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Introduction

3D printing creates parts by making parts one layer at a time. This process has many advantages over other manufacturing methods (for example CNC cutting) which are the most important of which that apply to the entire industry are described in this article.

3D Printing isn't likely to replace traditional manufacturing processes, however there are plenty of applications where a 3D printer can create a design fast, with high accuracy , using the material of use.

Understanding the advantages of 3D printing helps designers make better decisions when selecting the manufacturing method and allows them to produce a high-quality product. Speed

One of the primary advantages of additive manufacture is the speed with which parts can be produced as compared to traditional methods of manufacturing. Designs that are complex can be transferred from a CAD model and printed in a few hours. The benefit of this is the rapid verification and development of design ideas.

Where in the past it may have taken days or even weeks to receive an idea for a prototype, additive manufacturing places a model to the designer in a matter of hours. While the higher-end additive manufacturing machines require longer to print and then process parts, the capability to manufacture functional products at low or mid-sized volumes can be a major time-saving benefit in comparison to traditional manufacturing techniques (often manufacturing time for an injection molding die on its own can take weeks).

Single step manufacture

One of the major problems for designers is the ability to make the part as efficiently as it is feasible. Many parts require a significant quantity of manufacturing processes to be produce by traditional technologies. The order these steps occur determines the quality and manufacturing capability of the model.

Take a look at a custom steel bracket, which is produced via traditional manufacturing methods:

Similar to additive manufacturing the process starts with a CAD model. When the design is completed manufacturing begins by cutting the steel profiles into sizes. These profiles then are clamped in place and then welded one a time to form the bracket. Sometimes a custom jig will require to be designed in order to make sure that all parts are aligned correctly. The welds are polished to provide a nice surface appearance. The next step is drilling holes so that the bracket can be fixed onto the walls. Finally, the bracket is priming, sandblasted and painted to improve its appearance.

Additive manufacturing machines can finish a building in one go, and require minimal interaction from the machine operator during the construction stage. When you have the CAD design is finalized it is uploaded onto the machine and printed in one step in a couple of hours.

The ability to create parts in one process significantly reduces dependence on various manufacturing processes (machining and welding, painting) and gives the designer more influence over what is produced. Cost

The cost of manufacture is broken down into 3 categories; machine operating costs, material cost, and labor costs.

The cost of machine operation:

The majority of desktop 3D printers utilize similar power to laptop computer. Industrial additive manufacturing technologies consume plenty of energy to create just one piece. But, the capability to produce complex geometries in one step leads to more efficiency and faster time to market. Machine operations are generally the least significant factor in manufacturing costs overall. Material costs:

The cost of additive manufacturing is largely dependent on the type of technology. Desktop FDM printers employ filament coils, which cost about $25 per kilogram, while SLA printing needs resin that is priced at approximately $115 per liter. The variety of materials that are available to make additives makes a the difference between traditional manufacturing challenging. Nylon powder that is used in SLS is priced at around $70 per kg, while comparable nylon pellets used in injection molding can be bought for just $2-$5 per kilogram. Materials are the primary contributor to the cost of a product made by additive manufacturing.

Costs of labor:

One of the biggest advantages for 3D printing is the low cost of labor. The post-processing aspect aside, the majority of 3D printers need an operator to push a button. The machine then follows a completely automated process to produce the component. Compared to traditional manufacturing, which requires highly skilled machinists as well as operators are often required, the cost of labor for a 3D printer are virtually none.

Additive manufacturing at low volumes can be priced competitively when relative with traditional manufacturing. When it comes to the production of prototypes to verify the shape and fit, it's much less expensive than alternative manufacturing techniques (e.g. the injection molding) and can be comparable for the production of one-off functional components. Traditional manufacturing techniques become more efficient when the volume of production grows, and the cost of setting up can be justified by the enormous volumes of production.

Risk mitigation

A defective prototype can cost the designer both time and money. Making minor adjustments to the manufacturing method or mold could have a major financial impact.

The ability to test the design through printing a prototype that is ready for production prior to investing in costly machines for manufacturing (e.g. tools, molds and jigs) reduces the risk of this prototyping procedure. This aids in building confidence in the design before making the major investments required for mass production.

Design freedom and complexity

The limitations that traditional manufacturing on what products can be made are typically not relevant for additive manufacturing. Since components are constructed one layer at a time Design requirements such as draft angles, undercuts, and tool access are not needed in the case of designing parts that are 3D printed

Although there are some limitations on the minimum size features that can be produced accurately however, the majority of the limitations of additive manufacturing center around how to best position prints to decrease the dependence on support and increase the chance of print failure. This provides designers with a huge variety of design options and permits the simple creation of complex geometries.

Customization

Not only is it true that 3D printing allow more design flexibility, but it also lets you completely customize designs. Since current additive manufacturing technologies excel at creating single components one at each time, they are well suitable for single-time production.

This concept has been embraced by the dental and medical industry to produce customized prosthetics, implants or dental devices. From high-level sporting gear that is tailored to the needs of an athlete to custom-made sunglasses and fashion accessory, additive manufacturing allows low-cost single-run production of custom parts.