What is 3D printing?

3D printing or rapid prototyping (RP) is a form of additve manufacturing technology also known as stereolithography where a three dimensional object is created by laying down multiple successive layers of material. A 3D printer produces a solid object, rather than printing onto a 2D sheet like conventional printer. Our 3D Printer extrudes ABS plastic filament by melting it similar to a hot glue gun. The extrusion print head works in the x and y axis while the print bed on the Z axis lowers to allow the next layer to be printed on top. The innovation leader in 3D printing, provides 3-dimensional printing systems that enable designers to have a clear and more professional communication to present their designs.

3D Printers are widely used for:

• Product Design
• Character Design
• Architecture
• Entertainment & Art
• Industrial engineering and more

How does it work?

PRE-PROCESSING — "Slicing" or Sectioning CAD Design Into Layers

The FDM process begins in one of two build-preparation programms, Catalyst EX or Insight. In operation, after importing the design file. The preprocessing software calculates sections and “slices” the part design into many layers, ranging them from 0.005 inches (0.127mm)to 0.013 inches (0.3302 mm) in height. Using the sectioning data, the software the generates “toll paths” or building instructions which will drive the extrusion head. This step automatic when using Catalyst EX. Next send the job to the 3D printer.

Below here you can find the programs which the 3D printer supports: (3D studio Max, 3D studio viz, Alias, AutoCAD, Bentley, triforma, Blender, cAtlA, cosMos, form Z, inventor, lightwave, Magics 3-rP, Maya, Microstation, Mimics, Pro/engineer raindrop geoMagic, rapidform, rasMol, revit, solidworks, rhinoceros, sketchup, solid edge, ugn nX vectorworks)

PRODUCTION — The Layering Process

The building process contains two materials, one to make the part, and one to support it, enter the extrusion head. Heat is applied to soften the plastics, which are extruded in a ribbon, roughly the size of a human hair. Atternating between part material and support material, the system deposits layers as thin as 0.005 inch (0.13 mm).

POST-PROCESSING — Removing Disposable Support Material

This is a manual removal process, in which you twist, break, and scrape support material from the part. A needle nose pillers and a pick are usually sufficient. Next method uses an automated support-removal process in which the material removed in a tank via an agitated waterbased detergent solution. FDM machines have build volume capacities ranging roughly from 288 cu. In. to 31K cu. In. (4719 cu. cm to 508K cu. cm).

Why 3D Printing?

Concept Models

Early in the design process, you can use FDM to make models to review form, fit and ergonomics. Then update your design based on any flaws you have identified. Review and update your design. Repeat the iteration process until you find the perfect concept. Shifting from the 2D world to physical parts will accelerate the product development process and lower cost. The 3D part is much better at communicating the design, so you can make better decisions faster.

Functional Prototypes

To prove out your design, you can make a functional precision prototype. Use FDM parts for performance tests and rigorous engineering assessments. Producing functional prototype components typically takesfrom a few hours to over a week. It will allow you to catch flaws before the become costly engineering changes. It also reduces time to market and maximizes prodecut performance.

ABS Plastic

ABS (Arcylonitrille butadlene styrene) is considered to be the second easiest material to work with when you start 3D printing. ABS is an engineering polymer commonly used to produce car bumpers due to its toughness and strength. It’s also the same material that Lego blocks are made of, tough enough yet very easy to make glossy finishing.

Appraisement

Layer resolution

Layer resolution determines the height of each layer of material extruded to produce a part. Available resolutions are: .010 or .013 icnh (.254 or .330mm). Resolution will effect build time and surface finish. A shorter height creates a smoother finish, but will take longer to build. Only experience can help you make your decision.

Model Interior

Model Interior establishes the type of fill used for interior, solid areas of the part. The ‘Solid - normal’ option is ised when A stronger, more durable part is desirable. Build times will be longer and more material will be used, thus creating higher costs. The ‘Sparse’ option creates an interior that will be “honeycombed/hatched”. Sparse also allows for shorter build times, less material use. When printing surfaces or wall thicknesses smaller than 25”. Sparse Low density is considerably the cheapest way of printing the objects while Sparse High density is more stronger but uses more time to and uses slightly more material to build.

Support Fill

Support material is used to brace the model material during the build process. It is re-moved when the part is complete. Support fill options will effect the support strength and build time of the print. The ‘Basic’ option may be used for most parts. It provides more support than Sparse. Areas of the model that are considered to be of marginal strength will be supported. The ‘Sparse’ option minimizes the amount of support material. Sparse supports are accordion-pleated. This reduces structural support and is usually recommended for objects that aren’t too complex and have flat bottoms. Lastly, the ‘Surround’ option surrounds the entire model by support the material. Typically used for tall, thin (narrow) models (e.g., pencil). The factory recommends laying your part down in the print area rather than printing tall and thin.

Layer Resolution	Model Interior	Support Fill	Price
0.0070	Sparse - Low density	Sparse	Default
0.0100	Sparse - High density	Basic	Increase cost up to 10 to 20%
	Solid	Smart	Increase cost up to 30 to 50%
		Surround	Increase cost pending on size of product