3D printing

Prototyping made easy!

3D printing is an additive manufacturing process that is particularly suitable for prototype construction, individual items and components with complex geometries. Here, a computer-generated 3D model is divided into individual layers and then built up layer by layer. Depending on the printing process used, plastics, synthetic resins or metals can be 3D printed.

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The current status

The 3D printing of plastics is already well researched and there are numerous suppliers of 3D printers in different price segments. In addition to the resulting print quality, the price also determines reliability and user-friendliness. The associated software is also often easy to use, as manufacturers focus not only on industrial customers, but also on hobby 3D printers. Plastic 3D printing is therefore suitable for SMEs. Note: The chances of one of your employees owning a 3D printer are relatively high these days.

Although 3D printing of metal (and other special materials) is already being used in industry, it is still an active area of research and its use is not trivial. A deep understanding of materials science and the printing process is required in order to select a suitable material and to print or handle it correctly. Due to the current relatively high complexity and acquisition costs, the use of metal 3D printing in SMEs is only suitable to a limited extent.

Technology and use

Technology description

First, a three-dimensional model created on the computer is converted or triangulated into a suitable format, usually the STL format. The transformation therefore approximates the surface of the model using triangles. The model is then divided into individual layers by the so-called “slicer” software, which is then converted into machine-readable code. The code generated in this way enables the 3D printer to produce the individual layers sequentially.

The form in which the respective layers are produced depends on the 3D printing process used. Two typical processes are FDM (fused deposition modeling), in which the filament (the material to be printed) is melted and extruded, and stereolithography (SLA), in which either resin is cured by UV rays or powder is melted by lasers or electron beams. Depending on the end application, 3D printed parts must be post-treated (surface quality, dimensional accuracy, material properties).

Step-by-step introduction

Step 1: Selecting the area of application or the framework conditions

Think about exactly what you want to use 3D printing for. Important keywords here are: Material or material properties (plastic/metal), required installation space, surface quality and level of knowledge of the employees. Note: As soon as you start 3D printing metal, the purchase price and the necessary know-how multiply. A good compromise here can be a combination of 3D printed plastic parts with traditionally manufactured metal parts.

Step 2: Selecting the 3D printer and associated software

Select a suitable 3D printer based on the general conditions mentioned. SMEs often choose FDM (Fused Deposition Modeling) 3D printers with plastic filament (e.g. PLA, ABS, PETG). Entry-level models are available for just a few hundred euros, while premium models are in the lower five-figure range. For special manufacturing processes (e.g. infusion with carbon fibers) or metal 3D printing, you can expect to pay a six-figure sum. When selecting a 3D printer, please note the respective limitations of the 3D printer with regard to the additional software required.

Step 3: Workplace design

Depending on the selected printing process, you must design the workplace accordingly and provide PPE (personal protective equipment) if necessary. The lowest requirements are for an FDM printer for plastics and the highest for metal 3D printing (depending on the process, full-body suits with respirators, fume extraction systems and special cleaning and post-processing systems are required).

Step 4: Elimination and training of employees

Once the 3D printer has been purchased and the workstation has been designed, you need to train your employees in how to use the slicer, the 3D printer software and the 3D printer.

Opportunities for SMEs

Fast and cost-effective production of prototypes

Production of complex geometries possible

Relatively low acquisition costs (depending on process and application)

Often a useful addition to the existing infrastructure

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