There are many 3D printing technologies on the market today offering a huge range of capabilities depending on your budget, timescales, material choice and of course intended use.
At ARRK we’ve been supporting customer’s 3D printing needs for a very, very long time. As we’ve learned a thing or two about some of the technologies out there, we thought we would share some of our views on a few of these great technologies.
Stereolithography (SLA)
We were early adopters of 3D printing with the introduction of what is probably classed today as one of the more traditional processes. Stereolithography or SLA as it is more widely referred to, is a great all-rounder for designers and engineers to use to get a physical model of their CAD data in a short space of time. Offering a physical 3D model of a design is a powerful way of really understanding what has been created. The term “form, fit and function” is a phrase often used to describe the benefits of getting a prototype model made and it really does help designers to validate their design.
Key benefits of SLA
Accurate models, range of resins on offer, can be joined, finished and/or painted. Can also be used as a master model to create silicone tool/mould for use in vacuum casting or other processes. A widely available technology, SLA parts can be built in hours, subject to size and geometries.
Examples of finished and painted SLA models
Selective Laser Sintering (SLS)
Another mainstream 3D Printing process, SLS is a tried and tested technology, especially if you are looking for strong, robust parts that may be used in various environments. SLS is a powder-based process that builds in a heated chamber without the need for support structures. This therefore allows complex, sometimes even impossible geometries, to be built. Subject to size, many parts can be built in a single build cycle within the machine. Some customers are also using SLS as a manufacturing solution, especially useful where design modifications are frequent. The fact that parts are 3D Printed without the need for any tooling can be invaluable and very cost effective.
Key Benefits of SLS
Robust parts that can be used to prove design and/or satisfy production. Large parts can be built in sections and then joined, finished and painted. Ideal for producing full size structures for automotive, aerospace, marine or any other application where mock-ups are required to look like the real thing – or even used as the real thing.
Examples of multiple SLS parts and parts built in sections and later joined to form larger structures
Multi-Jet Fusion (MJF)
This additive manufacturing process is one of the latest ways to build a prototype or production part in a nylon material. An MJF machine builds parts layer by layer in a heated bed of thermoplastic powder and uses a binding agent where the part is to be formed. As with SLS, parts are built within the chamber of powder and then once cooled, the loose material can be removed and parts extracted. MJF offers fast build speeds and materials that provide excellent engineering characteristics and properties.
Key benefits of MJF
Consistent, reliable builds. Range of materials. Can be used as prototype or for serial production, where appropriate.
Example MJF parts
Digital Light Processing (DLP)
One of the more recent innovations in 3D printing. A resin-based process with a wide choice of materials available. These are generally much closer to production materials and performance characteristics. DLP builds parts exceptionally quickly and is ideal where fine detail or features are required. DLP also offers a good surface finish and parts can literally be despatched within hours in some cases. Although generally designed for small to medium size parts, the process is well suited to rapid change-over meaning increased throughput.
Key benefits of DLP
Rapid build times. Extensive range of resins. Ideal process where fine detail is required. Characteristics closer to production materials.
Examples of DLP components showing fine detail
Liquid Crystal Display (LCD)
Along the same lines as DLP, this more recent process offers high resolution parts with a smooth surface. LCD 3D printing polymerizes very thin layers of resin layer by layer. Depending on the material selected parts can be used as prototype or as a manufacturing solutions. Parts can also be joined to produce bigger strutures and if required additional finishing applied.
Key benefits of LCD
Similar to DLP regarding materials.
Continuous Fibre Fabrication (CFF)
This desktop printer allows engineers and designers to obtain a physical representation of their part quickly. With material supplied and fed off a reel the printer builds layer by layer to produce small to medium components. Material changeover is quick and easy. You can also identify key points within the build process where levels of specified material can be applied and apportioned. The build process can also be paused to allow inserts to be applied before being resumed and material applied around the insert. Range of materials available including Onyx and Carbon.
Key benefits of CFF
Ideal solution for low volume quantities. Fast turnaround times. Insert and overmoulding possible.
Images showing ARRK’s CFF printer and build process
DMLS – 3D Printed Metal components
When parts are needed in metal, but not possible to manufacture through more traditional methods like CNC Machining, Direct Metal Laser Sintering may be worth considering. If you can produce your part through CNC then this tends to be the most cost-effective route. If however, a part is not possible to be manufactured through CNC then Metal 3d printing is an option. Using additive manufacturing (AM) as opposed to machining (subtractive), allows complex geometries to be produced. It is worth noting that significant post processing may be required to make the component aesthetically presentable, this may add considerable cost to the project. For ideal benefit from this process, designing parts with the manufacturing method in mind makes most sense. (DFM – Design for Manufacture)
Key Benefits of DMLS
Complex geometries, impossible through traditional methods can be produced. Different surface finishes achievable.
Keen to know more?
If you would like to know more about these 3D Printing technologies and to see if they could fit with your next project, please contact our team of experts who will be happy to help.