3D Printed Car Parts for Solar-Electric Vehicles

April 29, 2024October 26, 2020

3D printed car parts are helping engineers to rapidly prototype solar-powered cars, accelerating research into fossil fuel alternatives for consumer vehicles.

The explosively growing trend of electric vehicles (EVs) is clearing the way for new methods of fuel-creation – away from finite, expensive, and environmentally hazardous resources. Since electricity is still largely produced by fossil fuels and other major pollutants, energy production is bottlenecking the reduced carbon footprint of EVs.

Fortunately, ongoing research into cars with integrated solar power cells promises new horizons of environmental responsibility, energy independence and unfettered access to power and mobility across the world.

A concept rendering of Futuro Solare's Archimede solar car as a consumer vehicle.

Spurred by global events like Australia’s international solar-car race, the Bridgestone World Solar Challenge, Researchers are already working towards vehicles with integrated solar panels.

BigRep and other corporate sponsors provide researchers with the means to construct and test vehicles with local solar power that participate in these races. The vehicles and their construction process, while sponsored and constructed for these publicized events, are used to advance research into solar vehicles and how we might work towards developing the technology for everyday consumers.

For some groups, BigRep’s large-format 3D printers have played a major role in advancing research. Lack of access to expensive traditional manufacturing technologies is a large barrier for the small teams working on solar vehicles. Fortunately, additive manufacturing easily fills in for the production of functional fixtures, prototypes and more 3D printed car parts.

3D Printed Car Parts: Heat-Resistant Battery Fixtures for Futuro Solare

At Futuro Solare, an Italian-Sicilian team of volunteer engineers and solar-vehicle enthusiasts, they’re dedicated to the mission of eliminating fossil fuels from everyday life. Like many other institutions, developing solar-powered vehicles is how they work towards their goal.

Archimede 1 is the solar racecar designed by the team of Futuro Solare.

When the group needed several end-use fixtures for their solar-car’s battery block they were stuck in a complicated acquisition dilemma. Since their racecar is entirely custom there isn’t a readily available solution on the market. Worse yet, since the prototype vehicle is always changing there’s a good chance the team will soon need another iteration of the fixture: taking expensive custom milled fixtures off the table entirely. The team needed a custom solution that was affordable, lightweight and, most importantly, able to resist any heat the battery block or other components might give off.

Futuro Solare approached NOWLAB, BigRep’s consultancy for engineered solutions, to 3D print suitable fixtures with a heat-resistant material that would meet their needs. BigRep’s HI-TEMP filament – an affordable bio-polymer able to withstand heat up to 115 ˚C – was the perfect solution. The part was printed and installed in their current solar-car and has since been quickly and easily updated to fit with their ever-evolving design.

Battery holder for Archimede von Futuro Solare are 3D printed.

Wind Tunnel Testing with Team Sonnenwagen

Team Sonnenwagen, a solar race team out of Germany’s Aachen University, was preparing for their second year participating in the World Solar Challenge. Having learned from their previous experience in 2017, they knew it was important to carefully check the aerodynamics of their solar-racecar before the race began. Unfortunately, the university’s wind tunnel was too small to test their full-sized vehicle. Team Sonnenwagen turned to BigRep for an additive manufacturing solution.

It was important for Team Sonnenwagen to understand how their vehicle will behave faced with the variety of forces present in a race. After all, they would be putting one of their own team in the driver’s seat to race at 140 km/h through the Australian outback. BigRep sponsored Team Sonnenwagen and, taking advantage of 3D PARTLAB, our 3D printing service bureau.

With our industrial 3D printers’ massive one-cubic-meter build volume, we created a perfect 1:2.5 scale model of the vehicle. Reasonably scaled down, the team could fit their design in Aachen University’s wind tunnel and undergo the tests to prepare them for their race. Because of the model they were able to validate the vehicle’s downforce lift, confirm its sail, and view a variety of other aerodynamic and force tests that helped the team compete and stay safe.

3D Printed Prototype for Wind Tunnel Tests

Das Team Sonnenwagen verwendet Rauch an seinem skalierten Solar-Rennwagen, um die Aerodynamik zu überprüfen

3D Printed Car Parts Bring Solar-Powered Cars Closer to Reality

Additive manufacturing plays an ever-increasing role in the development of bleeding-edge technology. Solar-powered vehicles are just one example of a technology that benefits from short rapid prototyping cycles, affordable scaled models, and on-demand engineering-quality solutions for spare parts and fixtures.

Because of the opportunities afforded by large-format additive manufacturing, like BigRep’s industrial 3D printers, innovative researchers like Futuro Solare and Team Sonnenwagen have resources never previously accessible at their scale. With them, accelerated research into integrated renewable power has been possible – inching the world closer to reliable solar-powered vehicles for new heights of environmental responsibility and energy independence around the world.

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Guide to Large Format Additive Manufacturing

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BLADE 3.1

August 2, 2023October 14, 2020

GCode Preview
- Seams visualization
- Enhanced colouring
Prime-Tower
- Automatic positioning
- Automatic sizing
Updated to Cura 4.7.1
Studio G2: Reduced max speed to reduce shifting (this will slow down prints by <1%)
Materials:
- Studio G2: HI-TEMP CF
- ONE/Studio G2: PLA Antibacterial, TPU A85

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

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.

4-Hour Parts! Fast 3D Printing in Large Scale

February 23, 2023September 24, 2020

Fast 3D printing has been the goal of new additive manufacturing technology forever. Unfortunately, when it comes to industrial 3D printers, the size of parts just hasn't been conducive to quick and quality prints. Now, as innovative new technologies hit the market that change the extrusion process allowing industrial 3D printers to produce large-scale parts in just 4 hours, that's finally changing.

A Fast Extruder for On-Demand Solutions

Thanks to the inclusion of BigRep’s proprietary Metering Extruder Technology (MXT®), the BigRep PRO is 3D printing large-format parts in just 4 hours - in this case a manifold for automotive applications. It's able to achieve these exceptional speeds because, unlike FFF, MXT melts filament in advance and stores it in an internal reservoir. The extra step enables unprecedented speed and precision in the printing process by separating the filament melting and material deposition processes, ensuring material passes through the hot end at its ideal temperature and viscosity.

With an identical nozzle size and layer height on a standard traditional 3D printer the parts take 14 hours, a far cry from the astounding 4 hours with MXT. At this speed, the PRO can help fulfill last minute or urgent part requests faster than any other large-format 3D printer. Beyond simply fast production, the full-scale manifolds were 3D printed with exceptionally strong PA6/66 filament (Nylon) - an advanced material with superior layer bonding. Even at speeds 3x faster than traditional FFF technology could produce with a standard PLA material the parts are stronger, breaking across layers before delamination. In urgent circumstances like Kawasaki’s 5-hour fixture for an aircraft cargo door, that kind of quality and on-demand responsiveness is priceless.

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When we talk about why you should invest in additive manufacturing the rationale is usually hard numbers: lower costs, faster lead times, and overall increases to productivity. Those are great talking points that speak to the metrics most businesses are looking to improve with a technology investment – or why your boss will be happy you bought a BigRep PRO. But really all of these metrics are just pleasant, measurable effects of how an industrial 3D printer makes your manufacturing operations more flexible. Having the fastest 3D printer in its category, capable of producing engineering-grade parts on-demand at high speed, just extends that flexibility.

The BigRep PRO is our ultimate industrial offering. It provides manufacturers with a variety of features to handle any circumstance you might be faced with. Its massive one-cubic-meter build volume enables the production of exceptionally large parts, or batches of parts that are either all the same or varying iterations. With other built-in quality of life features, like IoT connectivity to monitor ongoing prints and sequential printing to streamline print organization, the PRO gives manufacturers a lot of flexibility in how they want to produce parts. But what makes the PRO really special is that it raises the bar in not just how a part is produced, but the versatility of parts themselves – giving you the power to balance the PRO's enhanced production speed, strength, surface finish and other material properties as you see fit.

An Industrial Machine for Fast 3D Printing

Sometimes speed isn’t your first priority. MXT is unmatched in the fast creation of strong parts but, as a new technology, its compatible materials and resolutions are limited. That’s why the PRO includes BigRep’s fiber-ready Advanced Capabilities Extruder (ACE). It's a traditional FFF extruder for a variety of engineering-grade materials and resolutions to ensure the PRO meets your every need.

The PRO comes stacked with advanced components for faster printing with traditional FFF extruders, too. BigRep’s Precision Motions Portal enables high acceleration and stable printing with high-quality servo motor, a stiffened axis and a unique double rail that evenly distributes the weight of its advanced extruders. Meanwhile a Bosch Rexroth CNC Control System provides elevated responsiveness and repeatability with its 32 integrated sensors and spline interpolation for smooth surfaces. With its top-tier construction, even the PRO’s ACE extruder is capable of printing 1.5x faster than competing industrial 3D printers.

Manufacturing with industrial 3D printers costs less and produces more because they eliminate outsourcing, expensive molds, and all those other inefficiencies of traditional manufacturing. They’re faster because they can run unattended to produce parts in a lights-out manufacturing setting, and because they don’t need any retooling to work. But where industrial 3D printers really shine, and especially the BigRep PRO, is what can’t be expressed so well with metrics. The flexibility that the BigRep PRO brings to industrial manufacturers, from the how to the what, has enabled many businesses to rebalance production for any given task with just a single industrial tool.

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

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.

Learn more with these Additive Manufacturing Use Cases

Large-format 3D printers for education and research

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The BigRep STUDIO G2 gets 3D printing off your desk and takes it to the next level. Operating with the same ease as a desktop 3D printer and with 10 times the build volume, the STUDIO G2 provides large-scale industrial manufacturing capabilities in a compact “fits everywhere” build.

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PREMIUM-EFFIZIENZ FÜR ANWENDUNGEN IN DER INDUSTRIE

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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About the author:

Dominik Stürzer

Head of Growth Marketing

Blade 3.0.1

August 2, 2023July 30, 2020

Fixed an issue when populating and/or arranging model(s) with Batch Printing Plugin and Mixed Mode
Fixed an issue when loading a gcode for the PRO and PRO Early 2020
Fixed an issue that can crash Blade when saving a gcode

Blade 3.0.0

August 2, 2023July 16, 2020

Updated UI and Engine to Cura 4.6.1
- Updated UI which better reflects the user workflows
  (including lots of stability and performance improvements)
- Intent profiles to address the different needs for a specific print
- Align faces to the build plate
- Multi model improvements (e.g. object list)
- More supported file formats (amf, ply, etc.)
- Bug fixes
Intent Profiles:
- Default Profile is comparable to Quality Preset "Medium"
- Visual Profile is comparable to Quality Preset "Quality"
- In order to work properly with intent profiles 0.6 mm hotend was added to BigRep STUDIO, but should not effect anything
- When loading 3mf projects created with older versions:
  - Default profile will be selected when no intent profile can be found. Please select the wanted intent profile and save the 3mf again
BigRep PRO:
- ACE 1 mm:
  - Added ABS, ASA: 0.6 mm layer height
BigRep PRO Early 2020:
- Initial Release
- MXT 1 mm: PA6/66: 0.6 mm layer height
- ACE 1 mm:
  - ABS, ASA, BVOH, PA6/66, PETG, Pro HT: 0.6 mm layer height
- ACE 0.6 mm:
  - ASA, PA6/66, Pro HT, default/visual intent: 0.3 mm layer height
BigRep STUDIO:
- Added BVOH: 0.1/0.2/0.3/0.4 layer height
- Added HI-TEMP: 0.1/0.2/0.3/0.4/0.5 layer heights
- Added PLA Antibacterial: default/visual intent: 0.1/0.2/0.3/0.4/0.5 layer heights
- Added PLX: visual intent: 0.3 layer height
BigRep STUDIO G2:
- Added PLA Antibacterial: default/visual intent: 0.1/0.2/0.3/0.4/0.5 layer heights
BigRep ONEv3:
- Power Extruder 0.6 mm:
  - Added BVOH: 0.2/0.3/0.4 layer heights
  - Added HI-TEMP: default/visual intent: 0.2/0.3/0.4/0.5 layer heights
  - Added PET: default/visual intent: 0.2/0.3/0.4/0.5 layer heights
  - Added PLA Antibacterial: default/visual intent: 0.2/0.3/0.4/0.5 layer heights
  - Added PLX: default/visual intent: 0.2/0.3/0.4/0.5 layer heights
- Power Extruder 1 mm:
  - Added BVOH: 0.3/0.4/0.5/0.6 layer heights
  - Added HI-TEMP: default/visual intent: 0.3/0.4/0.5/0.6 layer heights
  - Added PET: default/visual intent: 0.3/0.4/0.5/0.6 layer heights
  - Added PLA Antibacterial: default/visual intent: 0.3/0.4/0.5/0.6 layer heights
  - Added TPU: default/visual intent: 0.3/0.4/0.5/0.6 layer heights

Design for Industrial Additive Manufacturing: Eliminating Support Structures

February 23, 2023June 19, 2020

Optimizing designs is a crucial skill to create manufacturing efficiencies. To get the most out of your additive manufacturing system, or the least in terms of time and material, you need to understand the nuances of your 3D printer and how design for additive manufacturing differs from design for other manufacturing technologies. Once you do, it’s easy to tweak designs in a way that helps meet your productivity goals.

If you’re working on increasing efficiency in your manufacturing processes you probably already have a goal in mind. It’s likely a high-level goal like total productivity or operational costs. Here we’re going to help save you time and money to meet those high-level goals with a few design tips to print faster, save material, and reduce post-processing by eliminating support structures from your designs.

We often use designs that were originally created for traditional manufacturing technologies, like injection moulding, and apply them to newer technologies. If you instead consider the strengths and weaknesses of additive manufacturing and redesign accordingly, it’s easy to optimize your production.

Orientation

If you’re trying to reduce the support materials for your part, overhangs will probably be your first concern. Overhangs can often be reduced or eliminated by simply reorienting a design in your slicer. If you can’t just turn the design as it is, consider whether you can redesign your part so its base structure will support its overhangs more effectively.

Take this hand jig designed by BigRep, for example. It’s an alignment tool for automotive manufacturing processes that doesn’t require significant force. Ordinarily, the handle for this kind of fixture would have three faces with the two that are protruding from the base at 90-degree angles. Since an especially firm grip isn’t required, we limited the handle to two faces and protruded them at 45-degree angles – an overhang angle favorable to most FFF materials. In doing this, we sacrificed some of the handle’s empty space but saved significantly on material – both in terms of support material and the part itself.

If such an acute angle won’t work for your design’s overhang, consider changing the material you use. While BigRep’s PLA and PRO HT both work best with 45-degree overhangs, our engineering-grade materials are often suitable for harsher angles - like HI TEMP which can effectively print overhangs at angles of up to 65-degrees.

Design for Industrial Additive Manufacturing: Orientation

Design for Industrial Additive Manufacturing: Angles

Design for Industrial Additive Manufacturing: Structural Support

Chamfering

Sometimes reducing the faces on your design isn’t possible, so you can always try chamfering between the overhang’s outmost edge and base object. A “chamfering” is the transitional edge between two sides of an object, usually a 45-degree angle between two right-angle surfaces. It’s an easy process that most CAD software provides automated tools to accomplish. By chamfering your design, you can remove sharp angled overhangs, reducing them to manageable angles that your printer and material process can handle.

Structural Support

If you can’t change the angles on your design, or need to apply more than one design strategy, you can forgo wasteful slicer-generated support structures and design them yourself. In our hand jig we added “fins” as structural supports for the overhangs needed to form a handle.

Support fins are thin overhang tracings used to reinforce your design. You can see in our hand jig that we completely outlined the gap for our handle – even on the object’s base – to ensure it prints successfully without adding support structures. Fins trade some of what would be empty space in your design, so it’s important to make sure that enough room is left for the part’s intended use, but can save lots of support material and serve to strengthen your part’s extremities.

Design for Industrial Additive Manufacturing: Water soluble support materials

Internal Channels

Small internal channels won’t usually need additional support since FFF printers can easily handle a circular gap. However, there are some use cases where internal channels are too large to print without added support – especially in industrial applications where air or liquid flow might be important to your design. In the unusual case that an internal channel requires supports, they can be very difficult to remove without a water-soluble support material used on a dual-extrusion 3D printer, if not impossible.

To solve this tricky problem, don’t limit yourself to circular internal channels. The common circular shape for internal channels seems like common sense, but it’s just one of those holdovers from traditional manufacturing when drilling was the easiest way to form a channel. To design for additive manufacturing, you can easily change your channel’s shape to print better. Usually a teardrop shape, with the point at the top, is preferred to keep all angles at 45-degrees and easily printable. Don’t limit yourself, though. If you’re still finding supports necessary in your internal channels take a closer look at the weak points and experiment with the channel’s shape to find one that suits your needs.

Conclusion

There are a lot of different ways you can optimize your designs to reduce or entirely remove support structures. By doing so, you can minimize post-processing, save material, and print your parts faster. Don’t be afraid to redesign features that we might take for granted. Remember that design lags behind production technology, so question the necessity of any inefficiencies in your designs and consider how they might be optimized with the advanced tools now at your disposal.

You can always find some inspiration by seeing how the experts tackle this change. Check out our free case study, How Airbus Manufactures Shipping Cases In-House with Large-Format Additive, to learn how Airbus, SAS reinvented shipping case design with additive manufacturing.

Find out how industry leaders are using BigRep 3D printers to create affordable and secure investment shipping containers on demand for sensitive aerospace equipment in our case study with Airbus:
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BLADE 3.3

August 2, 2023March 11, 2021

Update to Cura 4.8
- Much better object cloning
Added certification for easier installation
Renamed PRO Early 2020 to PRO 1.1 (affects only new added printers)
Fixed crashes in gcode preview
Fixed missing Tree Support
Automatic Batch Arrangement when Auto Orientation is used, also moves models onto the bed
Prime Tower Configurator:
- Set default position of the Prime Tower for the STUDIOs to the right
- Increase minimum size of the Prime Tower
Materials:
- Added HI-TEMP CF for ACE 0.6mm
- Added improved ASA and BVOH profiles for combined dual extrusion
- Improved PA6/66 profiles for Studio G2

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