customization can go into the very essence of a product, or be a bit more front-facing. Cosmetic customization comes into play for mass production that doesn’t “look mass produced.” No one wants to feel like they’re one of a crowd, so presenting essentially the same product in a few different ways can help differentiate between customers -- think company logos, different colors, and other cosmetic branding.

Challenges to mass customization

As valuable a prospect as mass customization is, actualizing the concept still faces some challenges. As more industrial 3D printing capabilities are put to use in mass customization, though, these challenges can be seen as simply the next landmarks of achievement.

Higher costs

The numbers are simple: it’s more cost-effective to mass produce batches of like items. We see this same split when considering injection molding versus additive manufacturing when it comes to mass production. As of today, injection molding is a more economical option for mass production.

The same cannot be said, however, when it comes to customization. Producing quantities of slightly different items means that the same mold will not suffice for each. Making new molds in this manner would be extremely expensive, and likely more costly in terms of both money and extended lead time to make them all than a manufacturer would find agreeable.

In order to effectively mass customize, either individualized molds must be made for each or manufacturing must be done with no molding at all - and that’s where industrial 3D printing comes into play. This changes the value proposition, as the lack of molds enables the individualization of each piece in a mass production pipeline without adding to costs as would happen with traditional processes.

When considering higher costs, comparisons must be apples-to-apples; like must be compared with like. Mass customization is not inexpensive, but with increasing demand from end-use consumers preferring their specific needs be met, it is only going to be on the rise across a variety of applications and industries.

Returning of customized products

Returns are a fact of life in any production environment. For any number of reasons, customers may see the need to return their goods. Any reason may be given, from having not selected the right item for their purpose to changing their minds - and most major suppliers have return policies in place.

When those items to be returned have been customized, though, things change for the supplier. Many returned goods can be returned to the shelves with only a slight inventory adjustment. Items made to fit a specific user or need, though, cannot simply go back on a shelf.

Returns must be handled on a case-by-case basis, with consideration of the ability to resell the product to a new buyer. When it comes to personalized medical goods, for example, there simply is no other customer. When customization came in the form of a size or color, though, more opportunities are likely for different buyers.

Supply chain efficiency

Finally, mass customization may alter the efficiencies of supply chain operations. Mass production typically requires longer lead times when custom options are available.

However, through advanced manufacturing technologies like large-format 3D printing, lead times may not see much impact. Because digital designs lead directly to the physical products, with no need for tooling or molding made along the way, each print job takes a specified amount of time regardless of the variation in designs on the build tray.

How can we achieve mass customization?

When it comes to true mass customization, making full product runs with slight-to-major variances among each object made, the single best option available today is to use 3D printing.

3D printing is a digital manufacturing technology that enables every object on a build plate, whether that be two or 2,000, to be different. By tweaking the 3D model, each design can be customized for its ultimate purpose without any additional expense. There is no need for tooling to be made, nor new molds for each individual design adjustment, significantly reducing the time and money typically involved in creating different designs.

When using large-format 3D printing equipment, new possibilities open up for industry and art alike, enabling every design to be as unique as a fingerprint.

How can we achieve mass customization?

When it comes to true mass customization, making full product runs with slight-to-major variances among each object made, the single best option available today is to use 3D printing.

When using large-format 3D printing equipment, new possibilities open up for industry and art alike, enabling every design to be as unique as a fingerprint.

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Read how Kingston University, Helmut Schmidt University and more are using BigRep 3D printers for their classrooms and research.

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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.

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Der industrielle 3D-Drucker STUDIO G2 wurde speziell auf Zuverlässigkeit bei abrasiven und technischen Werkstoffen ausgelegt. Er ist ein langlebiger und kostengünstiger Partner für Ihre Innovationen, da er das gegenwärtig beste Verhältnis zwischen Bauvolumen und Auflösung bei 3D-Druckern bietet. Der STUDIO G2 mit seinem ansprechenden und platzsparenden Gehäuse eignet sich perfekt zur Produktion großformatiger Teile in jeder Arbeitsumgebung – vom Büro bis zur Werkstatt.

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Head of Growth Marketing

HOW TO: 3 Steps to Hide the Seams and Become Design Leader

February 23, 2023October 17, 2018

Why is it important?

If one has a good knowledge of slicing software, they can reach a higher quality of the printed object. That naturally influences the general outlook of the one. Important aspect of the final print are the seams. They might spoil the effect of the design. The continuity of the print can be lost at start and end points of every layer. Hiding the seams is important in case of creating a prototype that is true to the final product as possible. Furthermore, it’s especially meaningful if you want to print the ready-to-use objects with important details.

In 3D models a slicing program transforms the model into G-code. The code includes any preferred optimizations and parameter changes. Thanks to that, the person printing the object has much more control of the quality and final outlook of the print. If the software is not set up properly, it automatically generates random starting points in different locations. That can affect the quality of the print. However, when the settings can be changed. It means that user can also change the whole project into one united object. That includes hiding the seams or unwanted curves.

In BigRep we understand the need for the best possible finish effect of the project. That is why we try different slicing methods, to find the perfect one and apply it for the full print height. In our case it is very important due to the large-scale printable quantity.

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The tutorial explains how to avoid this problem and how to, using Simplify3D slicing software, step-by-step generate optimal start points. Marco Mattia Cristofori, the Architect and 3D Printing Specialist at BigRep, explains that a few additional modifications of the start and end location of the layers can make it sure that the seam is created in an optimal spot on the print. Often there is a natural groove or corner in a print that is a hiding spot for the seam. For example, on the manifold pictured and printed on Bigrep STUDIO, the curve on the right-hand side covers up the seam nicely. “We can make the seams follow the exact path we want them to follow,” said Cristofori. “So, instead, we can optimize this when we generate the G-code”.

3 STEPS TO HIDE THE SEAMS

You can hide the seams on your print in 3 easy steps:

1) Import your model on Simplify3D and figure out how many processes you need to split the part in. Make sure the seams follow the path you want.

2) Edit singularly each process on the LAYER section changing the X & Y setting where the seams should be set up closer to.

3) Slice the part generating the G-code and check for possible improvements. Try different variation of the X & Y settings until you achieve the result you need.

However, Simplify3D is not the only possible tool. The list and description of popular slicing software can be found here.

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3D Printing Post Processing

March 28, 2023August 6, 2018

Guide to Post-Processing 3D Printed Parts: 16 Methods

Get more from your 3D prints with smoother surfaces, improved mechanical properties, enhanced aesthetics, and more.

Get an overview of 16 post-processing techniques in this guide or see some real life examples in the ebook and webinar:

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Why 3D Print Post Processing Smooth Surface

SMOOTH SURFACES

Reduce the appearance of print layers and refine surfaces

Strengthen Parts

Reinforce prints for added strength and durability

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From UV and weather resistance to conductivity and more

AESTHETIC FINISHING

Transform the surface appearance for visually striking parts

All 3D prints are produced layer by layer, which results in a notched surface texture that is more pronounced with lower print resolutions. If support structures are needed for your part, it may have additional flaws on its touch points. This guide covers the first step to part finishing, support removal, and the three categories of post-processing: Subtractive, Additive, and Material Changing.

Support Removal

Unless your print is optimized for supportless 3D printing, you’ll probably be printing with support structures. These are usually easy to snap off, but even well designed supports will leave behind imperfections where they were once attached. To smooth these areas, it is recommended to post-process the entire part by any number of methods outlined below.

With dual extrusion you can print soluble support structures that disintegrate in water and leave no trace on your part. They’re especially useful when post-processing isn’t otherwise necessary.

3D Print Post Processing Support Removal

SUBTRACTIVE

The most common post-processing category, subtractive post-processing is the act of removing material from the part surface to make it more uniform and smoother.

ADDITIVE

Additive post-processing puts additional material directly onto printed parts. Additive techniques are highly efficient for smoothing parts while adding strength and other mechanical properties.

PROPERTY CHANGING

Neither removing nor adding material, property changing post-processing redistributes molecules of a 3D print. Smoother and stronger parts are achieved with thermal and chemical treatments.

Subtractive Post-Processing Methods

Probably the most common post-processing category, subtractive post-processing is the act of removing some of your part’s material. Usually this is in the form of sanding or polishing a part, but there are a variety of other methods that includes tumbling, milling, abrasive blasting, and chemical abrasive dipping.

Sanding & Polishing

DIFFICULTY
SMOOTHNESS

Both sanding and polishing techniques remove surface layers by rubbing it with an abrasive material. Sanding requires coarser grit sandpaper and sanding tools, while polishing may use finer sandpaper, steel wool, polishing paste, or cloth.

Sanding removes larger blemishes such as support remnants or print irregularities and reduces the visibility of print layers. The sanding process will leave a gritty, although more uniform surface texture, and very course sandpaper will leave surface scratches. Polishing the part after sanding will produce an even smoother surface.

Simplicity and affordability make sanding and polishing the most common methods of post-processing, but both require labor that is time consuming for larger parts and batches. These methods may not be suited for parts with hard to reach cavities.

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

Tumbling

DIFFICULTY
SMOOTHNESS

A tumbling machine consists of a vibrating vat containing lubricating fluid and abrasive media, which are specialized stones that wear objects down according to their size, shape, and hardness as they tumble together. A 3D printed part is simply placed into the vat of tumbling abrasive media for a specific length of time. Some expertise is required to pair parts with the correct abrasive media and processing time, but when done correctly it is very effective at producing uniform finishes.

Tumbling is a largely automated subtractive method that can post-process multiple parts simultaneously, which is useful for smoothing batches of parts. Tumbling vats come in a range of sizes so larger parts can also be processed. Since the abrasive media is constantly in contact with the part, larger pieces do not require longer processing time, but only larger machines with the adequate amount of abrasive media. However, complex shapes may lose detail and sharp edges may become slightly rounded by tumbling.

Abrasive Blasting (Sand Blasting)

DIFFICULTY
SMOOTHNESS

Abrasive blasting, also known as sand blasting, is subtractive post-processing method where abrasive material is blasted onto 3D printed parts at high pressure. For large parts this can be done in an open environment, but smaller parts are typically processed in a containment chamber that collects and reuses the abrasive material. Like other grit-based subtractive methods, there are a range of grits available and grit must be chosen based on part geometry and desired finish. Sand is a frequently used abrasive material, but other small coarse objects such as plastic beads can be used for different results.

Since the abrasive material is smaller than that of tumbling, abrasive blasting is less effective on very rough parts or high layer heights. This method only treats surfaces reachable by the stream of blasted material, so complex geometries and cavities may not be feasible. Additionally, the blasting tool can only treat limited areas at a given time, so this method may be slower and difficult to process multiple parts simultaneously.

3d-print-post-processing-abrasive-blasting-sand-blasting

CNC Machining (Milling)

DIFFICULTY
SMOOTHNESS

CNC milling, also called CNC machining, is the inverse of 3D printing - it uses a computer-programmable drill moving (and sometime rotating) in three axes to carve out geometries. Like 3D printers, the technology uses a “G-Code” to program tool movements, in this case a milling bit rather than a filament extruder.

While CNC machining is considered highly accurate from 0.005” to 0.00005”, it cannot produce certain geometries and wastes material, which is often expensive. Conversely, large-format 3D printing cannot achieve the same accuracy, but can achieve much more complex geometries and wastes very little material.

It is typically not time or cost effective to mill the entire surface of a 3D print and it may be difficult to calibrate the milling tool to the print position. But while these two production methods are seemingly at odds, there are some situations where they may be used together. If a portion of a 3D printed part must be extremely smooth or accurate, that specific area can be milled. Alternately, manufacturers can save material by 3D printing a part in a rough finish before milling it to perfection.

Chemical Dipping

DIFFICULTY
SMOOTHNESS

Chemical dipping, also called aid dipping, is the process of submerging parts in a chemical bath that eats away the surface. The process involves caustic materials, such as lye, sodium hydroxide, or dichloromethan, and should only be done by experts in facilities with the requisite safety features. The appropriate chemical choice is entirely dependent on the material of the 3D print, as the chemical must be abrasive to the print material.

Some expertise is required to determine how long parts should remain submerged: too brief and the part will not be sufficiently smooth, too long and it could be ruined entirely. Some care should be taken to avoid air bubbles trapped inside the 3D print as they will prevent the chemical treatment of the surface. Typically the submerged part is gently moved to agitate the chemical bath and release any air bubbles.

The process is ideal for complex geometries as the chemical bath treats all surfaces of submerged parts simultaneously. However, the size of the chemical dipping container determines the limited part dimensions of treatable prints.

3D Print Post Processing Chemical Dipping Acetone

Additive Post-Processing Methods

Additive post processing puts additional material directly onto printed parts and is highly efficient for smoothing parts while adding strength and other mechanical properties. There is a wide spectrum of methods from filling to priming, coating, metal plating, and more.

Filling

DIFFICULTY
SMOOTHNESS

Filling is a surface treatment that uses a thick adhesive compound, typically a paste, to fill in notches like the tiny gaps between layers of a 3D print. It is commonly used as a first step before sanding or additional additive layers. A wide range of fillers from pastes to sprays are available in many materials from light spackle to 2K resins.

Paste fillers, like wood fillers or household spackle, are usually the most accessible option. They are simply spread over the part surface and can be easily smoothed with light sanding. Spray fillers are easy to apply but provide only a thin surface covering, resulting in a rougher coating. More robust, but more advanced options are resin fillers that must be cured by one of two methods: mixing with a hardener or UV exposure. Resins are available with various viscosity, cure speeds, and advanced features like UV and a high heat deflection temperature. For some UV-cured fillers leaving parts in the sun may be sufficient, but others will require a specialized UV chamber.

When using any kind of resin cover skin, wear gloves, and keep the working space well ventilated. Ensure you’re familiar with the requirements of your filler or coating before applying it to a part as this may drastically change the time or equipment required for post-processing.

villroy-boch-post-processing-filling-plaster

For some UV-cured fillers, leaving parts in the sun may be sufficient but others will require a specialized UV chamber. Ensure you’re familiar with the requirements of your filler or coating before applying it to a part as this may drastically change the time or equipment required for post-processing.

Priming

DIFFICULTY
SMOOTHNESS

Primers prepare 3D-printed parts for the addition of subsequent layers by pre-treating the surface for better adhesion. They are far less viscous than fillers and may only smooth very small surface imperfections, so their main function is adhesive surface preparation. Primers are available in spray or brush form, but spray primer may produce a more even coating.

To prime a part most effectively, the imperfections and layers notches should first be reduced by other post-processing methods such as sanding or filling. Ensure that your primer is made for plastic adhesion and is suitable for additional materials you intend to apply later. Leave the primer to set for 24 hours or as otherwise directed.

Brush Coating

DIFFICULTY
SMOOTHNESS

Liquid coatings vary widely in material such as paint, varnish, resin, or even plastic. While there are several application methods, brush coating is the simplest way to smooth unique or small batches of 3D printed parts. Although the surface smoothness may be inconsistent due to brush strokes, choosing a material with the proper viscosity can avoid these surface irregularities.

For a robust and smooth surface apply a 2K resin, which is a two-component mixture of resin with a hardener. When combined, the mixture creates an exothermic chemical reaction that cures the resin over a given amount of time. There is a huge range of resin products for a variety of uses: laminating resins for thin surface applications, casting resins for larger volumes, fast and slow curing resins, and resins with additives (like aluminum, for example) for additional performance enhancement such as temperature, UV, or chemical resistance. To achieve the smoothest surface when brush coating, use a resin with an appropriate “self-leveling” viscosity that will even out brush strokes without material dripping off the part. There are resin products specifically formulated for 3D prints that can achieve very smooth surfaces after one coating.

When brushing other materials such as paint or varnish it may be more difficult to avoid brush strokes, but many coatings can be sanded after drying to achieve a smoother surface. It is also possible to apply an additional coating of another material, 2K resin for example, to achieve a smoother final result.

Spray Coating

DIFFICULTY
SMOOTHNESS

A wide-ranging and scalable post-processing technique, spray coating a offers a number of viable methods ranging from DIY projects to robotic automation at an industrial scale. Spray coatings are available in a huge variety of materials such as paint, varnish, resin, plastics, and rubbers, just to name a few.

The simple approach for DIY projects is a spray can of a chosen material applied in a ventilated/outdoor space. Since this method typically results in minimal surface smoothing, it is recommended to sand the part first and apply several spray coats. Applying a spray primer may help the spray coating adhere to the part. Spray paint can be used for aesthetic enhancements and spray varnish can protect the surface against chipping, wear, and UV damage.

For large volume or industrial spray coating applications, a robotic arm fitted with a spraying tool head can apply a wide range of coatings to a 3D printed part. The application typically takes place in spray booth with an adequate air filter. This method allows a wider range of materials, including 2K spray coatings, primers, paints, and more, and results in higher application precision and uniformity. A robotic arm will speed up the processing time and make high-volume post-processing feasible at an industrial level.

Spray coating is most suitable for finishing large parts, rather than other additive methods such as dipping, foiling, or powder coating. The later methods all require a machine or vat that can contain the entire part, whereas spray coating is only limited by the size of the room in which it is done.

Foiling

DIFFICULTY
SMOOTHNESS

In foiling, or vinyl wrapping, an adhesive foil made of light metals or plastic is wrapped onto an object, often preceded by priming. Commonly known for wrapping vehicles, vinyl wrapping can also be applied to 3D-printed objects with a suitable material. Depending on the material, the foil may increase heat and stress resistance but is often applied for aesthetic enhancement like smoothing and surface quality.

The difficulty of this post-processing technique varies with the size and complexity of your part. A simple geometry, like the gently curved side panel of a vehicle, is relatively easy to foil, but complex shapes are more difficult with some being impossible to foil.

Wrapping is particularly suitable to apply detailed surface designs to 3D-printed parts. Adhesive foils come in a wide range of colors and patterns, as well as custom-printed designs. Foil can be applied by hand, stretching the material over objects to ensure no imperfections like air bubbles remain. Heat guns are often used in the process to make application easier and avoid imperfections. Vacuum foiling will automate the process for faster, precise results to ensure the material wraps around the part as perfectly as possible.

Foiling is usually not suitable for complex parts as the foil will be extremely difficult to apply uniformly and inside cavities.

The difficulty of vinyl wrapping varies with the size and complexity of your part. A smooth surface – like the side paneling of a vehicle – should be reasonably simple to foil but complex shapes will become exponentially more difficult.

Dip Coating

3D Print Post Processing Dipping Coating

DIFFICULTY
SMOOTHNESS

When dip coating, a part is submerged into a vat of material such as paint, resin, rubber, etc. and removed after a specified time, resulting in an even surface distribution. The part can be redipped multiple times for a thicker coating and smoother surface. Dipping can be used for aesthetic finishing and functional enhancement like increased strength and resistance to heat, chemicals, weather, etc.

The typical dipping process is comprised of five stages:

Immersion: The 3D printed part is immersed in a vat of material at a constant speed.
Start-up: The part remains submerged for a specified time for the coating to adhere.
Deposition: The part is removed at a constant rate as a thin layer of the material is deposited.
Drainage: Excess material will drip off of the part surface back into the vat.
Evaporation: As the coating sets the solvent evaporates from the material, leaving a solid film.

Hydro dipping, also known as water transfer printing is a unique method for applying detailed designs onto a 3D print. The part is submerged in a vat of clean water that has a layer of material floating on its surface, typically a water soluble printed film or an oil based paint. As the part passes through the floating layer, the film or paint adheres to the part’s surface. The surface tension of the water ensures that the film curves around any shape. The best results are achieved with parts containing gently curving geometries.

Dip coating is suitable for complex geometries and requires some expertise in the coating material used. The size of the vat determines the dimension of treatable parts. Large prints may not be feasible, although batch processing is possible for smaller parts.

Metal Plating

DIFFICULTY
SMOOTHNESS

Metal plating is a chemical process where a layer of metal is bonded to a 3D printed part. It is a highly effective method to create 3D printed objects with high resistance to heat, impact, weather, and chemicals, or to create conductive parts.

The first step in metal coating plastic parts is "electroless plating" which metalizes the surface of the print, priming it for proper metal plating. This process ranges from special metal paints that are simply brushed or sprayed onto the part to industrial processes involving numerous steps of cleaning, etching, neutralizing, activating, etc. Typically, this first layer is copper or nickel, although silver and gold layers are also possible.

In the second step in metal plating, the metalized 3D print is submerged in a bath for a specific length of time to deposit a wide range of metals like tin, platinum, palladium, rhodium, and even chrome. In electroplating, the part is placed in a galvanic bath that deposits a thin metal layer from 1 - 50 microns thick. Anode and cathode ions pass through the liquid and adhere to parts in microscopically fine layers. Additional metal plating processes can build up the metallic surface thickness or deposit a different metal material.

When using a metal-acid solution, parts are submerged in the liquid solution for a specific duration, depending on the desired plating thickness. A chemical reaction attracts and adheres the metal ions to the surface of the part. Once removed from the bath, the part can receive a protective coating to prevent oxidation, corrosion, or tarnishing. Heat treatments may be used to strengthen the metal layer adhesion and prevent brittleness.

Metal plating typically works well for complex parts and can produce a range of surface qualities, smoothness, and mechanical enhancements. However, the process requires many stages and expertise.

Powder Coating

DIFFICULTY
SMOOTHNESS

With powder coating, also known as rotational sintering, a part is heated and rotated within a cloud of powdered plastic. As the powder compound meets the heated part, it is melted to the surface to produce a fine coating. Due to surface tension while spinning, the adhered powder produces a homogeneous, non-porous layer about 400-microns thick. The surface is typically not glossy smooth, but rather has a fine matte texture caused by the plastic cloud particle size, typically 2-50 microns.

Powder coating is a common method for protecting large metal components, but it is difficult to achieve with 3D prints. In traditional powder coating, the metal parts experience temperatures up to 200 °C, but the lower temperature resistance of most 3D printed plastics greatly limits the use of a post-processingsing method. When possible, powder coating is highly efficient for batch production with uniform surfaces, although cavities may be difficult to post-process.

Property Changing Post-Processing Methods

Neither removing nor adding material, property changing post-processing redistributes molecules of a 3D print. Smoother and stronger parts are achieved with thermal and chemical treatments.

Local Melting

DIFFICULTY
SMOOTHNESS

Local melting is an easy way to reduce the appearance of surface scratches from damage, support removal, or abrasive post-processing like sanding. Rough surfaces are particularly visible on dark-colored 3D prints, which appear to be a white-ish color. Using a heat gun set to high heat, quickly pass hot air over the area requiring treatment, keeping the heat gun 10-20 cm away from the part. Within seconds, the surface will melt to resemble the original print surface quality. A heat gun can also remove strings from travel moves during printing. Using the same method as described above will melt and shrink the strings. If the strings are large, small remnants may cling to the part but are often easily removed by brushing or clipping them off.

This method is not suitable for deep scratches as it is only effective for light surface roughness. It also can easily deform the part, so take care to limit the time an area is heated. The best results are achieved by sweeping hot air across the surface for several seconds. Local melting is not recommended for overall surface smoothing, but for the easy and effective smoothing of small defects and scratches.

Annealing

DIFFICULTY
SMOOTHNESS

Annealing is the process of heating a print to re-organize its molecular structure, resulting in stronger parts that are less prone to warping. Untreated 3D prints have an amorphous molecular structure, meaning that the molecules are unorganized and weaker. Being a poor heat conductor, the extruded plastic cools quickly and unevenly during the printing process causing internal stresses, particularly between print layers. These stress points are most prone to breakage.

To strengthen the part at its molecular level, it is heated to its glass transition temperature, but below its melting point. Achieving the glass transition temperature allows the molecules to redistribute into a semi-crystalline structure without melting the part to the point of deforming. Glass transition and melting temperatures vary between materials and some expertise is required to heat parts to the correct temperature for the proper length of time. 3D prints will shrink during the annealing process, which can be corrected by increasing the original printing dimensions accordingly.

Vapor Smoothing

DIFFICULTY
SMOOTHNESS

Vapor smoothing is the chemical process of smoothing 3D prints in which parts are exposed to vaporized solvents in an enclosed chamber. Similarly to chemical dipping, the correct solvent must be used in correspondence with the 3D print material. The cloud of solvent dissolves the surface of the print, while its surface tension redistributes the dissolved material, resulting in a smoother finish. Unlike chemical dipping, no material is actually removed from the part.

Solvents can either be heated to a gaseous state or vaporized by ultrasonic misting. The 3D print is exposed to the vaporized solvents for a specific length of time: too short and the part is not adequately smoothed, too long and the part can deform and become brittle. Most suitable solvents are caustic and combustible, and therefore require extreme levels of caution, adequate chemical containment, and disposal, and should only be handled by qualified persons.

Many vapor smoothing machines are available for use with a variety of solvents suitable for different print materials. These machines make the process automated and much safer, but most can only treat smaller parts due to the chamber's limited dimensions.

3D Print Post Processing Vapor Smoothing

Post-Processing eBook

For real life industrial examples, download our free eBook Post-Processing for FFF Prints and see this webinar about post-processing techniques.

The eBook explores the three types of FFF post-processing techniques: 1) Material Removal, 2) Material Addition and 3) Material Property Change. Also, learn more about how various techniques like high resolution tumbling, resin coating and aluminum plating are transforming 3D printed parts.

Get eBook + Webinar

3d Printing Post Processing FAQs

What is 3D printing post-processing?

Once the printer has finished printing, there may still be some work to do on the printed piece. For example, many shapes require supports to print properly. Removing those is a post-processing task. Some people might want to sand or put a finish layer onto a piece. Resin, as opposed to filament, based prints need to have any uncured resin washed off and final curing under UV light.

3D printing post processing is used to enhance the surface properties of prints in many aspects to deliver improved mechanical performance and aesthetic appearance. By improving these key surface characteristics, post processing widely extents the range of use cases and applications across all industries. 3 types of post-processing techniques can be applied to fused filament fabrication (FFF) prints:

Material Removal
Material Addition
Material Property Change

How do you post process PLA 3D prints?

What is the most critical step in the post processing process of 3D printing FDM parts?

How do I complete FDM parts?

Can acetone smooth PLA?

Do I need to cure 3D prints?

Large-Scale Hybrid Parts in Automotive

May 31, 2023March 13, 2018

Three views of a complex exhaust manifold as 3D printed prototypes

The Automotive industry continues its ongoing race to find ways to accelerate the process of designing and developing new and better vehicles. If we examine a modern car design closely, we see that it contains around 30,000 components, of different sizes and materials, manufactured using a range of techniques. Introducing 3D printing into the process of designing a machine with this number and diversity of parts can make that process of moving from new concept to marketable product much more efficient.

When it comes to the functional testing of large automotive components, any vehicle manufacturer will be happy to have the capacity to produce prototypes with realistic mechanical properties at low cost, and with few limitations on design. The combination of large-scale 3D printing with metal plating is a powerful production solution which can deliver automotive firms this prototyping capacity.

Discover our Industrial Use Cases

Software render of a complex exhaust manifold design

Rendering of a complex exhaust manifold design

The Manifold

The exhaust manifold plays a leading role in a car or larger vehicle’s exhaust system.
It connects to each exhaust port on the engine's cylinder head and funnels the hot exhaust down to a single exhaust pipe. Manifolds are manufactured by metal casting and have to withstand a high-temperature environment around the engine. Finding a fast, cost-effective way to perform basic fit-form-functional manifold testing can help reduce costs and shorten the product development process.

The Hybrid Concept

As part of the mutual research BigRep and Polymertal are conducting into possible applications for large-scale 3D printing and metal plating, a large manifold was printed to which was then added a thin layer of nickel in a metal plating process. The goal was to significantly improve the mechanical properties of the prototype, bringing them closer to those of a finished, cast metal part.

Exhaust manifold: software render, 3D-printed polymer, and finished nickel-plated part

Render, polymer 3D printed, and metal-plated versions of a simple exhaust manifold

Printing data

Printed on the BigRep STUDIO
Material - PLA/PRO-HT
Printing Time - 15 h
Layer thickness - 0.3 mm
Nozzle - 0.6 mm
Material weight - 450 g
Material cost - under 20 Euros

Plating Data

Technique - Direct Metalization plating
Material - Nickel
Plating thickness - 20 microns

Inlet and outlet views of an exhaust manifold

This exhaust manifold has four entry points and two outlets

Benefits of Plating

Increased heat deflection temperature
Increased chemical resistance
Increased part strength

The Result

The new manifold was manufactured quickly and at very low cost. The BigRep STUDIO delivered a precision-print of the design, the plating process improved the part’s mechanical properties making it suitable for real functional testing. The fast process and quality of the part suggest this method can be used for improved and accelerated testing of new automotive component designs. The result is increased confidence that 3D printing, and hybrid parts in particular, can give automotive firms who adopt the technology a lead over their competitors in bringing innovative vehicle designs to market.

Learn About BigRep 3D Printers

With over 22 years in the printing industry, Gil Lavi is a Sr. 3D-Printing Specialist with vast experience in implementing diverse 3D-printing technologies in design and manufacturing processes.

Connect with Gil on Linkedin HERE.

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Discover all our previously published Ebooks

UPCOMING EVENTS

Defining 3D Printer Speed

What Influences 3D Print Speed?

Pre-Processing

3D Model Preparation

Slicing

3D Printer Calibration

3D Print Time

3D Print Speed

Travel Speed

Layer Height

Nozzle Diameter

Infill Density

Support Structures

Post-Processing

Support Removal

Sanding and Polishing

Priming and Coating

Conclusion

Dominik Stürzer

How much is a 3D printer?

Part One: Capital Equipment Expenditures + Purpose

Part Two: Service Contracts, Consumables, + Post Processing

Part Three: Intangibles + Obsolescence

Conclusion

Talk to a 3D Printing Expert to help you calculate your ROI with a BigRep 3D Printer

Assembly Time

Costs

Down Time

Quality Assurance

Conclusion

Limitations of Single Extruder 3D Printers

The Value of Dual Extruder 3D Printers

Ludwig Wittgenstein - Referenced in Aaron Council’s 3D Printing: Rise of the Third Industrial Revolution

Impossible Parts

Enhanced Mechanical Properties

Ergonomic Improvements

Improve Aesthetics

True Mass Production

The Future of Dual Extruder 3D Printers

Dual Extruder 3D Printers in Short

About the author:

Dominik Stürzer

What is Vacuum Forming & Thermoforming?

How Does Vacuum Forming Work?

Types of Plastic for Vacuum Forming

How to Create Molds for Vacuum Forming

3D Printed Molds

Wood, Aluminium and Structural Foam Molds

Applications for Vacuum Forming

Aerospace

Automotive

Packaging

Consumer Goods

Conclusion

GRADUATE FROM DESKTOP. GET INDUSTRIAL.

GRADUATE FROM DESKTOP. GET INDUSTRIAL.

Vacuum Forming and Thermoforming FAQs

About the author:

Dominik Stürzer

Understanding Rapid Prototyping

What is Rapid Prototyping?

Is Rapid Prototyping the Same as 3D Printing?

The Importance of Rapid Prototyping in Innovation

The Process of Rapid Prototyping

Steps Involved in Rapid Prototyping

Tools and Techniques for Rapid Prototyping

The Benefits of Rapid Prototyping for Businesses

Time and Cost Efficiency

Decrease Time to Market

Enhancing Design and Functionality