Have you heard about 3D printing and want to know what it is and how it really works? Then you are exactly right here.

From buildings to prosthetics to aerospace and even food, 3D printing is an ever-evolving manufacturing technique that is growing in popularity every day.

Although still in its infancy, 3D printing has taken the manufacturing world by storm with its unmatched benefits and amazing potential.

Whether you are a complete beginner or a seasoned pro, the following 3D printing explanations and tips are sure to bring you joy.

What is 3D printing?

In 3D printing, three-dimensional objects are created based on a previously designed digital model.

It is a layering technology, meaning products are made by printing layer upon layer until the entire object is formed.

Whether it's a work of art, an architectural form, the prototype of a product you want to test, a home accessory, an automotive part, a biomedical device, an aerospace component, or even a biological organ - by As you build layer by layer, you can create products with a high level of complexity that would not be possible with conventional manufacturing methods.

This of course depends on the limitations of the 3D printer you are using.

But it shows how diverse the possible applications of 3D printing already are (and will be in the future). 3D printing is also known as additive manufacturing (AM). 

Why should you choose 3D printing and not other manufacturing methods?

Not only can 3D printing produce complex parts, it can do it in a fraction of the time and at a significantly lower cost than traditional processes such as forging, casting, and modeling.

Interestingly, more and more user-friendly printers are being released, which is the next step in revolutionizing the manufacturing world.

What are the advantages of 3D printing?

Here's how 3D printing can support your desire for better manufacturing.

1. Fast manufacturing

One of the most important factors in manufacturing is time.

It is important that the manufacturing time is as short as possible and the quality is maintained.

The print with a matching 3D printer can save a lot of time.

That is why it is also known as "rapid prototyping".

Rapid prototyping is essentially a one-step manufacturing process that helps minimize process time while maintaining the complexity, precision, and fidelity of the final product.

In short, a prototype that used to take days (or even weeks) to complete or test can simply be 3D printed in the morning, tested, modified, and reprinted in the evening.

2. Precise complexity and flexibility in design

Traditional manufacturing techniques limit design freedom and complexity.

Requirements such as undercuts, draft angles and mold access restrict the design freedom.

With 3D printing, you can avoid this problem because of its inherent layered construction.

You don't need all these elaborate requirements.

3D printing allows you to print objects with a high level of complexity and precision.

3. Versatility and Accessibility

An amazing feature of 3D printers is that they fit almost anywhere.

• in your home
• In your office.
• in your school
• In your lab or studio.

As long as you have design software and cutting software on your Desktop your 3D printer will do the rest.

3D printing is being used by more and more people... not necessarily by professionals. Thanks to its versatility and ease of use, even non-professionals can use it effectively.

4. Personal Customization

Industrial manufacturers usually mass-produce their products; That means they use the same molds and design specifications to shape and produce their products.

Adapting the shape and design of the product even slightly to specific customer needs involves considerable effort and investment. 3D printing, on the other hand, offers infinite freedom and easy customization options.

Change your designs as you like. Give each family member their own personal gift. Stand out from the crowd by creating your jewelry design.

Make custom dental or medical products for your customers. The possibilities are endless.

5. Risk Minimization

An essential step in building projects is testing the prototype to avoid the risk of making a defective product or investing in expensive tooling.

This is where 3D printing comes to the rescue. By printing and testing a prototype that closely resembles the final product, you can build a high level of confidence before spending the big bucks.

Conventional processes consist of many manufacturing steps to obtain the desired product.

This poses a significant risk of error during the process.

In contrast, 3D printing is a one-step manufacturing process that requires no operator intervention.

So it helps you to eliminate uncertainties and reduce errors in a quick and cost-effective way.

6. Sustainability and waste reduction

Conventional manufacturing methods are, by definition, top-down approaches.

They are subtractive. A block of material is cut through to form the product. Significant amounts of unwanted material are removed in the process. This unwanted material ends up in the trash.

Some will be recycled, but that takes time, effort and money. In contrast, 3D printing is a bottom-up approach.

He is additive. Only the amount of material necessary to produce the part is used. These materials are also largely recyclable and reusable. Therefore, there is little to no waste.

3D printing is also relatively energy efficient.

The reduced energy consumption and waste generation help to reduce the impact on the environment and therefore increase the level of sustainability.

7. Cost efficiency

This is arguably the most outstanding feature of 3D printing.

The costs incurred by companies and individuals in using traditional manufacturing techniques are very high.

Imagine.

• All tooling.
• The machines... and their maintenance.
• The material cost.
• The energy costs.
• The cost of labor... and the cost of error and inflexibility.
• Conventional processes are expensive, especially for small series production and prototyping.

This is where 3D printing can play an important role.

• Additive manufacturing has a significant competitive advantage over other manufacturing processes in terms of machine, material and labor costs.
• Machine cost is usually the least contributor to the total manufacturing cost.
• However, the time efficiencies and one-step manufacturing give 3D printing an edge, which in turn leads to increased sales.
• The cost of materials depends on the type of technology used.

Labor costs are the be-all and end-all of 3D printing! You don't need multiple highly skilled employees to get the job done. All you need is one.

Most 3D printers are capable of performing the entire process without any further intervention at the touch of a button.

Other benefits include smaller storage space, the ability to stay ahead of the competition, market testing, better communication of products, and confidentiality.

What are the disadvantages of 3D printing?

But like any other technology, 3D printing is not perfect. There are definitely some limitations as well. This includes:

1. Product weakness

The layer-by-layer method of 3D printing can result in a product being 10-50% weaker and more brittle in certain directions than traditional materials.

This isn't usually a big problem, but you wouldn't use it for critical applications.

Some 3D printers, like DMLS and SLM, can make stronger parts.

In industries that demand reliable, long-lasting products - like aerospace - these printers are becoming increasingly popular.

2. Economies of scale

3D printing is quite advantageous in small series production.

But as soon as that Volume is increased, 3D printing loses its competitive advantage as the production price per unit decreases only minimally.

In comparison, with traditional manufacturing processes, the price per product drops drastically as volume increases.

More cost-effective methods for high-volume production are CNC machining and injection molding.

Basically, 3D printing is well suited for small series - but not yet cost-effective enough for mass printing.

3. Accuracy

There is a small tolerance for error in 3D printing. This is usually between ± 0,01 mm and ± 0,5 mm.

What does that mean? Let's say you're printing a product with an 8,5mm hole.

Actual measurement could be between 8mm and 9mm.

So if you're a commercial company producing for a client, there's a small risk that your product won't exactly meet your client's needs.

Of course, as technology advances, so should accuracy.

4. Post-processing of the print

Once you've printed a part, it usually needs post-processing before it's ready to use. This may include sanding and painting the part.

So although the 3D printing process saves time, you still need to factor in the time spent on post-processing.

You may also need to make support parts - especially if the object has an overhang or underhang.

Other disadvantages include waste products, potential toxic emissions, limited print materials, size restrictions, and potential product counterfeiting.

A few final tips on 3D printing

Buying a 3D printer is like buying a car, only without the test drive. In other words, user experience is very important. Don't just focus on the specs and metrics. Do some research on users' experiences and what people think and say about the printer you're considering buying.

Talk to the manufacturer about the printer's energy efficiency before making a purchase. This allows you to make a rough estimate of energy costs and ultimately save money.

If you are planning to pursue 3D printing as a career, it is best to research university courses, online courses, and internship opportunities with additive manufacturing companies that can help you get started.

Sönke Schmidt gives many other helpful tips and tricks on the subject of 3D printing, the selection of the right printer and filaments on his 3D Printing Blog.