3 D printing

Prototyping made easy!

3D Printing is an additive manufacturing process that is particularly suitable for prototype construction, individual pieces and components with complex geometry. Here, a computer-generated 3D model is divided into individual layers and then assembled in layers. Depending on the printing process used, 3D plastics, resins or metals may be printed.

Prototypes and demonstrators available
Cross-industry deployment
Suitable for SMEs?

State of play

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 printing quality, the price also determines reliability and user-friendliness. The associated software is also often easily applicable, as manufacturers focus not only on industrial customers but also on amateur 3D printers. Therefore, 3D printing is suitable for SMEs. Note: The chances of one of your employees having a 3D printer privately are nowadays relatively high.

While 3D printing of metal (and other special materials) is already used in industry, it is still an active subject of research and its use is not trivial. This requires a thorough understanding of material science and the printing process in order to select a suitable material on the one hand and to print or handle it in accordance with professional practice on the other. The current relatively high level of complexity and acquisition cost makes the use of 3D metal printing in SMEs only to a limited extent.

Technology and deployment

Description of technology

First, a three-dimensional model generated on the computer is converted or triangulated into a suitable format, usually the STL format. The conversion thus approximates the surface of the model by triangles. The model is then divided into individual layers by the so-called ‘slicer’ software, which is then converted into a machine-readable code. The code thus created allows the 3D printer to be able to produce the individual layers produced sequentially.

The way in which the respective layers are produced depends on the 3D printing method used. Two typical methods are FDM (Fused Depostion Modeling), in which the filament (the material to be printed) is melted and extruded and stereolithography (SLA) is either hardened by UV radiation or powder is melted by lasers or electron beams. Depending on the end-use application, 3D pressure parts must be retreated (surface quality, accuracy, material self-assembly).

Gradual introduction

Step 1: Selection of the operational area/framework

Think about what exactly you want to use 3D printing for. Keywords here are: Material characteristics (plastic/metal), necessary building space, surface quality and level of knowledge of staff. Note: Once you enter the 3D printing of metal, the purchase price and the necessary know-how increase. A good compromise can be an addition to 3D-printed parts made of plastic with traditionally manufactured metal parts.

Step 2: Selection of 3D printer and related software

Select an appropriate 3D printer based on the above framework conditions. For SMEs, the choice is often made by FDM (Fused Deposition Modelling) 3D printers with artificial filament (e.g. PLA, ABS, PETG). New entrants’ models are given for a few hundred euros, while premium models are in the lower five-digit range. For special manufacturing processes (e.g. infusion with carbon fibres) or metal 3D printing, you can expect a 6-digit amount. When selecting the 3D printers, take into account the respective limitations of the 3D printers with regard to any additional software required.

Step 3: Job design

Depending on the type of printing chosen, you will need to design the workplace accordingly and, if necessary, provide PPE (personal protective equipment). The lowest requirements here are an FDM printer for plastics and the highest of metal 3D printing (depending on the procedure, whole body suits with respiratory masks, venting systems, special cleaning and follow-up systems are required).

Step four: Removal and training of staff

Once the 3D printer has been acquired and the workplace has been designed, you will need to train your staff on the slicer, 3D printer software and 3D printer.

Opportunities for SMEs

Fast and cost-effective prototyping

Production of complex geometries possible

Relatively low acquisition cost (depending on procedure and use case)

Often a useful complement to existing infrastructure

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