3D printing is a process of making three dimensional solid objects from a digital file. The creation of a 3D printed object is achieved by additive processes. In an additive process an object is created by laying down successive layers of material until the entire object is formed. Each of these layers can be seen as a thinly sliced horizontal cross-section of the eventual object.
How does 3D printing work?
It all starts with making a virtual 3D design of the object you want to create. This virtual design is made in a CAD (Computer Aided Design) file using a 3D modeling program (for the creation of a totally new object) or with the use of a 3D scanner (to copy an existing object). A 3D scanner makes a 3D digital copy of an object.
3d scanners use different technologies to generate a 3d model such as time-of-flight, structured / modulated light, volumetric scanning and many more.
Recently, many IT companies like Microsoft and Google enabled their hardware to perform 3d scanning, a great example is Microsoft’s Kinect. This is a clear sign that future hand-held devices like smartphones will have integrated 3d scanners. Digitizing real objects into 3d models will become as easy as taking a picture. Prices of 3d scanners range from very expensive professional industrial devices to 30 USD DIY devices anyone can make at home.
To prepare a digital file for printing, the 3D modeling software “slices” the final model into hundreds or thousands of horizontal layers. When the sliced file is uploaded in a 3D printer, the object can be created layer by layer. The 3D printer reads every slice (or 2D image) and creates the object, blending each layer with hardly any visible sign of the layers, with as a result the three dimensional object.
To prepare a digital file for printing, the 3D modeling software “slices” the final model into hundreds or thousands of horizontal layers. When the sliced file is uploaded in a 3D printer, the object can be created layer by layer. The 3D printer reads every slice (or 2D image) and creates the object, blending each layer with hardly any visible sign of the layers, with as a result the three dimensional object.
Processes and technologies
Not all 3D printers use the same technology. There are several ways to print and all those available are additive, differing mainly in the way layers are build to create the final object.
Some methods use melting or softening material to produce the layers. Selective laser sintering (SLS) and fused deposition modeling (FDM) are the most common technologies using this way of printing. Another method of printing is when we talk about curing a photo-reactive resin with a UV laser or another similar power source one layer at a time. The most common technology using this method is called stereolithography (SLA).
To be more precise: since 2010, the American Society for Testing and Materials (ASTM) group “ASTM F42 – Additive Manufacturing”, developed a set of standards that classify the Additive Manufacturing processes into 7 categories according to Standard Terminology for Additive Manufacturing Technologies. These seven processes are:
- Vat Photopolymerisation
- Material Jetting
- Binder Jetting
- Material Extrusion
- Powder Bed Fusion
- Sheet Lamination
- Directed Energy Deposition
Below you’ll find a short explanation of all of seven processes for 3d printing:
Vat Photopolymerisation
Vat photopolymerisation schematics. Image source: lboro.ac.uk
Material Jetting
In this process, material is applied in droplets through a small diameter nozzle, similar to the way a common inkjet paper printer works, but it is applied layer-by-layer to a build platform making a 3D object and then hardened by UV light.
Material Jetting schematics. Image source: CustomPartNet
Binder Jetting
Binder jetting 3D printing technology overview. Image source: additively.com
Material Extrusion
The most commonly used technology in this process is Fused deposition modeling (FDM)
Fused deposition modelling (FDM), a method of rapid prototyping: 1 – nozzle ejecting molten material (plastic), 2–deposited material (modelled part), 3 – controlled movable table. Image source: Wikipedia, made by user Zureks under CC Attribution-Share Alike 4.0 International license.
Powder Bed Fusion
The most commonly used technology in this processes is Selective laser sintering (SLS)
SLS system schematic. Image source: Wikipedia from user Materialgeeza under Creative Commons Attribution-Share Alike 3.0 Unported license.
Sheet Lamination
Sheet lamination involves material in sheets which is bound together with external force. Sheets can be metal, paper or a form of polymer. Metal sheets are welded together by ultrasonic welding in layers and then CNC milled into a proper shape. Paper sheets can be used also, but they are glued by adhesive glue and cut in shape by precise blades. A leading company in this field is Mcor Technologies.
Simplified model of ultrasonic sheet metal 3D printing. Image source: Wikipedia from user Mmrjf3 shared under Creative Commons Attribution 3.0 Unported license.
Directed Energy Deposition
This process is mostly used in the high-tech metal industry and in rapid manufacturing applications. The 3D printing apparatus is usually attached to a multi-axis robotic arm and consists of a nozzle that deposits metal powder or wire on a surface and an energy source (laser, electron beam or plasma arc) that melts it, forming a solid object.
Direct Energy Deposition with metal powder and laser melting. Image source: Merlin project
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