2015

BEGINNERS GUIDE TO
3D PRINTING
VERSION 0.1

THINK3D TEAM

Welcome to think3Ds Beginners Guide to 3D Printing. This document is for people

who are completely new to 3D printing technology or who are looking at gaining
additional information on 3D printing technology. It is very imperative that 3D printing
technology is going to change the world. Experts claim 3D printing is a much bigger
revolution than internet. We at think3D, completely agree to those viewpoints. In this
document, we shall be providing data to illustrate the true revolutionary nature of 3D
printing.
This document is structured into 6 chapters, (a) Introduction of 3D printing (b) History
of 3D printing (c) 3D Printing Technology (d) 3D Printing Processes (e) 3D Printing
Materials (f) 3D Printing Applications (g) 3D Printing Glossary.
3D printing is an umbrella term for a host of processes and technologies that offer a
full spectrum of capabilities for the production of parts and products in different
materials. One thing common in all these processes is the manner in which production
is carried out layer by layer in an additive process. That is why 3D Printing is also
called additive manufacturing in contrast to traditional methods of production that are
primarily subtractive in nature, also called as subtractive manufacturing or
molding/casting processes.
Applications of 3D printing are emerging almost by the day, and, as this technology
continues to penetrate more widely and deeply across industrial, maker and consumer
sectors, this is only set to increase. Most reputable commentators on this technology
sector agree that, as of today, we are only just beginning to see the true potential of 3D
printing.
About think3D:
think3D is Indias largest 3D printing platform covering all aspects of 3D printing
technology like Latest News, 3D Printers, Print On Demand Services, 3D Design
Store & 3D Scanning Services. This document is an attempt to provide the readers a
reliable authentic information on various terms and terminologies involved in 3D
printing, its history, application areas and benefits.
If you wish to contact us and gain more information on 3D printing technology, you
can always reach us at 040-3091 1007 or email us at [email protected]

CHAPTER 01

What is 3D Printing?

In the 20th century, no other invention affected the mankind more than technology did.
With the advent of computers in 1950s and internet in 1990s, the fundamental way of
doing things has through a massive changes. These technologies made our lives
better, opened up new avenues and possibilities and gave us a hope for the future. But
it generally decades for an ecosystem to be built across a particular technology to
take it to masses and achieve the truly disruptive nature of that technology.
It is widely believed that 3D printing or additive manufacturing (AM) has the vast
potential to become one of these technologies. There is a lot of coverage on 3D
printing across many television channels, newspapers and online resources. What
really is this 3D printing that some have claimed will put an end to traditional
manufacturing as we know it, revolutionize design and impose geopolitical, economic,
social, demographic and environmental and security implications to our everyday
lives?
The most basic, differentiating principle behind 3D printing technology is that it is an
additive manufacturing process. And this is indeed the key because 3D printing is a
radically different manufacturing method based on advanced technology that builds
up parts, additively, in layers at the sub mm scale. This is fundamentally different from
any other existing traditional manufacturing techniques.
Traditional manufacturing process has evolved a lot over time from hand based
manufacturing to the automated processes such as machining, casting, forming and
molding. Yet these technologies all demand subtracting material from a larger block
whether to achieve the end product itself or to produce a tool for casting or molding
processes and this is a serious limitation within the overall manufacturing process.
For many applications traditional design and production processes impose a number
of unacceptable constraints, including the expensive tooling, fixtures and the need for
assembly for complex parts. In addition, the subtractive manufacturing processes,
such as machining can result in up to 90% of the original block of material being
wasted.
In contrast, 3D printing process can create objects directly by adding material layer by
layer in a variety of ways, depending on the technology used. Simplifying the ideology
behind 3D printing, for anyone that is still trying to understand the concept, it could be
likened to the process of building something with Lego blocks automatically.

3D printing is an enabling technology that encourages and drives innovation with

unprecedented design freedom while being a tool-less process that reduces prohibitive
costs and lead times. Components can be designed specifically to avoid assembly
requirements with intricate geometry and complex features created at no extra cost.
3D printing is also emerging as an energy efficient technology that can provide
environmental efficiencies in terms of both the manufacturing process itself, utilizing
up to 90% of standard materials and throughout the products operating life through
lighter and stronger design.
In recent years, 3D printing has gone beyond being an industrial prototyping and
manufacturing process as the technology has become more accessible to small
companies and even individuals. Previously, only big corporates used to own 3D
printers as the scale and economics of owning 3D printer make it prohibitive for
smaller companies to own one. But with the rapid decline of the printer cost, the
technology has become more affordable. Now a days, smaller and less capable 3D
printers can be acquired for under $1000.
This has opened up the technology to a much wider audience, and as the exponential
adoption rate continues apace on all fronts, more and more systems, materials,
applications, services and ancillaries are emerging.

CHAPTER 02

History of 3D Printing

The earliest 3D printing technologies first became visible in the late 1980s, at which
time they were called Rapid Prototyping (RP) technologies. This is because the
processes were originally conceived as a fast and more cost-effective method for
creating prototypes for product development within industry. As an interesting side
note, the first patent application for RP technology was filed by Dr. Kodama in Japan in
May 1980. But the full patent specification was not filed before the one year deadline
after the application thus voiding the patent application.
The first patent for 3D printing technology was issued in 1986 to Mr. Charles Hull for
stereolithography apparatus (SLA). He invented the machine in 1983 and went on to
cofound 3D Systems Corporation one of the largest and most prolific organizations
operating in the 3D printing sector today.
3D Systems first commercial RP system, the SLA-1, was introduced in 1987. As with
every new technology, there were lot of researchers working on various ways to attain
additive manufacturing in 1980s. In 1987, Mr. Carl Deckard, who was working at the
University of Texas, filed a patent in the US for the Selective Laser Sintering (SLS) RP
process. This patent was issued in 1989 and SLS was later licensed to DTM Inc, which
was later acquired by 3D Systems.
In 1989, one Mr. Scott Crump also filed a patent for Fused Deposition Modeling (FDM).
He went to co-found another major 3D printing company called Stratasys Inc. As of
2015, FDM has become the most popular 3D printing technology for entry level
machines. This technology is based on open source RepRap model. The FDM patent
was issued to Stratasys in 1992. In Europe, 1989 also saw the formation of EOS GmbH
in Germany, founded by Hans Langer. After a dalliance with SL processes, EOS R&D
focus was placed heavily on the laser sintering (LS) process, which has continued to
go from strength to strength. Today, the EOS systems are recognized around the world
for their quality output for industrial prototyping and production applications of 3D
printing. EOS sold its first Stereos system in 1990. The companys direct metal laser
sintering (DMLS) process resulted from an initial project with a division of Electrolux
Finland, which was later acquired by EOS.
Other 3D printing technologies and processes also emerged during these years,
namely Ballistic Particle Manufacturing (BPM) originally patented by William Masters,
Laminated Object Manufacturing (LOM) originally patented by Michael Feygin, Solid
Ground Curing (SGC) originally patented by Itzchak Pomerantz and three dimensional
printing (3DP) originally patented by Emanuel Sachs. And so the early nineties
witnessed a growing number of competing companies in the RP market but only three
of the originals remain today 3D Systems, EOS and Stratasys.
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Throughout the 1990s and early 2000s a host of new technologies continued to be
introduced, still focused wholly on industrial applications and while they were still
largely processes for prototyping applications, R&D was also being conducted by the
more advanced technology providers for specific tooling, casting and direct
manufacturing applications. This saw the emergence of new terminology, namely
Rapid Tooling (RT), Rapid Casting and Rapid Manufacturing (RM) respectively.
In terms of commercial operations, Sanders Prototype (later Solidscape) and
ZCorporation were set up in 1996, Arcam was established in 1997, Objet Geometries
launched in 1998, MCP Technologies (an established vacuum casting OEM) introduced
the SLM technology in 2000, EnvisionTec was founded in 2002, ExOne was established
in 2005 as a spinoff from the Extrude Hone Corporation and Sciaky Inc was pioneering
its own additive process based on its proprietary electron beam welding technology.
These companies all served to swell the ranks of Western companies operating across
a global market. The terminology had also evolved with a proliferation of
manufacturing applications and the accepted umbrella term for all of the processes
was Additive Manufacturing (AM). Notably, there were many parallel developments
taking place in the Eastern hemisphere. These technologies enjoyed some local
success but couldnt really impact the global market around that time.
During the mid-nineties, the sector started to show signs of distinct diversification with
two specific areas of emphasis that are much more clearly defined today. First, there
was the high end of 3D printing, still very expensive systems, which were geared
towards part production for high value, highly engineered, complex parts. At the other
end of the spectrum, some of the 3D printing system manufacturers were developing
and advancing 3D printers that kept the focus on improving concept development and
functional prototyping. These were built to be cost-effective systems. These machines
are prelude to todays desktop machines. However, these systems were all still very
much for industrial applications. Looking back, this was really the calm before the
storm.
In 2007, the market saw the first system under $10,000 from 3D Systems, but this
never quite hit the mark that it was supposed to. This was partly due to the system
itself, but also other market influences. The holy grail at that time was to get a 3D
printer under $5000 this was seen by many industry insiders, users and
commentators as the key to opening up 3D printing technology to a much wider
audience. For much of that year, the arrival of the highly anticipated Desktop Factory
was heralded as the one to watch. It came to nothing as the organization faltered in
the run up to production. Desktop Factory and its leader, Cathy Lewis, were acquired,
7

along with the IP, by 3D Systems in 2008 and all but vanished. As it turned out though,
2007 was actually the year that did mark the turning point for accessible 3D printing
technology even though few realized it at the time. Dr Bowyer conceived a concept
called RepRap. RepRap concept is to build an open source self-replicating 3D printer.
The idea occurred in 2004 and the seed was germinated in the following years with
some heavy slog from his team at Bath, most notably Vik Oliver and Rhys Jones, who
developed the concept and built a working prototype of 3D printer using the deposition
process. 2007 was the year the shoots started to show through and this embryonic,
open source 3D printing movement started to gain visibility.
But it wasnt until January 2009 that the first commercially available 3D printer in kit
form and based on the RepRap concept was offered for sale. This was the BfB
RapMan 3D printer. Closely followed by Makerbot Industries in April the same year, the
founders of which were heavily involved in the development of RepRap until they
departed from the Open Source philosophy following extensive investment. Since
2009, a host of similar deposition printers have emerged with marginal unique selling
points (USPs) and they continue to do so. The interesting dichotomy here is that, while
the RepRap phenomenon has given rise to a whole new sector of commercial, entrylevel 3D printers, the ethos of the RepRap community is all about Open Source
developments for 3D printing and keeping commercialization at bay.
2012 was the year that alternative 3D printing processes were introduced at the entry
level of the market. The B9Creator (utilizing DLP technology) came first in June,
followed by the Form 1 (utilizing stereolithography) in December. Both were launched
via the funding site Kickstarter and both enjoyed huge success.
As a result of the market divergence, significant advances at the industrial level with
capabilities and applications, dramatic increase in awareness and uptake across a
growing maker movement, 2012 was also the year that many different mainstream
media channels picked up on the technology. 2013 was a year of significant growth
and consolidation. One of the most notable moves was the acquisition of Makerbot by
Stratasys.
Heralded as the 2nd, 3rd and, sometimes even, 4th Industrial Revolution by some, what
cannot be denied is the impact that 3D printing is having on the industrial sector and
the huge potential that 3D printing is demonstrating for the future of consumers. What
shape that potential will take is still unfolding before us.

CHAPTER 03

3D Printing Technology

The entire 3D printing technology can be divided into 3 steps (a) 3D Design (b)
Slicing (c) 3D Printing. 3D digital model is the starting point for any 3D printing
process. This digital model can be created using various 3D design softwares or can
also can be created using 3D scanning. Once the 3D model is created, it is then sliced
into layers thereby converting the design into a file readable by 3D printer. 3D printer
will then print this file layer by layer using the material given as input to the 3D printer.
As stated, there are a number of different types of 3D printing technologies, which
process different materials in different ways to create the final object. Functional
plastics, metals, ceramics and sand are all routinely used for industrial prototyping and
production applications. Research is also being conducted for 3D printing bio
materials and different types of food.
Generally speaking though, at the entry level of the market, materials are much more
limited. Plastic is currently the only widely used material usually ABS or PLA. There
is also a growing number of entry level machines that have been adapted for
foodstuffs, such as sugar and chocolate.
The different types of 3D printers each employ a different technology that processes
different materials in different ways. It is important to understand that one of the most
basic limitations of 3D printing in terms of materials and applications is that there
is no one solution fits all. For example some 3D printers process powdered materials
(nylon, plastic, ceramic, metal), which utilize a light/heat source to sinter/melt/fuse
layers of the powder together in the defined shape. Others process polymer resin
materials and again utilize a light/laser to solidify the resin in ultra-thin layers. Jetting
of fine droplets is another 3D printing process, reminiscent of 2D inkjet printing, but
with superior materials to ink and a binder to fix the layers.
Perhaps the most common and easily recognized process is deposition, and this is the
process employed by the majority of entry-level 3D printers. This process extrudes
plastics, commonly PLA or ABS, in filament form through a heated extruder to form
layers and create the predetermined shape. Because parts can be printed directly, it is
possible to produce very detailed and intricate objects, often with functionality built in
and negating the need for assembly.
However, another important point to stress is that none of the 3D printing processes
come as plug and play options as of today. There are many steps prior to pressing
print and many more steps after the print is done. Apart from the realities of designing
for 3D printing, which can be demanding, file preparation and conversion can also
prove time-consuming and complicated, particularly for parts that demand intricate
supports during the build process. However there are continual updates and upgrades
10

of software for these functions and the situation is improving. Furthermore, once the
object is 3D printed, it needs to undergo finishing operations. Support removal is an
obvious one for processes that demand support, but others include sanding, lacquer,
paint or other types of traditional finishing touches, which all typically need to be done
by hand and require skill, time and patience.

11

CHAPTER 04

3D Printing Processes

12

SLA

Stereolithography (SL) is widely recognized as the first 3D printing process. It was

certainly the first to be commercialized. SL is a laser-based process that works with
photopolymer resins that react with the laser and cure to form a solid in a very precise
way. It is a complex process but simply put the photopolymer resin is held in a vat with
a movable platform inside. A laser beam is directed in the X-Y axes across the surface
of the resin according to the 3D data supplied to the machine (the .stl file), whereby the
resin hardens precisely where the laser hits the surface. Once the layer is completed,
the platform within the vat drops down by a fraction (in the Z axis) and the subsequent
layer is traced out by the laser. This continues until the entire object is completed and
the platform can be raised out of the vat for removal.
Because of the nature of the SL process, it requires support structures for some parts,
specifically those with overhangs or undercuts. These structures need to be manually
removed. In terms of other post processing steps, many objects 3D printed using SL
need to be cleaned and cured. Curing involves subjecting the part to intense light in an
oven-like machine to fully harden the resin.
Stereolithography is generally accepted as being one of the most accurate 3D printing
processes with excellent surface finish. However limiting factors include the postprocessing steps required and the stability of the materials over time, which can
become more brittle.

13

DLP

DLP (Digital Light Processing) is a similar process to stereolithography in that it is a

3D printing process that works with photopolymers. The major difference is the light
source. DLP uses a more conventional light source, such as an arc lamp with a liquid
crystal display panel, which is applied to the entire surface of the vat of photopolymer
resin in a single pass, generally making it faster than SL.
Also like SL, DLP produces highly accurate parts with excellent resolution, but its
similarities also include the same requirements for support structures and post-curing.
However, one advantage of DLP over SL is that only a shallow vat of resin is required
to facilitate the process, which generally results in less waste and lower running costs.

14

Laser Sintering / Laser Melting

Laser sintering and laser melting are interchangeable terms that refer to a laser based
3D printing process that works with powdered materials. The laser is traced across a
powder bed of tightly compacted powdered material, according to the 3D data fed to
the machine, in the X-Y axes. As the laser interacts with the surface of the powdered
material it sinters, or fuses, the particles to each other forming a solid. As each layer is
completed the powder bed drops incrementally and a roller smoothens the powder
over the surface of the bed prior to the next pass of the laser for the subsequent layer
to be formed and fused with the previous layer.
The build chamber is completely sealed as it is necessary to maintain a precise
temperature during the process specific to the melting point of the powdered material
of choice. Once finished, the entire powder bed is removed from the machine and the
excess powder can be removed to leave the printed parts. One of the key advantages
of this process is that the powder bed serves as an in-process support structure for
overhangs and undercuts, and therefore complex shapes that could not be
manufactured in any other way are possible with this process. However, on the
downside, because of the high temperatures required for laser sintering, cooling times
can be considerable.

15

Furthermore, porosity has been an historical issue with this process and while there
have been significant improvements towards fully dense parts, some applications still
necessitate infiltration with another material to improve mechanical characteristics.
Laser sintering can process plastic and metal materials, although metal sintering does
require a much higher powered laser and higher in-process temperatures. Parts
produced with this process are much stronger than with SL or DLP, although generally
the surface finish and accuracy is not as good.

Extrusion / FDM / FFF

DO NOT COPY

3D printing utilizing the extrusion of thermoplastic material is easily the most common
and recognizable 3DP process. The most popular name for the process is Fused
Deposition Modelling (FDM). However this is a trade name, registered by Stratasys, the
company that originally developed it. Stratasys FDM technology has been around
since the early 1990s and today is an industrial grade 3D printing process. However,
the proliferation of entry-level 3D printers that have emerged since 2009 largely utilize
a similar process, generally referred to as Freeform Fabrication (FFF), but in a more
basic form due to patents still held by Stratasys. The earliest RepRap machines and all
subsequent evolutions employ extrusion methodology. However, following Stratasys
patent infringement filing against Afinia there is a question mark over how the entrylevel end of the market will develop now, with all of the machines potentially in
Stratasys firing line for patent infringements.
16

The process works by melting plastic filament that is deposited, via a heated extruder,
a layer at a time, onto a build platform according to the 3D data supplied to the printer.
Each layer hardens as it is deposited and bonds to the previous layer.
Stratasys has developed a range of proprietary industrial grade materials for its FDM
process that are suitable for some production applications. At the entry-level end of
the market, materials are more limited, but the range is growing. The most common
materials for entry-level FFF 3D printers are ABS and
PLA.
The FDM/FFF processes require support structures for any applications with
overhanging geometries. For FDM, this entails a second, water-soluble material, which
allows support structures to be relatively easily washed away, once the print is
complete. Alternatively, breakaway support materials are also possible, which can be
removed by manually snapping them off the part. Support structures, or lack thereof,
have generally been a limitation of the entry level FFF 3D printers. However, as the
systems have evolved and improved to incorporate dual extrusion heads, it has
become less of an issue.
In terms of models produced, the FDM process from Stratasys is an accurate and
reliable process that is relatively office/studio friendly, although extensive postprocessing can be required. At the entry-level, as would be expected, the FFF process
produces much less accurate models, but things are constantly improving.
The process can be slow for some part geometries and layer-to-layer adhesion can be
a problem, resulting in parts that are not watertight. Again, post-processing using
Acetone can resolve these issues.

17

Inkjet: Binder Jetting

There are two 3D printing process that utilize a jetting technique.

Binder jetting: Where the material being jetted is a binder, and is selectively sprayed
into a powder bed of the part material to fuse it a layer at a time to create/print the
required part. As is the case with other powder bed systems, once a layer is completed,
the powder bed drops incrementally and a roller or blade smoothens the powder over
the surface of the bed, prior to the next pass of the jet heads, with the binder for the
subsequent layer to be formed and fused with the previous layer.
!
Advantages of this process, like with SLS, include the fact that the need for supports is
negated because the powder bed itself provides this functionality. Furthermore, a
range of different materials can be used, including ceramics and food. A further
distinctive advantage of the process is the ability to easily add a full color palette
which can be added to the binder.
The parts resulting directly from the machine, however, are not as strong as with the
sintering process and require post-processing to ensure durability.

18

Inkjet: Material Jetting

Material jetting: a 3D printing process whereby the actual build materials (in liquid or
molten state) are selectively jetted through multiple jet heads (with others
simultaneously jetting support materials). However, the materials tend to be liquid
photopolymers, which are cured with a pass of UV light as each layer is deposited.
The nature of this product allows for the simultaneous deposition of a range of
materials, which means that a single part can be produced from multiple materials
with different characteristics and properties. Material jetting is a very precise 3D
printing method, producing accurate parts with a very smooth finish.

19

Selective Deposition Lamination (SDL)

SDL is a proprietary 3D printing process developed and manufactured by Mcor

Technologies. There is a temptation to compare this process with the Laminated
Object Manufacturing (LOM) process developed by Helisys in the 1990s due to
similarities in layering and shaping paper to form the final part. However, that is where
any similarity ends.
The SDL 3D printing process builds parts layer by layer using standard copier paper.
Each new layer is fixed to the previous layer using an adhesive, which is applied
selectively according to the 3D data supplied to the machine. This means that a much
higher density of adhesive is deposited in the area that will become the part, and a
much lower density of adhesive is applied in the surrounding area that will serve as the
support, ensuring relatively easy weeding, or support removal.
After a new sheet of paper is fed into the 3D printer from the paper feed mechanism
and placed on top of the selectively applied adhesive on the previous layer, the build
plate is moved up to a heat plate and pressure is applied. This pressure ensures a
positive bond between the two sheets of paper. The build plate then returns to the
build height where an adjustable Tungsten carbide blade cuts one sheet of paper at a
time, tracing the object outline to create the edges of the part. When this cutting
sequence is complete, the 3D printer deposits the next layer of adhesive and so on
until the part is complete. SDL is one of the very few 3D printing processes that can

20

produce full colour 3D printed parts, using a CYMK colour palette. And because the
parts are standard paper, which require no post-

EBM
The Electron Beam Melting 3D printing technique is a
proprietary process developed by Swedish company
Arcam. This metal printing method is very similar to the
Direct Metal Laser Sintering (DMLS) process in terms of
the formation of parts from metal powder. The key
difference is the heat source, which, as the name
suggests is an electron beam, rather than a laser, which
necessitates that the procedure is carried out under
vacuum conditions.
EBM has the capability of creating fully dense parts in a
variety of metal alloys and as a result the technique has
been particularly successful for a range of production
applications in the medical industry, particularly for
implants. However, other hi-tech sectors such as
aerospace and automotive have also looked to EBM
technology for manufacturing fulfillment.

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CHAPTER 05

3D Printing Materials

22

The materials available for 3D printing have come a long way since the early days of
the technology. There is now a wide variety of different material types that are
supplied in different states (powder, filament, pellets, granules, resin etc.)
Specific materials are now generally developed for specific platforms performing
dedicated applications (an example would be the dental sector) with material
properties that more precisely suit the application. There are way too many such
proprietary materials from many different 3D printer vendors. In this article, we shall
look at the most popular types of generic materials available.

Plastics

Nylon, or Polyamide, is commonly used in powder form with the sintering process or in
filament form with the FDM process. It is a strong, flexible and durable plastic material
that has proved reliable for 3D printing. It is naturally white in color but it can be
colored - pre or post printing. This material can also be combined (in powder format)
with powdered aluminum to produce another common 3D printing material for
sintering Alumide.
ABS is another common plastic used for 3D printing, and is widely used on the entrylevel FDM 3D printers in filament form. It is a particularly strong plastic and comes in a
wide range of colors. ABS can be bought in filament form from a number of
nonproprietary sources. This made the filament very popular in the market.
PLA is a bio-degradable plastic material that has gained traction with 3D printing for
this very reason. It can be utilized in resin format for DLP/SL processes as well as in
filament form for the FDM process. It is offered in a variety of colors, including
transparent, which has proven to be a useful option for some applications of 3D
printing. However it is not as durable or as flexible as ABS.
LayWood is a specially developed 3D printing material for entry level extrusion 3D
printers. It comes in filament form and is a wood/polymer composite.

Metals

A growing number of metals and metal composites are used for industrial grade 3D
printing. Two of the most common are aluminum and cobalt derivatives.
One of the strongest and therefore most commonly used metals for 3D printing is
Stainless Steel in powder form for the sintering/ melting/EBM processes. It is naturally
silver, but can be plated with other materials to give a gold or bronze effect.
23

In the last couple of years Gold and Silver have been added to the range of metal
materials that can be 3D printed directly, with obvious applications across the jewelry
sector. These are both very strong materials and are processed in powder form.
Titanium is one of the strongest possible metal materials and has been used for 3D
printing industrial applications for some time.

Other 3D Printing Materials

Ceramics
Ceramics are a relatively new group of materials that can be used for 3D printing with
various levels of success. The particular thing to note with these materials is that, post
printing, the ceramic parts need to undergo the same processes as any ceramic part
made using traditional methods of production namely firing and glazing.
Paper
Standard A4 copier paper is a 3D printing material employed by the proprietary SDL
process supplied by Mcor Technologies. The capital outlay for the machine is in the
mid-range but the emphasis is very much on an easily obtainable, cost-effective
material supply that can be bought locally. 3D printed models made with paper are
safe, environmentally friendly, easily recyclable and require no post-processing.
Bio Materials
There is a huge amount of research being conducted into the potential of 3D printing
bio materials for a host of medical applications. Living tissue is being investigated at a
number of leading institutions with a view to developing applications that include
printing human organs for transplant, as well as external tissues for replacement body
parts. Other research in this area is focused on developing food stuffs meat being
the prime example.
Food
Experiments with extruders for 3D printing food substances has increased
dramatically over the last couple of years. Chocolate is the most common one. There
are also printers that work with sugar and some experiments with pasta and meat are
undergoing.

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Chapter 06

3D Printing Applications

25

The origins of 3D printing in Rapid Prototyping were founded on the principles of

industrial prototyping as a means of speeding up the earliest stages of product
development. This saves time and money at the outset of the entire product
development process and ensures confidence ahead of production tooling.
Prototyping is still probably the largest application of 3D printing today.
The developments and improvements of the process and the materials since the
emergence of 3D printing for prototyping saw the processes being taken up for
applications further down the product development process chain. Tooling and casting
applications were developed utilizing the advantages of the different processes. Again,
these applications are increasingly being used and adopted across industrial sectors.
Similarly for final manufacturing operations, the improvements are continuing to
facilitate uptake. In terms of the industrial vertical markets that are benefitting greatly
from industrial 3D printing across all of these broad spectrum applications, the
following is a basic breakdown:
The medical sector is viewed as being one that was an early adopter of 3D printing, but
also a sector with huge potential for growth, due to the customization and
personalization capabilities of the technologies and the ability to improve peoples
lives as the processes improve and materials are developed that meet medical grade
standards.
3D printing technologies are being used for a host of different applications. In addition
to making prototypes to support new product development for the medical and dental
industries, the technologies are also utilized to make patterns for the downstream
metal casting of dental crowns and in the manufacture of tools over which plastic is
being vacuum formed to make dental aligners. The technology is being used to directly
manufacture both stock items, such as hip and knee implants, and bespoke patientspecific products, such as hearing aids, orthotic insoles for shoes, personalized
prosthetics and one-off implants for patients suffering from diseases such as
osteoarthritis, osteoporosis and cancer. 3D printed surgical guides for specific
operations are also an emerging application that is aiding surgeons in their work and
patients in their recovery. Technology is also being developed for the 3D printing of
skin, bone, tissue, pharmaceuticals and even human organs. However, these
technologies remain largely decades away from commercialization.
Like the medical sector, the aerospace sector was an early adopter of 3D printing
technologies in their earliest forms for product development and prototyping. These
companies, typically working in partnership with academic and research institutes,
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have been at the sharp end in terms or pushing the boundaries of the technologies for
manufacturing applications.
Because of the critical nature of aircraft development, the R&D is demanding and
strenuous, standards are critical and industrial grade 3D printing systems are put
through their paces. Process and materials development have seen a number of key
applications developed for the aerospace sector and some non-critical parts are allready flying on aircraft.
High profile users include GE / Morris Technologies, Airbus / EADS, Rolls-Royce, BAE
Systems and Boeing. While most of these companies do take a realistic approach in
terms of what they are doing now with the technologies, some do get quite bullish
about the future.
Another general early adopter of Rapid Prototying technologies was the automotive
sector. Many automotive companies particularly those at the cutting edge of motor
sport and F1 have followed a similar trajectory to the aerospace companies. First
using the technologies for prototyping applications, but developing and adapting their
manufacturing processes to incorporate the benefits of improved materials and end
results for automotive parts.
Many automotive companies are now also looking at the potential of 3D printing to
fulfill after sales functions in terms of production of spare/replacement parts on
demand, rather than holding huge inventories.
Traditionally, the design and manufacturing process for jewelry has always required
high levels of expertise and knowledge involving specific disciplines like fabrication,
mold-making, casting, electroplating, forging, silver/gold smithing, stonecutting,
engraving and polishing. Each of these disciplines evolved over many years and each
requires technical knowledge. Just one example is investment casting the origins of
which can be traced back more than 4000 years.
For the jewelry sector, 3D printing has proved to be particularly disruptive. There is a
great deal of interest and uptake based on how 3D printing can, and will, contribute to
the further development of this industry. From new design freedoms enabled by 3D
CAD and 3D printing, through improving traditional processes for jewelry production all
the way to direct 3D printed production eliminating many of the traditional steps, 3D
printing had and continues to have a tremendous impact in this sector.

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Artists and Sculptors are engaging with 3D printing in myriad of different ways to
explore form and function in ways previously impossible. Whether purely to find new
original expression or to learn from old masters this is a highly charged sector that is
increasingly finding new ways of working with 3D printing and introducing the results
to the world. There are numerous artists that have now made a name for themselves
by working specifically with 3D modelling, 3D scanning and 3D printing technologies.
Architectural models have long been a staple application of 3D printing processes, for
producing accurate demonstration models of an architects vision. 3D printing offers a
relatively fast, easy and economically viable method of producing detailed models
directly from 3D CAD, BIM or other digital data that architects use. Many successful
architectural firms, now commonly use 3D printing (in house or as a service) as a
critical part of their workflow for increased innovation and improved communication.
More recently some visionary architects are looking to 3D printing as a direct
construction method. Research is being conducted at a number of organizations on
this front, most notably Loughborough University, Contour Crafting and Universe
Architecture.
As 3D printing processes have improved in terms of resolution and more flexible
materials, one industry, renowned for experimentation and outrageous statements, has
come to the fore.
3D printed accessories including shoes, head-pieces, hats and bags have all made
their way on to global catwalks. And some even more visionary fashion designers have
demonstrated the capabilities of the tech for haute couture dresses, capes, fulllength gowns and even some under wear have debuted at different fashion venues
around the world.
Iris van Herpen should get a special mention as the leading pioneer in this vein. She
has produced a number of collections modelled on the catwalks of Paris and Milan
that incorporate 3D printing to blow up the normal rules that no longer apply to
fashion design. Many have followed, and continue to follow, in her footsteps, often
with wholly original results.
Although a late-comer to 3D printing, food is one emerging application that is getting
people very excited and has the potential to truly take the technology into the
mainstream. 3D printing is emerging as a new way of preparing and presenting food.

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Initial forays into 3D printing food were with chocolate and sugar and these
developments have continued apace with specific 3D printers hitting the market. Some
other early experiments with food include the 3D printing of meat at the cellular
protein level. More recently pasta is another food group that is being researched for 3D
printing food.
Looking to the future 3D printing is also being considered as a complete food
preparation method and a way of balancing nutrients in a comprehensive and healthy
way.
The holy grail for 3D printing vendors is consumer 3D printing. There is a widespread
debate as to whether this is feasible in future. Currently, consumer uptake is low due
to the accessibility and application issues that exist with entry level machines. There
is headway being made in this direction by the larger 3D printing companies such as
3D Systems and Makerbot, as a subsidiary of Stratasys as they try to make the 3D
printing process and the ancillary components (software, digital content etc) more
accessible and user-friendly.

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Contact Us

Phone: 040-3091 1007

Email: [email protected]

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