Rapid prototyping technologies & online quote: how does the additive manufacturing help you to get the parts for your projects ?

There are several additive manufacturing process applied for Rapid prototyping technologies and here below we are going to get an overview of each 3D printing technology. With the advent of new layer manufacturing and CAD/CAM technologies, prototypes may now be rapidly produced from 3D computer models. There are many different rapid prototyping technologies available. This paper presents an overview of the most rilevant Rapid prototyping technologies available today.

3D printing has taken by the storm design companies all over the world. It allows designers to visualize the object in 3D. It is thus a prototyping process in which a real object is created from a 3D model.  Since the raw material is added layer by layer to form the final object, 3D printing is also called as additive manufacturing and it is different from cnc machining as they operate by removing material to achieve the desired part shape. Both of them may contribute (in different manner) to Rapid prototyping technologies.

The prototype can be regarded as “the first element of a series,” and it is of fundamental importance to perform evaluation such as dimensional tests or support the marketing dep. for the costs evaluation or the market response index, elements now become a fundamental and essential importance with the dynamics development of new products on every industrial sector.

There are several technologies used for 3D printing. Let’s take a look below and the main features of Rapid prototyping technologies available today:

FDM – Fused deposition modeling (FDM) was developed in the late 1980s (developed by Stratasys): filament made from polymers (with different diameters, typically using the 3 mm and 1.7 mm) heated by a resistance (at temperatures of about 250 ° C) escapes through a nozzle, layer by layer, is created and give shape to the object. This is most widely used and affordable Rapid prototyping technologies. The  parts built are more stronger, durable and widely used for functional testing applications. You can build parts directly into ABS, polycarbonate, nylon and various other materials. Due to its simplicity and ease of use; these machines are office friendly machines and can be installed in Design office.

SLS – selective laser sintering or Liquid Based 3D Printing: represents a technological evolution of the FDM, allowing the selective melting of a material in a granular bed. A laser hits the blending polymers and creating thin layers of plastic powder; With SLS a computer controlled laser pulses down on the platform, tracing a cross-section of the object onto tiny particles of plastic, ceramic or glass. The laser heats the powder either to just below its boiling point (sintering) or above its boiling point (melting), which fuses the particles in the powder together into a solid form. This process continues until the entire object has been printed. SLS parts are widely used for snap-fit applications. As powder is used for printing the parts; special care needs to be taken while handling these machines that are not suitable in office environment.

DMLS – Direct metal laser sintering: like the SLS, the print media is different, being able to also print the metals. As for the SLS, the detail is built layer by layer by localized melting of metal powder with laser. DMLS uses a fibre laser fired into a bed of powdered metal, aiming the laser automatically at points in space defined by a , melting or rather, welding the material together to create a solid structure. The metal powder is placed into a container and a special Print Bed picks up the necessary amount of powder for the Laser to melt. The Print Bed moves around until the necessary layers are made.

SLM – Selective Laser Melting: for the Rapid prototyping technologies, SLM totally melts the material, using a high energy laser and selectively melt the material powder; The laser will heat particles in specified places on a bed of metallic powder until completely melted. The CAD 3D file dictates where melting will occur. Then, the machine will successively add another bed of powder above the melted layer, until the object is completely finished.

EBM – Electron beam melting literally melting Electron beam. Equipped with a high-energy source, the material is hit in the form “micro granulometric” causing its complete melting (normally are used metals such as titanium or aluminum); The process fully dense metal components are built up, layer-by-layer of metal powder, melted by a powerful electron beam. Each layer is melted to the exact geometry defined by a CAD model.

LOM – Laminated Object Manufacturing: printing technique continuously on a sheet or laminate. Subsequently, the various layers are divided and reassembled to form the 3D object; It was developed by the California-based Helisys Inc.. During the LOM process, layers of plastic or paper are fused — or laminated — together using heat and pressure, and then cut into the desired shape with a computer-controlled laser or blade. While LOM is not the most popular method of 3D printing used today, it is still one of the fastest and most affordable ways to create 3D prototypes.

SLA – Stereolithography is the most dated technique. Through the photopolymerization solidifies a liquid resin; 3D printers, successive layers of fluid resin are hardened using UV rays or lasers.  After each layer is fused, the perforated platform is lowered very slightly and another slice is traced out and hardened by the UV / laser. This technology is widely used in jewellery industry due to its fine surface finish and accuracy. It is one of the most expensive technologies to use and the parts need post-curing operation.
In Stereolithographic 3D printers, successive layers of fluid resin are hardened using UV rays or lasers.  After each layer is fused, the perforated platform is lowered very slightly and another slice is traced out and hardened by the UV / laser. This process is repeated until a complete object has been printed.
This technology is widely used in jewellery industry due to its fine surface finish and accuracy. It is one of the most expensive technologies to use. Objects printed cannot be used directly as it needs post-curing operation to strengthen the parts.

PP – Plaster-based 3D Printing: using a piezoelectric inkjet head prints a binder on a powder bed (chalk, starch, resins), always progressing layer by layer until the completion of the object; Plaster is a mixture of dry powder and water to form a paste, similar to adding water to baby powder. Heat and/or air  is then applied to the paste evaporating a certain amount of water which causes the paste to harden. Plaster-based 3D Printing (PP) is also knows as Binder Jetting. PP uses inkjet heads similar to those on regular home Printers and can 3D Print Plaster in full color. PP is excellent for artistic projects, especially those in structures, like a wall in a house. In the PP process, sections are Printed first, like a waffle. The Print Bed holds the powdered Plaster and the Print head deposits a binding material in the desired shape into the sections. Plaster powder is then placed over that Layer and the process is performed again until the object is complete.