These new-age additive manufacturing methods have permanently changed production lifecycles for good.
3D printing is a form of additive manufacturing in which three-dimensional objects are constructed layer by layer according to computer-aided design data. During this process, materials are fused together through a number of wide-ranging techniques — melting, sintering, curing, adhesive bonding and so on — in order to rapidly create iterative, tailor-made prints with total design freedom in a matter of hours. titanium vs aluminum weight
Today, the International Organization for Standardization defines all existing 3D printing methods under seven different categories, distinguished by the way in which layers of material are created. Given that this technology has only been around since the 1980s, new types are likely to develop in the near future as leaders continue to innovate this space.
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Material extrusion (MEX) is the most common 3D printing method. It melts mixed filaments, typically thermoplastics, as they extrude through a heated nozzle attached to a robotic arm. These printheads move along a predefined path as instructed by a CAD file, depositing molten material on top of previous layers as they cool, cure and solidify. Layer by layer, this process repeats in a continuous stream until the desired structure is formed. Material extrusion is popular among hobbyists as it’s user-friendly, doesn’t come with a steep learning curve and is relatively inexpensive after upfront costs.
Binder jetting (BJT) constructs three-dimensional objects by binding powdered materials — such as metal, sand or ceramics — with a liquid bonding agent. As thin layers of powder are spread across a build tray, a print head zips across x, y and z axes, selectively depositing an adhesive substance according to a CAD model. This glue binds the particles together — no heat or light source required. Binder jetting’s ability to turn out high-volume production makes it a competitor to traditional manufacturing practices. It’s also known for printing prototypes and large-scale parts at high speeds and low cost.
Directed energy deposition (DED) uses a focused thermal energy source — such as a laser, plasma arc or electron beam — to melt and fuse materials together as they are being deposited. These systems feature a multi-axis robotic arm that can deposit molten powder or wire at any angle, making directed energy deposition useful for performing repairs or adding material to existing components. Typically, this technique is performed within a controlled chamber or vacuum at reduced oxygen levels. Since DED prints are only limited by the reach of the robotic arm, this method is used to work on large-scale projects of near-net shape.
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Material jetting (MJT) builds three-dimensional objects one droplet at a time. This method shares likeness with your average office inkjet printer, featuring an oscillating printhead that swings back and forth across a build tray. But instead of ink, material jetting printers deposit drops of liquid photopolymer resin. Each layer cures under a UV light that is applied immediately after deposition, forming a solid object. Material jetting is the only additive manufacturing method capable of mixing resins in a single print.
Powder bed fusion (PBF) selectively joins powder particles using a heat source, typically a laser. As each cross section is fused together, a recoater blade covers the build platform with a fresh layer of powder, repeating this process until the entire object is fabricated. This 3D printing technique is a relatively high-cost method of additive manufacturing that’s known to create high-precision structures with fine details and intricate geometries. Parts made from powder-bed infusion tend to display exceptional weight distribution and dimensional accuracy, resulting in extraordinary mechanical properties that are otherwise unobtainable via traditional manufacturing methods. Because of these qualities, it’s most often used in industrial and commercial applications.
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Sheet lamination (SL or SHL) bonds sheet stacks together to create three-dimensional objects. These thin layers of paper, plastic, ceramic, polymer or metal foil are joined using a variety of methods — either welding, heat, pressure or a type of adhesive. Guided by a CAD file, a laser, blade or cutting tool cuts shapes into each new layer that’s distributed by a feedstock roller over a descending build platform. Excess materials — which acts as a structural support in the meantime — are cut away to shape the object’s final form, and recycled for the next project. SL is the only additive manufacturing technique that can construct metal prints at low temperatures, and is often used to create colored objects in high resolution.
Vat polymerization (VPP) uses UV light to turn liquid photopolymers into solid structures. These pieces are typically constructed upside down, where a build platform lowers into a vat of resin. A UV light, directed and intensified with mirrors, cures the resin onto the build platform layer by layer until the print is complete. VPP is known for creating high resolution prints that are unmatched in accuracy, complete with fine details and smooth surfaces. As one of the only biocompatible 3D printing methods, it’s commonly used to create orthodontic models, like dentures and retainers, as well as hearing aids and facial prosthetics.
Polycarbonate is widely recognized as the strongest 3D print material . Polycarbonate-based filaments create durable prints that can withstand high impact and heat resistance.
Fused deposition modeling (FDM) — a material extrusion method — is the most common type of 3D printing.
machinist tools While it depends on the project and the printer model, stereolithography (SLA) is widely considered as the fastest 3D printing method .