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PLA vs. ABS Filament and More – Choose the Right Material

May 5, 2023July 20, 2021

PLA and ABS filaments are the most commonly used 3D printing materials out there.

But which one should you pick? And are there other filament options for your application?

The power of 3D printing is the ability to produce impossible designs that lead to enhanced functionality and performance. While it’s important to evaluate different technologies and processes, never underestimate material selection and capabilities.

With so many different 3D printing options in the marketplace and countless material options available, what makes the most sense for you? In this post we will compare several FDM materials and how these thermoplastics can be augmented to service a wider range of manufacturing applications. PLA vs. ABS, ASA, PLX, PRO HT, HI-TEMP, Carbon Fiber, Bio-ABS, and more.

ABS Filament

A commonly used 3D printing material is ABS (Acrylonitrile Butadiene Styrene). ABS variations are used in every industry imaginable (transportation, consumer products, electronics, etc.). For example, plastic components make up 50 percent of a vehicle’s volume, but only about 10 percent of its weight. Therefore, prototypers, product developers, and production engineers feel comfortable printing materials that mimic the end-use product or purpose.

Excellent mechanical strength and durability properties
Cost effective & recyclable
Better heat performance compared to PLA

ASA Filament

ASA (Acrylonitrile Styrene Acrylate) is an improved ABS alternative with higher weather resistance properties that make it ideal for many outdoor applications.

Compared to ABS, ASA has better mechanical properties, superior aesthetics, and it’s UV resistant. Printing with ASA is advantageous for industrial and end-use parts, oftentimes used for automotive, sporting goods, and consumer appliances.

The only downside is that ASA is slightly more expensive than ABS.

ASA is easier to use in 3D printing than ABS, since it warps less than ABS and can also be easily post-processed. Automotive manufacturers will prototype with ASA material. For aerospace equipment like UAVs (unmanned aerial vehicles) you could even consider using it in the final product due to its UV stability and weather resistance.

Enhanced UV stability
Ideal for outdoor applications
Improved aesthetics compared to ABS and PLA
Key industries: Consumer products, defense applications, automotive, and aviation

PLA Filament & PLX

Second only to ABS, PLA (Polylactic Acid) is a highly preferred 3D printing material because it is inexpensive, easy to use, and accessible on many platforms. Compared to ABS, PLA has slightly better tensile strength properties but generally doesn’t have enough flex strength. Both materials are comparable when it comes to pricing. However, under the right conditions, PLA is biodegradable and oftentimes used for food and packaging products making it rather attractive for many consumer product industries. In many instances, PLA is the preferred material choice. PLX, a PLA derivative, was recently introduced by BigRep and available on all platforms. PLX prints up to 80% faster and produces excellent surface features, eliminating the need for post processing.

Biodegradable
Up to 80% faster extrusion throughput
Tensile strength (ISO 527) | 48 MPa
Key industries: Consumer products, food packaging, prototyping, form, fit, and function

PRO HT: High Temperature Filament

PRO HT, BigRep’s flagship material, is the most popular filament amongst BigRep customers and users. With a softening resistance up to 115 °C, it has significant increase in temperature resistance compared to the average PLA, making it ideal for practical, end-use applications. In addition, PRO HT is FDA compliant for food safety and meets all requirements of EU Directives for food contact. Derived from organic compounds, PRO HT is biodegradable under the correct conditions and has a much lower ecological impact than other plastics derived from fossil fuels. Most common applications include consumer products, packaging, general prototyping, manufacturing and low production tooling.

Simple to print and easy post processing
Low warping and shrinkage
Biodegradable
Heat deflection temperature up to 115 °C

HI-TEMP CF: Carbon Fiber Filament

Carbon fiber materials are unique and fairly new to the 3D printing industry. Highly stiff and incredibly durable, HI-TEMP CF has a heat deflection temperature of up to 115 °C and is perfect for many tooling applications. For example, thermoforming, pattern and mold making will use HI-TEMP CF for class A surface finish and low moisture absorption.

Compared to many other thermoplastics, the carbon fiber attributes provide significant strength capabilities (>65 MPa) and is recommended as a superior alternative to ASA for functional prototyping or production. HI-TEMP CF is robust and resilient to withstand harsh manufacturing environments.

Jigs, Fixtures, and Tooling
Automotive prototyping and production
Assembly line, manufacturing, and production
Tensile strength (ISO 527) | 65 MPa

PLA vs ABS Filament: HI-TEMP CF Carbon Fiber Filament

Production Tool From Carbon Fiber Filament

Positioning jig for car production 3D printed with HI-TEMP CF

Conclusion

How to truly maximize the right filament for your application? When it comes to general prototyping, all of these materials can be considered and will most likely yield positive results for your product development. However, prototyping goes beyond just form, fit and function so we recommend taking a deeper dive into specific material characteristics to determine which makes the most sense for you. When it comes to production, it’s very important to consider the mechanical properties of your chosen material and how it will perform. Tooling or end-use products are required to meet certain standards and more often than not, sacrifices cannot be made.

To simplify, we recommend:

PLA for simple prototype development.
If you own BigRep 3D printer equipment, reach out to us to learn about PLX and the time savings it can provide.
If you’re looking for UV stability or slightly better strength performance for prototyping or production, we recommend ASA.
Finally, PRO HT and HI-TEMP CF are the most robust materials for low volume production, tooling or any other application that requires parts to perform in harsh environments.

Check out our wide range of 3D printing filaments and find the right material for your application:

Filaments

About the author:

Dominik Stürzer

Head of Growth Marketing

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.

FDM vs. SLA 3D Printer: Choose the Right Technology

June 16, 2023July 12, 2021

SLA vs FDM 3D Printer: Which Should I Choose

Two main 3D printing methods, Fused Deposition Modeling (FDM) and Stereolithography (SLA), are popular in the industry because of their unique capabilities.

If you want to choose the best 3D printing technology, understanding the differences between FDM and SLA is important.

But what are the advantages and disadvantages of FDM and SLA 3D printing?

We compare the two processes based on:

Size
Print speed
3D printing materials
Strength and durability
Precision and quality
Applications in various industries

You can navigate the complicated landscape of 3D printing technologies with this in-depth analysis. It will help you make the right choice for your business or project.

What is FDM 3D Printing?

Fused Deposition Modeling (FDM), alternatively referred to as fused filament fabrication (FFF), is the most common 3D printing technology available on the market. Typically, FDM 3D printers operate with singular or dual extruders that are compatible with thermoplastic filaments. The filament is loaded into the machine via material spool, melted and deposited onto a heated build platform following a predetermined guide path. The materials simultaneously cool and adhere to another to create a 3-dimensional part.

FDM printers come in a variety of sizes and material compatibilities, and can range from $5,000 to $500,000. Materials may include plastics such as ABS, ASA, PLA and more advanced 3D printers are beginning to offer carbon filled and nylon materials that are stronger and longer lasting.

Strengths

FDM is relatively inexpensive compared to alternate 3D printing methods and tends to yield the most consistent results when it comes to repeatability and strength. In addition, post processing with FDM is simple and most of the time, non-hazardous.

Weaknesses

Printing with thermoplastic materials through extrusion nozzles leads to tolerance and resolution challenges. Compared to other 3D printing technologies, FDM may leave layer lines or slight build blemishes due to the heating and cooling of materials.

What is SLA 3D Printing?

Stereolithography (SLA) was introduced to the market during the 1980’s and was quickly adopted by many service manufacturers and consumer product companies. Instead of filament SLA 3D printers operate with photopolymers, which is a light-sensitive material that changes physical properties when exposed to light. Instead of an extrusion nozzle, SLA uses a laser to cure a liquid resin into a physical piece through a process called photopolymerization.

This unique printing process enables higher resolution parts that have isotropic and watertight properties. Photopolymers are thermoset materials, meaning they react differently than thermoplastics. Similar to FDM, there is a range of SLA printers available in the market with different sizes, material capabilities and price ranges.

Strengths

Laser technology creates pinpoint accuracy which allows for higher tolerance parts with improved resolution compared to alternative technologies. If you require a highly aesthetic part, you may want to consider SLA.

Weaknesses

What SLA gains in beauty it loses in strength. While some SLA materials are engineered to perform better in some scenarios, it’s almost impossible to replicate the same mechanical properties of ABS, nylon, and other FDM filaments. If your parts require functional testing, we recommend sticking with FDM.

FDM vs. SLA: Choosing the Right Technology

Build Volume

Printing large parts or need a large enough build platform for multiple parts/low volume production? It’s not easy to find a 3D printer capable of printing large pieces and of course, size is subjective so it’s important to determine what big means to you.

Since we are working in three dimensions, never underestimate Z height and always remember that parts can be built in different directions to optimize strength or finish. When comparing technologies, it’s important to determine what type of parts you intend to 3D print today and proactively plan for what may be produced in the future. The most common regret is lack of 3D printer capacity.

Finding a large format SLA 3D printer is very difficult and nearly impossible due the nature of the technology. First, there is more waste associated with a large vat of liquid resin. Second, individual part costs tend to be higher since materials will be more expensive. Finally, the pinpoint accuracy of a laser is certainly beneficial for higher resolution parts but that leads to much longer printing times.

★ FDM 3D printing is the ultimate choice when building large parts and has been for quite some time. The inherent benefits of FDM indicates that it’s much easier to have repeatable results, regardless of part or build platform size. Next, there is much less material waste and the time it takes to produce large or many parts is much shorter than many SLA alternatives. Simply put, it’s affordable to print big with FDM.

Large Build Volume FDM vs SLA 3D Printer

Printing Speed

In our hyper competitive commercial and industrial marketplace, new product development and manufacturing speed is paramount to capturing early adopters and market share. 3D printing provides that edge and enables the overnight production of parts without operator oversight. Whether you are deciding between SLA or FDM technologies, speed may not be the most important factor since conventional manufacturing or manual processes take longer than both. With that being said, if 3D printing speed is a priority—consider part aesthetics or resolution.

SLA is famous for building parts that are cosmetically superior to FDM due to the laser technology capable of printing down to 25 micron layers. Taking part size into account helps to accurately determine how long the part will print. Compared to FDM, the speed is almost negligible.

★ However, FDM technologies are typically capable of offering several different nozzle sizes (.6mm, 1mm, 2mm) which provides flexibility for engineers to speed up the printing process. Compared to SLA, FDM is significantly faster but it comes with a compromise. Naturally, the larger nozzle sizes lead to thicker layer lines. Ultimately, you must consider your part requirements and balance between resolution and speed.

Materials

A 3D printer is useless without materials. What is your testing and evaluation process throughout prototype development? How important is it to prototype or produce parts that are mechanically identical to the end-use parts? Would it be advantageous to your engineering team to have parts with chemical resistance capabilities? Static dissipative advantages? There is so much to consider when determining the right 3D printing technology for you but none is more valuable than understanding the material capabilities and output.

SLA materials are ideal for niche applications but lack overall strength and functionality compared to FDM. For example, some SLA materials have biocompatible characteristics that combined with the high resolution capabilities make it perfect for some medical device prototyping and dental use cases. However, SLA materials hardly meet the mechanical properties required for the majority of commercial or industrial requirements.

★ If you require materials that are representative of the end product then you should consider FDM 3D printing. Standard thermoplastics such as ABS, PLA and nylon are commonly used throughout major industries and available on most FDM technology platforms. The strength and durability properties of FDM are superior compared to SLA. This improves product testing and will enable engineers to advance new product development with more confidence and accuracy.

*FDM 3D printing technology is uniquely beneficial compared to SLA because of the ability to build parts with varying densities. While retaining part functionality, it’s possible to create internal honeycomb structures that reduce overall weight and part fatigue. Learn more about how to optimize your designs.

Strength & Durability

Prototyping and product validation can be a rigorous process that includes a series of testing that puts a significant amount of wear and tear on a part. Every industry imaginable must ensure product performance to some degree and the great companies invest accordingly to make this possible. As previously noted, the strength and durability of FDM materials are superior to SLA. ASA materials printed on FDM 3D printers have UV resistant properties that make it ideal for outdoor applications (lawncare, homeowner equipment, etc). Nylon materials are oftentimes used for automotive aftermarket parts that require long lasting durability.

When prototypes or production parts must perform in harsh environments, SLA materials tend to degrade, break or deform simply because the mechanical properties are not completely representative of the end-use part. When determining which technology works for your application, remember to consider what type of environment these parts will need to perform in. It may look nice in the laboratory but it must function in the real world.

SLA vs FDM 3D Printer Strength Durability Example Hook

SLA vs FDM 3D Printer Strength Durability Example Lifting

3D Printed carabiner carries the 500 kg wight of a large 3D Printer

Precision & Quality

Precision and quality are subjective terms that are informed by deisgn intent. For example, those operating in the consumer product and packaging industries require tight tolerances since they will inevitably move to injection mold tooling and are unable to sacrifice precision. Having a speedy printer or advanced material options is great but are your printed parts representing the design intent?

If your product development lifecycle inevitably includes mass manufacturing with injection molding, SLA may be the right option for you. However if you need high quality parts for industrial applications, consider FDM. For example, custom fixtures built to function in a production environment require ultimate functionality and do not necessarily need to have cosmetically clean features. By understanding the design intent of your part you can manage expectations and determine which 3D printing technology works for you.

Applications & Industries

According to AMFG, 3D printing adoption is growing across shop floors globally, evidenced by more than 70% of enterprises finding new applications for 3D printing (Sculpteo, 2019). In addition, the number of manufacturers using 3D printing for full-scale production has doubled between 2018 and 2019 and the overall market is expected to exceed $20 billion by 2022 with an anticipated CAGR between 18.2—27.2%. This represents a wide range of industries, applications and use cases that are pushing 3D printing further than ever before.

Aerospace

Encompassing aviation, space and satellite manufacturing, the aerospace industry is the most cutting edge when it comes to 3D printing and technology adoption. The strict requirements for functionality limit SLA 3D printing simply because the materials do not perform well in rugged environments.

However, advanced thermoplastic materials with FDM have improved strength or ESD properties have been utilized for prototype development and interior cabin components. As previously mentioned, the inherent benefits to create lightweight structures with FDM printing is uniquely advantageous to the aerospace market.

FDM ★★★★★

SLA ★★

Automotive

The automotive market is notorious for using ABS plastic and polypropylene for prototyping and end-use purposes. Since the majority of their applications require robust and durable materials, FDM tends to be the most common 3D printing technology for prototyping, jigs & fixtures, drill guides and low volume production requests. It’s common that automotive engineers require materials with advanced chemical resistant properties that continue to perform when exposed to gasoline and other chemicals, justifying the use of FDM. However, SLA does have an advantage printing clear parts used to test reflectors and lighting mechanisms.

FDM ★★★★★

SLA ★★

Consumer Products

The consumer product industry encompasses everything from kitchen appliances to toys, or handheld hardware equipment to electronic devices. Speed to market is imperative, therefore new product development requires quick iterations and immediate feedback. Oftentimes, products are introduced to consumers before product launch and require it to exceed form, fit and functionality.

It’s not uncommon that both technologies are used in the prototyping process or early validation testing. For example, a handheld device may have an ESD enhanced ABS plastic shell combined with a soft touch TPU grip printed on SLA. More often than not, the ability to print in high resolution with SLA is more attractive to consumer product manufacturers when compared to FDM.

FDM ★★★

SLA ★★★★★

Healthcare

The healthcare market includes medical device development, educational training aids and niche applications for the dental and hearing aid market. Typically, the medical device market requires prototypes and parts to be sterilized which means that the material must withstand certain temperatures through a process called autoclaving. SLA and FDM technologies offer the appropriate materials, but it takes some investigation.

Educational training aids typically require high resolution since they are used for communication purposes, making SLA ideal. The dental market is notorious for using SLA, and the hearing aid market is split between SLA and FDM. Due to the nature of the healthcare market and the importance of printing tiny details, SLA is most preferable.

FDM ★★★

SLA ★★★★★

Education

Research and academic institutes across the world have adopted FDM and SLA technologies in droves. There isn’t a single university without a makerspace, and most secondary schools are beginning to position 3D printing in a variety of different ways. Typically, it’s used to motivate students to try new technologies and embrace their inner entrepreneur.

Many researchers have an interest in expanding material capabilities that make 3D printing a viable option for the future. Whether the purpose is research or student learning, most universities and teaching institutes lean towards FDM due to the relatively low cost and equipment simplicity. Post processing can be challenging with SLA, therefore FDM is a more student friendly option. In addition, the future of FDM looks brighter when it comes to material expansion for manufacturing purposes.

FDM ★★★★★

SLA ★★★

Conclusion

What is your design intent? What problems will 3D printing solve for you today? Tomorrow? What are the most important factors when determining a capital equipment expenditure at your facility (ROI, productivity, innovation)?

To quickly summarize the information presented above, FDM and SLA 3D printing technologies have their own advantages and disadvantages when it comes to specific applications or usage. When building larger prototypes or industrial parts, consider FDM for the size and cost benefits. When determining which materials mimic your design intent, take a hard look at the material compatibility and evaluate the benefits from each technology—FDM is more robust for functionality while SLA provides higher resolution and better accuracy.

There are thousands of examples where the aforementioned industries have adopted either SLA or FDM technology so although this comparison gives some information, it does not complete the entire picture. Not every industry, production facility or prototype department acts the same and not everyone fits into nice, neat check boxes. Therefore, we recommend speaking with the experts to determine what makes the most sense for you.

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FAQ: Short Overview

What is an FDM 3D Printer?

FDM stands for Fused Deposition Modeling, alternatively referred to as fused filament fabrication (FFF), is the most common 3D printing technology available on the market. FDM printers operate with extruders that are compatible with thermoplastic filaments. The filament is loaded into the machine via material spool, melted and deposited onto a heated build platform following a predetermined guide path. The materials simultaneously cool and adhere to another to create a 3-dimensional part.

What is an SLA 3D Printer?

Is SLA stronger than FDM?

Is SLA printing faster than FDM?

Which is better FDM or resin?

How fast is FDM printing?

About the author:

Dominik Stürzer

Head of Growth Marketing

3D Printed Auto Interior Design and Manufacturing

September 7, 2023July 1, 2021

The 3D printed car is still a dream that has to come into reality. But you can already have 3D printed car parts in your own vehicle today.

And large 3D printers allow you to have full scale interior parts or body kits.

Passion and Vision

Jeremy Katz, owner of JK Automotive Designs in Stoneham, Massachusetts, is one of the many American entrepreneurs that has built a business from the ground-up. With a lifetime of experience working with automotive suppliers, businesses and enthusiasts, Katz saw an opportunity to make his passion profitable.

JK Automotive Designs  is an automobile interior designer and manufacturer that builds custom upholstered interiors from scratch that consist of dashboards, consoles, door panels and more with integrated audio and visual systems to improve the vehicle’s aesthetics and functionality. From personal restoration projects to high-performance customization requests, JK Automotive Designs is willing to take on the most challenging tasks. With a 5,000 square foot facility filled with state-of-the-art technology, Katz and his team believe they are ahead of the curve and defining the future of automotive customization.

“For this ‘73 Bronco console, we 3D printed with our in-house BigRep 3D printer. This is by far the largest print we have tried and couldn’t have been happier with the results. The console consists of 6 main printed parts that bolt and magnetize together to create this massive console that we could not have made by hand.”

“We take a different approach and stay ahead of the curve,” Katz humbly responds when asked about his business. “By embracing different technologies, we can offer more to our clients and continue exceeding expectations.” Equipped with 3D scanning, CNC, multiple laser machines and several 3D printers, Katz and crew are able to do more, with less. Most notably, the BigRep STUDIO G2 enables the team to 3D print large trim panels and frames that are directly mounted to the vehicle.

Most 3D printing technologies are used as a tool for rapid prototyping purposes (quick iterations, form, fit and function testing). However, JK Automotive Designs saw an opportunity and decided to take advantage of the BigRep STUDIO G2’s size benefits and material capabilities.

Engineering Made Easy

“We have been 3D scanning, designing in CAD, and building parts for quite some time,” says Katz. “But we needed something bigger that would give us more flexibility and be compatible with stronger materials. The BigRep STUDIO G2 and Pro HT materials did exactly that.” Believe it or not, Katz and his team are self taught CAD designers, machinists, and installation specialists. The BigRep STUDIO G2 is specifically designed to be a simple piece of machinery for users but Katz and his team are pushing the limits and developing hybrid manufacturing solutions that are actively changing the game for automobile customization.

“Our team is hyperfocused on productivity and quality. The expertise in this shop is second-to-none and together, we complement each other's strengths to maximize our output.” Katz expresses gratitude for his team and makes it clear that his employees and their capabilities are what sets them apart in the industry. Adding the BigRep STUDIO G2 to the facility is like adding another professional and Katz relies on the same productivity and quality.

For example, JK Automotive Designs was tasked to develop a full interior for a 33 Ford Roadster. One of the components designed was a custom door panel that required an unconventional approach. The door itself had an odd contour and complex design that made it challenging to machine or fabricate with traditional processes. Not to mention, expensive and time consuming. Instead, the team digitized the existing frame with their Creaform 3D scanner, reverse engineered it, and brought it into CAD. Then designed the panel and sent it directly to the BigRep STUDIO G2.

The STUDIO 3D printer requires no additional user operation so while it’s printing, the team is able to work on other aspects of the job. 56 hours later the part was bonded to a flat panel, previously machined on the 3-axis CNC, and ready for fit and finish. JK Automotive Designs added a new arm rest also printed on the BigRep STUDIO G2, upgraded the electronics, and eventually placed the hybrid (half machine/ half printed) door panel to the vehicle.

“The conventional way to produce something like this is highly manual,'' Katz says. “You would need to heat plastic and bend it to get it to fit close, then use body fillers to achieve perfect fitment. With the BigRep and 3D printing, it fits perfectly the first time which really helps us stay on project timelines.”

Process	Time	Cost
CNC Machining	4+ days	$ 3,000+
BigRep STUDIO G2 3D Printer	56 hours	$ 896
Savings	~80% Time Savings	$ 2,000+ per part Savings

Thinking BIG

“Technology is just another tool for us to solve problems. Our mindset is to redefine next generation trends and that is what differentiates us from anyone else in our industry.” Katz postulates as he rotates a design on his computer and passionately shares the future of his business. Dedicated to the craft, the JK Automotive Designs team is constantly educating themselves and doing whatever it takes to stay ahead of the curve. The automotive aftermarket is incredibly unique and ultra competitive so it’s important to embrace innovation. “We want to be trend setters,” says Katz. “To that end, we only use the best techniques and equipment available in the industry.”

For more information on BigRep 3D Printers, check out our full line up of industrial 3D printers. Let us help you THINK BIG!

Want to Learn More About Car Customization with 3D Printing?

Learn how digitizing the customization process drastically reduces production time and number of stages while saving money and material costs. Also hear from Jeremy Katz, owner of JK Automotive Designs to see how his company embraced different technologies to exceed client expectations. Don't miss out, watch the webinar now:

DIGITIZING PRODUCTION OF CUSTOM LARGE FORMAT AUTOMOTIVE PARTS

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About the author:

Dominik Stürzer

Head of Growth Marketing

Local Manufacturing Accelerates with BigRep PRO

November 4, 2022June 24, 2021

The Berkshire Innovation Center (BIC), located in Pittsfield, Massachusetts, is a centralized technology hub that provides academic research and commercial manufacturing services to a vast partner community. Their strategic location in western Massachusetts provides convenient access to companies located in New York, Vermont, Connecticut and New Jersey. Affectionately referred to as the BIC, Berkshire Innovation Center is a world-class R&D facility that offers advanced technologies for local manufacturing. Founded in 2016, the BIC has amassed an eclectic collection of simulation softwares, video production capabilities and additive manufacturing technologies that enable the partner community to reinvent what’s possible for their businesses. In 2020, the BIC welcomed the newest addition to its advanced manufacturing capabilities with the BigRep PRO 3D printer. The high demand for larger parts is what justified the initial printer purpose but the ability to optimize materials and functionality is becoming a significant advantage for local manufacturers.

“Our region is so commercially diverse. It’s our responsibility to understand what technologies will bring the most value to our partner network,” says Steven Longpre, Operations Manager at BIC. “When we presented the BigRep PRO as a potential new addition, our partners were thrilled with the idea.”

BIC members include industrial manufacturers, medical device developers, agricultural specialists and defense suppliers. Gaining access to the BigRep PRO large build platform (1m3) provides immediate benefits for short run production applications and full-scale prototyping.

Autonomous Underwater Vehicles

Dive Technologies, an American veteran-owned small business that produces autonomous underwater vehicles (AUV) designed to withstand long operations at oceanic depths, constitutes one printing success with BIC.

“Yes, the ability to print large parts was advantageous for this particular project, but having stronger materials and the freedom to design complex structures is what really drove this project forward,” Longpre says. Dive Technologies printed in several materials, eventually settling on ABS plastic due to the strength characteristics that could withstand the underwater environment. Dive Technologies develops AUV’s that serve a variety of functions so building quick prototypes to scale gives them the ability to iterate faster and customize devices that are designed to solve specific problems.

Autonomous Underwater Vehicles - Prototype

Commercial AUV, the DIVE-LD, in-water

Agricultural Product Development

One of the major challenges for the Berkshire Innovation Center is to educate the region about the value of advanced manufacturing. Many of the local businesses are familiar with injection molding, CNC machining and other fabrication methods, but are somewhat hesitant to adopt new practices. This is common for any new technology adoption, so BIC addresses this by taking on any project, large or small, with the intention to share the inherent benefits of additive manufacturing. DfAM (design for additive manufacturing) is the practice of designing parts and products that take advantage of AM technology. This includes:

Embracing design complexity
Lightweighting of parts that retain similar or better strength properties
Product simplification, no assembly required

One such example was when the BIC 3D printed a large sled used for agricultural purposes. Typically, this product requires large tooling investments or parts must be welded together for it to function properly. The time it takes to produce this sled with traditional means could be weeks or months. 3D printing on the BigRep PRO took approximately 3.5 days.

Defense Applications

There are a variety of defense contractors located in the Berkshire region. While the BIC is unable to publicly share details about projects being worked on, there are several applications where members have taken advantage of BigRep PRO's extensive material portfolio in defense manufacturing.

Nylon PA 6/66 | This lightweight material from BigRep has excellent strength-to-weight ratios and is ideal for assembly line jigs, fixtures and other production applications.
High Temperature Carbon Fiber | High Temp CF has a heat deflection temperature of up to 115C and has increased durability for UV applications, perfect for outdoor product testing or under-the-hood applications.
PETG | PETG is one of the most commonly used materials for BigRep. It’s quick to print, reliable and incredibly cost effective making it ideal for low volume production purposes.

“With a more industrial system, we can bridge the gap between software, materials and hardware for true production purposes,” says Longpre. “The BigRep PRO is a robust piece of machinery that is scalable, repeatable and reliable. Something all our partners are interested in.”

Longpre and the BIC team anticipate new opportunities that capitalize on the BigRep PRO’s unique advantages.

Conclusion

The Berkshire Innovation Center is poised to accelerate the innovation and growth of existing companies within their region. Strategically focused on small to medium sized manufacturing companies (SME’s) enables BIC to respond quickly and develop creative solutions with advanced manufacturing. Although the knowledge transfer gap continues to be a challenge for Longpre and his team, they share optimism and excitement about the future. “We don’t want cheap and easy,” says Longpre. “We want the hardest challenges and are prepared to be transparent with our capabilities. Our goal is to improve product performance, test new ideas and find innovative ways to solve problems for our local industrial community.”

The BigRep PRO is one of the premiere advanced manufacturing platforms available at the Berkshire Innovation Center. The BIC is equipped with a variety of 3D printing machines and is capable of tackling any sized project. Longpre and his team consider the BIC to be an industry agnostic facility, so they pride themselves on building a diverse network of partners and collaborators. If you’re interested to learn more about the BIC, we invite you to visit them at https://berkshireinnovationcenter.com/. BIC acquired their BigRep PRO through our partner, Select Additive.

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

The BigRep PRO is a 1 m³ powerhouse 3D printer, built to take you from prototyping to production. It provides a highly scalable solution to manufacture end-use parts, factory tooling or more with high-performance, engineering-grade materials. Compared with other manufacturing and FFF printing solutions, the PRO can produce full-scale, accurate parts faster and at lower production costs.

Explore the PRO

BigRep PRO: Large-Format 3D Printer showcasing advanced technology and high-quality printing capabilities

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

Explore the PRO

Automotive Applications with the BigRep PRO

September 29, 2023June 14, 2021

Whether you operate the BigRep PRO today, outsource to a machine shop or are currently contemplating a new equipment purchase, this article is for you.

The BigRep PRO is the most user-friendly, large format 3D printer available on the market and adoption continues to increase, specifically in the automotive sector for a variety of applications.

While 3D printing began as a rapid prototyping solution for many automobile OEMs and suppliers, it has since become a highly useful machine for product customization, tooling, and even end-use production possibilities. According to a recent report by AMFG, the automotive 3D printing market is expected to grow to $5.8 billion by 2025.

Automotive Productivity

Compared to most industries, automotive is on the cutting edge of technology adoption and additive manufacturing has become a critical consideration for the future of product development and production. New technologies are being implemented on the manufacturing floor to increase efficiencies, provide a safer environment for workers, and embrace Industry 4.0 for smarter manufacturing. In the following video, BigRep prints a full scale fixture that is ergonomically improved for manual labor applications and concurrently used as a hand jig for alignment. The BigRep PRO is advantageous for many automotive applications due to its large build platform (1m²), remote monitoring system and advanced material capabilities.

57% of manufacturers purchase or use additive manufacturing equipment for jigs, fixtures and tooling. Source: Jabil, AM Survey 2019

Smart Manufacturing

Operating the BigRep PRO is simple and intuitive. Begin by installing BLADE slicing software and take a moment to review the material profiles available on the BigRep PRO. Although the PRO is an open system platform capable of running a variety of 3rd party materials, we include custom material profiles with our own proprietary filaments, which were developed and certified specifically for the PRO. This dramatically reduces print setup time and allows engineering to immediately begin print requests. Custom sensors are integrated into the PRO which enables real-time equipment feedback and the remote monitoring system allows you to monitor printer performance at any time. Printing large parts takes hours, sometimes days, so it’s certainly convenient to occasionally check in on your parts while finishing other tasks. This is smart manufacturing.

BLADE Software with predetermined material profiles for optimal printing performance
Smart sensors for real-time equipment feedback
Remote monitoring that enables lights-out manufacturing

High-Performance Processes and Materials for Improved Functionality

Fixtures on an automotive assembly line must be rugged and durable. Before 3D printing, fixtures were designed and machined using subtractive manufacturing. This process was reliable but designs were limited, lead times were too long, and the costs didn’t always outweigh the benefit. Even worse, some production facilities needed to bond or weld tooling fixtures together which may lead to structural deficiencies and major problems on the manufacturing floor. Using the BigRep PRO, automotive OEMs and suppliers are embracing the ability to immediately build tools that are sized appropriately and require no additional post processing. In this particular case, BigRep prints HI-TEMP CF (carbon fiber) that is built to withstand significant forces with no warping or part degradation. It’s ideal for large parts that require ultimate strength and functionality.

High Temp CF is a lightweight material ideal for stiff and durable applications
65 MPa tensile strength
Low moisture absorption

Subtractive vs. Additive: Handheld Automotive Fixture

Process	Time to Produce	Cost
CNC Subtractive Manufacturing	15 Days	~5,000 €
Other FDM Additive Manufacturing Services	8 Days	~1,000 €
BigRep PRO Additive Manufacturing	1.3 Days	~675 €
Savings	91% Time Savings	77.5% Cost Savings

Fixtures and the Future

This particular fixture is approximately 130 cm x 14 cm x 22 cm and was printed in 32 hours. This is lightning fast compared to conventional subtractive or other additive manufacturing technologies. Furthemore, it was printed in one single pass without the need for bonding, finishing, or welding. The BigRep PRO is built to tackle the largest (or smallest) prototyping and production requests from any department in your organization. While this article strategically focuses on automotive fixturing applications, it’s obvious that this can be adopted for many other industrial manufacturers and use cases. BigRep prides itself on being the most reliable, user-friendly, large platform additive manufacturing machine in the market.

Want to Learn How Ford Optimizes Manufacturing with 3D Printed Tooling?

Ford Motor Company has compared 3D-printed jigs and fixtures to conventional machining, finding they take less time and cost a fraction to produce. Learn what this integration looks like, plus how Ford experienced ROI on its large-format system by implementing its first application. Don't miss out, watch the webinar now:

HOW FORD DOES OPTIMIZE MANUFACTURING WITH 3D PRINTED TOOLING AND FIXTURES

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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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BigRep and Forward AM Expand Strategic Partnership with new Material, CONCRETE FORMWORK

May 10, 2021May 10, 2021

BigRep and Forward AM, the 3D printing business of BASF, are excited to introduce a new material, CONCRETE FORMWORK, targeted to the architecture and construction industry.

Berlin, Germany. May 10, 2021. Architecture is the representation of a cultural era. By transforming its design language, creators can redefine the world around us. However, reality comes crashing down when conventional formwork solutions quickly reach their limits as construction elements become more complex. To overcome this challenge, Forward AM and BigRep are expanding their partnership and have joined forces again to leverage the synergies between their main areas of expertise: Virtual Engineering, Additive Manufacturing, advanced material development, and large-format printing.

Formwork, the molds used in concrete construction, can make up 40 - 60% of a total budget, especially for complex shapes. Without 3D printing, some designs like organic geometries, double-curved surfaces, and cavities are simply not feasible to produce. They require highly skilled laborers to build customized formwork resulting in high costs, long lead times, and material waste.

“We are excited to work with Forward AM to bring more solutions to the architecture and construction industry,” said Dr. Sven Thate, Managing Director of BigRep. “Our customers are seeing huge gains in terms of cost and speed thanks to our large-format machines and the new CONCRETE FORMWORK filament. Our solutions are opening the doors to many new possibilities.“

BigRep 3D printers, which are up to 1 cubic meter in build volume, can produce large, complex formwork up to 3x faster at a fraction of the cost of traditional methods. With BigRep's new CONCRETE FORMWORK filament enabled by Forward AM, the massive benefits of 3D printed formwork are yours for the taking.

“At Forward AM, we developed a highly dimensionally stable, rigid formwork material, especially tailored to work seamlessly on the BigRep’s large-format3D printers. We are excited to be able to deliver this ready-to-use, end-to-end fabrication solution for bespoke formwork,” says François Minec, Managing Director BASF 3D Printing Solutions.

Demonstrating the material's effectiveness and advantages for the construction industry, Forward AM and BigRep showcase the “Bespoke Stair at Nest Step2,” designed by DBT at ETH Zürich with ROK, SW Umwelttechnik, and WaltGalmarini. The innovative concrete staircase expands the design possibilities of structural architectural elements, while minimizing costs, material waste, and skilled labor. NEST, to be built at EMPA in Zürich, is an innovative building utilizing digital fabrication and circular economy.

For more information on the partnership and to see the printers and material in action, visit

• BigRep https://bigrep.com/applications/concrete-formwork/

• Forward AM https://forward-am.com/use-cases-and-whitepapers/concrete-formwork/

CNC vs 3D Printing – How to Decide

September 7, 2023May 4, 2021

Subtractive manufacturing (computer numerical control, or CNC machining) has been one of the most preeminent manufacturing methods for the past several decades. Introduced in the 1940’s, subtractive manufacturing was used as a tool to machine highly complex parts that require optimal precision. Essentially, the process involves subtracting or cutting from a block of material to create an end product. Today, subtractive manufacturing comes in many different forms (milling, turning, laser cutting, wire EDM, and carving) and is used for a wide variety of prototyping, production and assembly line applications.

Additive manufacturing (3D printing or rapid prototyping) is a newer fabrication process, and is experiencing significant growth due to technology and material advancements. Introduced in the 1980’s as a tool for product developers to physically reproduce prototypes from their digital designs, 3D printing has become commonplace due to its speed, flexibility and cost advantages. Antithetical to subtractive manufacturing, AM deposits materials only where it is necessary on the build platform and typically does so layer-by-layer. AM comes in many different technology forms (FFF, SLA, DLP, MJF, etc.) and is capable of printing a plethora of polymer and metal materials.

Both technologies have their strengths and weaknesses when it comes to a product development and the manufacturing environment. There are certainly arguments to be made to determine which process is ideal for your business or application, but it’s important to note that these technologies are oftentimes complementary and can exist side-by-side. You can identify ways for these technologies to benefit your department by looking at several factors, such as business model, company maturity, design development or production process. For example, a machine shop will use CNC machining for voluminous production requirements and alternatively, use 3D printing to produce parts that are designed with advanced complexities or geometries that are just not possible with subtractive technology.

To better understand how your department can optimize current and new technologies, we have provided a brief guide to help discover which technology will provide the most benefit to your application. Subtractive and additive manufacturing is very broad so, for reference, this guide will compare general CNC machining vs. FFF thermoplastic 3D printing.

Prototypes of Office Furniture at Steelcase

Prototyping

When to use subtractive manufacturing?

CNC machining equipment can be expensive and is typically reserved for production purposes. Due to setup time and operator oversight, CNC machining requires a more hands-on approach. However, if the equipment is available - subtractive technology is a viable option due to part precision and build tolerance. It’s an excellent piece of machinery but could be considered overkill due to the cost or time associated for setup.

When to use additive manufacturing?

3D printing was strategically designed for rapid prototyping because CNC equipment was either unavailable or too expensive to operate. Although some subtractive technologies are theoretically faster, additive manufacturing provides an advantage when it comes to design and cost efficiency requirements. Many product developers will create several iterations of a prototype and print them overnight for review the next day. In addition, the cost is significantly lower than subtractive manufacturing—especially when it comes to revisions.

It’s always important to compare speed, quality and cost. While the act of fabrication with CNC is faster than AM, set up time is an important consideration and holistically, will take longer compared to 3D printing. It’s possible to argue that subtractive manufacturing may produce higher tolerance parts (not always the case), but additive manufacturing is certainly the ideal choice when it comes to cost and multiple revisions. And let’s face it—no one gets their prototype perfect the first time. Check Mark Prototyping.

	Subtractive Manufacturing	Additive Manufacturing
Speed to Build
Quality of Build
Cost Effectiveness
Overall

Production

When to use subtractive manufacturing?

As previously mentioned, subtractive manufacturing technologies such as CNC are predominantly used for voluminous production. Setting up a CNC machine requires collecting stock, writing G-code, tooling and post processing so the labor time is longer compared to AM. However, once the machine is operational, it is considerably faster and part size will no longer be a factor. It’s always important to consider the breakeven cost point when it comes to technology comparison, but for the most part, CNC is a great tool for production purposes.

When to use additive manufacturing?

Material advancements in AM have led to fascinating production applications with many companies operating in the automotive, aerospace and consumer product markets. For example, the aviation industry has adopted 3D printing to print lighter weight frames, doors and brackets that capitalizes on the advantages of selective material deposition. These advantages enable the production of highly complex designs that are traditionally not possible with CNC. Customized components and short run production requests are also possible with 3D printing. However, the major limitation for high volume production with 3D printing remains to be the cost per part.

Car Restoration: 3D Printed Center Console

JK Automotive 3D printed this center console for a classic Ford Bronco

If you are looking for assistance to determine which technology is right for your production application, we recommend benchmarking your part for a cost and time analysis. This is common in the marketplace, and will help you better understand the technological and economical benefits associated with either subtractive or additive manufacturing.There are many factors such as size, quantity, time, materials and post processing that need to be accounted for and we suggest contacting the experts.

Intangibles

What is the intrinsic value of subtractive manufacturing?

Next to injection molding, subtractive machining is the most cost effective mass production technology in the industrial world. It’s been a tried-and-true method for generations. There isn’t a machine shop or service manufacturer that doesn’t either operate or outsource subtractive manufacturing for production purposes. It’s commonality within industry means that it is easier to find technically competent resources. Just by sheer volume, subtractive manufacturing is inherently more accessible.

What are the advanced benefits of additive manufacturing?

The limitless design freedom available with AM is unparalleled to any other fabrication technology. The ability to strategically deposit material and design with support structures breaths life to innovation and engineering possibilities. Working gears, complex airflow channels, lightweighting with honeycomb structures and many more applications are possible with additive manufacturing. It enables engineers to think outside the traditional box of machining and identify new ways to produce better and higher performing parts.

Conclusion

One size does not fit all when it comes to fabrication technologies. Injection molding and CNC machining have been the most cost effective mass production methods available to industry, while 3D printing adoption has grown significantly within the past decade. Amongst other variables, it’s important to compare size, quantity, functionality and purpose to establish what makes the most sense for you.

If you address these questions by industry, you may want to consider the following: The consumer product industry is experiencing massive growth with personalized footwear, accessories and electronics with the use of 3D printing. The automotive and transportation markets have invested significant time and resources to identify large format 3D printers that can replace bonding, welding and tooling requirements necessary on the production floor. Custom AM materials with superior mechanical properties have led to major advancements in biomedical and healthcare approved medical devices and applications. What industry are you in?

Want to Learn More About 3D Printing vs CNC Milling?

CNC has been the backbone of manufacturing for decades. While more recently, additive manufacturing has started to gain traction. Learn about the strengths and weaknesses of both manufacturing methods in terms of cost, materials, lead times, and more. Don't miss out, read the eBook here:

CNC AND 3D PRINTING - TWO MANUFACTURING METHODS

Talk to an expert to learn more about how 3D printing can benefit your prototyping or production needs today.

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FAQs

Is CNC better than 3D printing?

You can identify ways for these technologies to benefit your department by looking at several factors, such as business model, company maturity, design development or production process. For example, a machine shop will use CNC machining for voluminous production requirements and alternatively, use 3D printing to produce parts that are designed with advanced complexities or geometries that are just not possible with subtractive technology.

Will 3D printing replace CNC machining?

One size does not fit all when it comes to fabrication technologies. Injection molding and CNC machining have been the most cost-effective mass production methods available to industry, while 3D printing adoption has grown significantly within the past decade. Amongst other variables, it’s important to compare size, quantity, functionality and purpose to establish what makes the most sense for you.

If you address these questions by industry, you may want to consider the following: The consumer product industry is experiencing massive growth with personalised footwear, accessories and electronics with the use of 3D printing. The automotive and transportation markets have invested significant time and resources to identify large format 3D printers that can replace bonding, welding and tooling requirements necessary on the production floor.

Is CNC same as 3D printing?

The basic difference between 3D printing and CNC is by its principles. 3D printing works on additive manufacturing principle. Whereas CNC works on subtractive manufacturing principle.

CNC machining is a subtractive process, starting with a chunk of metal and using programming controls (CNS Computer Numerical Control) which controls the machine tools movements in three dimensions, removing material until the object is complete.

3D printing is additive, and the most common sort uses a plastic filament and melts it’s via a hot end extruder. The movement of the extrude are controlled by the printer so that a line of plastic is laid down in a programmed shape, layer by layer.

What are some advantages of 3D printing over CNC?

Is CNC or 3D printing cheaper?

Though on average 3D printing is cheaper, costs depend on how many parts are required and how quickly you need them. For larger quantities (higher double digits to 100s) CNC is likely to be more appropriate. For low volumes, 3D printing is more appropriate and lower cost. 3D printing is also more appropriate if you need your prototypes or parts very quickly. There are additional factors however that make comparing the two technologies more difficult. These include materials varying in cost (from cheap materials like ABS to materials that can cost $500/kg like PEEK) and repairing and changing machinery (such as CNC heads).

What is the difference between CNC machining and 3D printing?

3D printing is known to be simpler to use than CNC machining. This is because once the file is prepared, you just need to choose the part orientation, fill, and supports if needed. Then once printing has commenced, no supervisor is required, and the printer can be left until the part is finished. Post-processing requirements depends on the technology.

However, CNC machining is a far more labour-intensive process. A skilled operator is required to choose between different tools, rotation speeds of tools, the cutting path, and any repositioning of the material the part is being created from. There are also post-processing techniques which can require more time.

Will metal 3D printing replace CNC machining?

CNC and 3D printing use the same core technologies, so advances in one also pushes advances in the other. If considered whole manufacturing process of metal parts, it will appear that metal 3D printing and CNC machining are somehow two different things, and one cannot replace the other.

Metal 3D printing is constantly improving and can replace some of the processes but can still require CNC machining.

Should I buy a 3D printer or CNC machine?

It depends on what you want to do. The short answer can be “3D printer”, because it is very versatile. Long answer is that there are dozens of factors that could affect your decision. In general, if you are undecided, you would probably be happier with a 3D printer.

CNC routers need highly skilled specialists, they produce a lot of noise and waste and can only be used in a workshop environment.

A 3D printer is slower, but producing low volumes is a lot cheaper. 3D printers can be operated after basic training and with lower emissions they can also be placed in an office surrounding.

About the author:

Dominik Stürzer

Head of Growth Marketing

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

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About the author:

Dominik Stürzer

What is FDM 3D Printing?

Strengths

Weaknesses

What is SLA 3D Printing?

Strengths

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FDM vs. SLA: Choosing the Right Technology

Build Volume

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INDUSTRIAL QUALITY MEETS COST EFFICIENCY. COMPLEX PARTS IN LARGE SCALE.

INDUSTRIAL QUALITY MEETS COST EFFICIENCY. COMPLEX PARTS IN LARGE SCALE.

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When to use subtractive manufacturing?

When to use additive manufacturing?

Intangibles

What is the intrinsic value of subtractive manufacturing?

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Conclusion

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Talk to an expert to learn more about how 3D printing can benefit your prototyping or production needs today.

FAQs

About the author:

Dominik Stürzer

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.

INDUSTRIAL QUALITY MEETS COST EFFICIENCY.
COMPLEX PARTS IN LARGE SCALE.