10 tips on designing for additive manufacturing (FDM 3D printing)

10 tips on designing for additive manufacturing (FDM 3D printing)

by | Jul 29, 2024 | Uncategorized, Uncategorized

Additive manufacturing, in particular Fused Deposition Modeling (FDM) 3D printing, has transformed the way engineers approach design and production. By allowing for complex geometries and reducing the need for traditional manufacturing limitations, FDM opens up a world of possibilities. However, to use this technology to its full potential, it’s crucial to follow best practices in design. Here are 10 tips to help you optimize your designs for FDM 3D printing.

1. Understand material properties

The first step in designing for FDM is understanding the properties of the materials you’ll be using. Common materials include PLA, ABS, PETG, and TPU, each with its own strengths and weaknesses. For example, PLA is easy to print and biodegradable, but it’s less heat-resistant. ABS is stronger and more heat-resistant but can be prone to warping. Knowing the characteristics of your material can influence your design choices significantly.

 

Serial production in 3d printing

2. Optimize for layer adhesion

Layer adhesion is a n important factor in FDM printing. Poor adhesion can lead to weak parts and print failures. To improve adhesion:

  • Increase surface contact: Design flat surfaces that maximize contact between layers.
  • Avoid overhangs: Where possible, minimize overhangs or design them with support structures in mind.
  • Adjust infill: Use higher infill densities in critical areas to enhance structural integrity.

3. Consider print orientation

The orientation of your part on the print bed can greatly impact the final strength and surface finish. Parts printed with layers aligned along the direction of stress are typically stronger. Experiment with different orientations to find the best balance between strength, print time, and surface quality.

4. Use appropriate wall thickness

Thin walls can lead to weak and fragile parts, while overly thick walls can result in unnecessary material use and longer print times. A wall thickness of 1.2mm to 3mm is generally effective for most FDM applications, balancing strength and material efficiency.

5. Incorporate support structures wisely

Support structures are often necessary for complex geometries but can be difficult to remove and may affect surface finish. Design with support removal in mind:

  • Use support-friendly angles: Overhangs of 45 degrees or less typically do not need supports.

6. Optimize overhangs and bridges

Overhangs and bridges can be challenging in FDM printing. To ensure successful printing:

  • Limit overhang angles: Keep overhangs below 45 degrees when possible.
  • Use fillets and chamfers: Instead of sharp overhangs, use chamfers and use fillets for corners in the X and Y plane to reduce stress.
  • Bridge distances: Keep bridges short and ensure your printer settings are optimized for bridging

7. Account for shrinkage and warping

Different materials have different rates of shrinkage and warping. ABS, for example, has a higher shrinkage rate than PLA. To mitigate these effects:

  • Use brims and rafts: These can help parts adhere to the bed and reduce warping.
  • Design compensation: Incorporate allowances in your design for shrinkage, particularly in larger parts.

    8. Integrate snap-fit joints and threads

    FDM printing allows for the integration of functional components like snap-fit joints and threads directly into your design:

    • Snap-fits: Design with precise tolerances to ensure a snug fit without causing stress concentrations.
    • Threads: Use standardized thread designs and consider post-processing like tapping to ensure accuracy.

    9. Leverage infill patterns

    Infill patterns can significantly impact the strength, weight, and print time of your part. Common infill patterns include honeycomb, grid, and gyroid. Each pattern has its own advantages:

    • Honeycomb: Good balance of strength and weight.
    • Grid: Simple and quick, offering decent strength.
    • Gyroid: Excellent strength and stiffness, but may increase print time.

      10. Test and iterate

      Finally, always test your designs and iterate based on real-world feedback. Even the best-designed parts can have unforeseen issues when printed. By continually testing and refining your designs, you can achieve optimal performance and reliability.

      Conclusion

      Designing for FDM 3D printing involves a blend of creativity and technical knowledge. By following these tips, you can create parts that are not only functional and robust but also efficient to produce. Remember, the key to successful additive manufacturing is continuous learning and adaptation.

      Get in touch!   Curious about industrial 3D printing? Reach out to one of our team members to learn more!    
      In-house 3D printing or outsourcing: which option is best for you?

      In-house 3D printing or outsourcing: which option is best for you?

      by | Jul 26, 2024 | Blog

      3D printing is becoming more and more popular, and businesses everywhere are trying to figure out if they should invest in their own 3D printers or outsource their printing needs. This decision can really affect how your company operates, spends money, and innovates. Let’s dive into the pros and cons of in-house 3D printing versus outsourcing, so you can decide what’s best for you.

      1. Cost considerations

      Initial Investment: Purchasing your own 3D printer translates to a higher initial investent. Industrial, large-format 3D printers can cost anywhere from $10,000 to $100,000 or more.

      Operational Costs: After you purchase the printer, printing in-house often is cheaper per part, especially if you print frequently. Outsourcing, however, means you don’t have to spend a lot of money upfront. Service providers charge based on how complex, big, and numerous your prints are. If you only need to print occasionally or in small quantities, outsourcing might save you money.

       

      Serial production in 3d printing

      2. Speed and turnaround time

      In-House Printing: Having a 3D printer on-site means you can print prototypes and parts quickly. This speed is crucial if getting products to market fast is important for your business. Some companies have cut their product development time by up to 50% with quick in-house prototyping.

      Outsourcing: While outsourced services often have advanced equipment and expertise, shipping and handling can slow things down. Depending on the provider and your location, it could take anywhere from a few days to several weeks to get your parts.

      3. Flexibility and control

      In-House Printing: Owning your own 3D printer gives you complete control over the printing process. You are able to experiment with different materials, designs, and techniques whenever you want, withoutbeing tied to an external schedule. This flexibility often leads to more innovation and faster iterations.

      Outsourcing: Outsourcing allows you to scale up or down based on your project needs without worrying about equipment limitations. However, you might have less control over the process and quality, as you’re dependent on the service provider’s standards and practices.

      4. Confidentiality and intellectual property

      In-House Printing: Printing prototypes and parts in-house minimizes the risk of intellectual property theft or confidentiality breaches. Sensitive designs and proprietary information stay within your company’s secure environment.

      Outsourcing: When you outsource, you have to share your designs with third parties, which can pose risks to your intellectual property. Make sure the service provider has strict confidentiality agreements and secure processes.

      Conclusion: making the right choice

      Deciding between in-house 3D printing and outsourcing depends on your specific business needs, budget, and long-term goals. Here are a few questions to help guide your decision:

      1. How often do you need 3D printed parts?
      2. What’s your budget for initial investment and ongoing costs?
      3. How critical is turnaround time for your projects?
      4. How important is confidentiality and control over the printing process?
      If you frequently need 3D printed parts and can afford the investment in equipment and training, in-house printing offers speed, control, and potentially lower long-term costs. On the other hand, if you have occasional needs or a limited budget, outsourcing gives you access to high-quality prints and expert services without a big upfront investment.

      Ultimately, the choice between in-house 3D printing and outsourcing is a strategic decision that can drive innovation and efficiency in your operations. By carefully evaluating your needs and resources, you can make an informed decision that aligns with your business goals.

      Get in touch!   Curious about industrial 3D printing? Reach out to one of our team members to learn more!    
      Your Plastic Solutions – Optimized production with the dddrop RAPID ONE

      Your Plastic Solutions – Optimized production with the dddrop RAPID ONE

      by | May 2, 2024 | User Story

      Who is Your Plastic Solutions?

      Located in the Achterhoek, Your Plastic Solutions is a prominent player in the plastic processing industry, focusing on sustainable solutions for various sectors such as logistics, mobility, packaging and construction. As a total partner, Your Plastic Solutions offers an extensive range of manufacturing technologies, including 3D printing, thermoforming and injection molding, as well as assembly and post-processing, giving customers a one-stop-shop experience.

      3D Printing in the plastics industry

      One of the technologies that has boosted Your Plastic Solutions’ manufacturing efficiency is the dddrop RAPID ONE 3D printer. This advanced printer allows them to produce large parts that are not feasible with smaller 3D printers, allowing them to meet their customers’ specific requirements.

      “We use FDM printing because it is inexpensive and quite fast,” says Sander Feuler of Your Plastic Solutions. “With the dddrop RAPID ONE, we do not suffer from high entry costs as with traditional injection molding processes because we can produce immediately without the need for molds.”

      Local partner with excellent service

      Choosing dddrop as a partner was a logical step for Your Plastic Solutions because of their need for a local partner offering high-quality 3D printing solutions. During the 2.5 years of collaboration, they have experienced the benefits of dddrop’s close cooperation and excellent service. “When we started with the dddrop RAPID ONE, we did not think we would go for a second one after only 1.5 years,” notes Sander. “But that has turned out differently. What our future will hold, we don’t know yet. But if we need a third one, we will gladly come back to dddrop.”

      “When we started with the dddrop RAPID ONE, we did not think we would go for a second one after only 1.5 years. If we need a third 3D printer, we will gladly come back to dddrop.”

      Sander Feuler, Your Plastic Solutions

      With the dddrop RAPID ONE, Your Plastic Solutions has not only increased their production capacity, but also strengthened their competitive position by quickly and cost-effectively delivering high-quality plastic products to their diverse customer base.

      Explore more about Your Plastic Solutions at yourplasticsolutions.com.

      Optimising serial production with 3D printers

      Optimising serial production with 3D printers

      by | Mar 13, 2024 | Blog

      In an era when speed and efficiency are the backbone of industrial activities, series production is central to the quest for competitive advantage. The landscape of manufacturing processes is constantly evolving, and one of the most notable innovations driving this revolution is the rise of 3D printing.

      Change in the way of serial production.

      Traditional methods of serial production were characterised by complex and time-consuming processes, with significant overheads and limitations on design freedom. But 3D printing has broken these conventional boundaries by adding a new dimension of flexibility and speed.

      With 3D printing, manufacturers can realise complex geometries with unprecedented precision and reproducibility. This opens the door to new design possibilities previously unthinkable, allowing products to be optimised for performance and functionality.

      Serial production in 3d printing

      Efficiency as a key point

      Efficiency is the backbone of serial production, and 3D printing offers a range of benefits that enhance this efficiency. By eliminating tooling costs and minimising raw material wastage, 3D printing significantly reduces operational costs. Moreover, it enables on-demand production, which can optimise inventory levels and avoid excess inventory.

      In addition, 3D printing enables manufacturers to take advantage of digital design and manufacturing processes. Through the use of advanced simulation software, designs can be validated before printing, identifying errors at an early stage and avoiding costly revisions. This reduces development time and accelerates time-to-market, giving companies a competitive advantage.

      Quality and consistency

      While speed and efficiency are vital, this should not come at the expense of quality and consistency. 3D printing, however, offers a high level of reproducibility, with each printed part being identical to the original. This reduces variability in the production process and ensures consistent quality of final products.

      Moreover, the digital nature of 3D printing enables real-time monitoring and control, allowing any deviations to be detected and corrected in a timely manner. This increases the reliability of the production process and ensures consistent results across the entire series production.

      Sustainability and environmental friendliness

      In addition to operational benefits, 3D printing also contributes to sustainability and environmental friendliness. By minimising waste of raw materials and using recycled materials, 3D printing reduces the ecological footprint of series production. Moreover, local production centres can be set up, reducing transport costs and emissions.

      Conclusion

      In an era when speed, efficiency and quality are crucial to the success of mass production, 3D printing represents a revolutionary force. By breaking the traditional boundaries of manufacturing processes, 3D printing opens up new opportunities for manufacturers to innovate and excel in a competitive market.

      With its ability to realise complex geometries, reduce costs and promote sustainability, 3D printing promises to have a lasting impact on the industry. As manufacturers strive to optimise series production, 3D printing will undoubtedly be an integral part of their strategies for success in the 21st century.
      Carbon fiber reinforced filaments: the power behind industrial 3D printing revolution

      Carbon fiber reinforced filaments: the power behind industrial 3D printing revolution

      by | Aug 22, 2023 | Blog

      Incorporating carbon fiber (CF) into filaments results in remarkable improvements in strength and stiffness. The increased strength and stiffness resulting from the addition of CF contribute to an improved strength-to-weight ratio. This performance translates into the creation of components that are not only lighter but also more resilient, all while speeding up the printing process.

      Read on below to discover how carbon fiber integration can benefit your manufacturing operation and why the RAPID ONE is a suitable printer for this particular material.

      Understanding carbon fiber filaments

      Carbon fiber-reinforced plastics (CFRP) amalgamate the commendable traits and performance characteristics of carbon fiber with the host polymer substance they fortify. By integrating carbon fiber content, the printability and user-friendliness of conventional thermoplastics like PLA, ABS, or PET acquire heightened performance attributes.

      carbon fiber filmament

      Chopped fibers, predominantly employed in both industrial manufacturing and 3D printing, serve as the crux. These carbon fibers are introduced either as a “filler” within thermoplastic materials for injection molding or as dedicated carbon fiber filaments tailored for 3D printers. Their processing closely resembles that of any other thermoplastic substance, albeit with additional prerequisites that will be elaborated upon subsequently.

      In the realm of FFF (extrusion-based) 3D printing, chopped carbon fibers take center stage. These diminutive fibers are seamlessly blended into a standard thermoplastic matrix to serve as a reinforcing element.

      The significance of carbon fiber 3D printing

      Within industrial settings, specific mechanical attributes and meticulous precision often take precedence. In this context, the convergence of robust material capabilities and the myriad benefits of additive manufacturing propels carbon fiber 3D printing to the forefront. This innovative approach bestows exceptional dimensional stability upon sturdy components, accentuated by a refined surface finish and elevated heat deflection temperature. These qualities render it an optimal choice for functional, high-performance applications.

      As 3D printing continues its trajectory toward broader end-use production, the demand for manufacturing both components and tooling using carbon fiber filaments is on the rise.

      From molds and jigs to fixtures, tooling, high-performance race cars, specialized aerospace equipment, and professional cycling gear, the utilization of carbon fiber 3D printer filament empowers the creation of components with remarkable strength. Naturally, as a relatively novel offering in the manufacturing landscape, carbon fiber 3D printing boasts numerous advantages. However, familiarizing yourself with the specific printing requisites is prudent before embarking on your journey.

      Applications of CF Filaments

      Carbon Fiber 3D printing finds its most promising applications within manufacturing environments, largely attributable to its impressive strength-to-weight ratio and inherent rigidity. Principally, these materials are leveraged for the production of molds, jigs, fixtures, and tooling.

      Composite and thermoforming molds

      In the industrial realm, the synergy between advanced 3D printing and traditional manufacturing techniques is strikingly evident in the domain of 3D printed molds. These molds amalgamate the swiftness and intricacies of 3D printing with the scalability inherent in mold-based manufacturing. Within the realms of composite molds and thermoforming molds, the performance attributes of CF materials manifest naturally.

      Composite molds are pivotal for economically producing large quantities of identical components. Aptly named, they consist of composite materials that can be intricately shaped and endure repetitive utilization, all at a considerably lower cost compared to aluminum or steel molds.

      Thermoforming molds employ heat and pressure to mold a flat thermoplastic sheet into a desired form, using various heating methods. Given the requirement for enduring high-temperature cycles, CF materials present an optimal choice for delivering the specific performance capabilities essential for thermoforming molds.

      Jigs, fixtures and tooling

      Jigs, fixtures, and tooling are often deemed supplementary to manufacturing processes, yet they hold intrinsic significance. These aids facilitate tasks such as milling, drilling, and subtractive operations. Playing a crucial role in holding components securely during various manufacturing stages, they are increasingly being 3D printed on-site. Customizability to specific requirements and the capacity for on-demand reproduction without external reliance or replenishment underscore their prominence.

      When fortified with materials like CF filaments, 3D printed jigs, fixtures, and tooling exhibit prolonged durability and heightened performance. This is particularly advantageous in terms of enduring repetitive use and maintaining overall effectiveness.

      Automotive and aerospace sectors

      The design flexibility afforded by carbon fiber facilitates the realization of intricate geometries that conventional methods might deem cost-prohibitive. This liberty in design expedites iterative processes and, owing to augmented stiffness and thermal stability, enables the creation of more functional prototypes. Enhanced aesthetics, encompassing intricate curvature achieved through 3D printing and improved surface quality via CF filaments, fosters innovation across automotive, aerospace, and related industries.

      Advantages of carbon fiber 3D printing

      Undoubtedly, one of the most widely acclaimed attributes of carbon fiber 3D printer filament is its exceptional strength, which lies at the core of its performance and allure as a 3D printing medium. Carbon fiber presents a remarkable strength-to-weight ratio, fostering high-performance outcomes while maintaining minimal material density.

      Through mitigating the inclination towards part shrinkage, the elevated strength and rigidity of carbon fiber substantiate its exceptional dimensional stability during utilization. This stability stands as a vital attribute for components demanding meticulous dimensions and stringent tolerances.

      In tandem with its robustness, the lightweight nature of a carbon fiber 3D printer filament is of paramount significance. The inherent lightness is a central advantage in the realm of 3D printing as a whole. The incorporation of carbon fiber materials into the equation facilitates this reduction in weight without compromising the strength that meets performance standards.

      When contrasted with conventional 3D printing materials such as PLA, ABS, and PETG, carbon fiber filaments exhibit notable resilience against elevated temperatures. Carbon fiber composite materials elevate the base material’s heat deflection temperature, thereby augmenting its operational efficacy under high-temperature conditions.

      CF filaments effectively minimize the visibility of layer lines, resulting in superior surface quality and tactile feedback. This diminishes the necessity for subsequent post-processing tasks like sanding.

      Carbon fiber parts crafted through 3D printing exhibit exceptional form retention even when subjected to significant stress. Unlike alternative materials that compromise durability and strength in pursuit of stiffness, carbon fiber’s rigidity guarantees unwavering structural integrity.

      RAPID ONE: the ultimate ally for carbon fiber reinforced filaments

      The rapid one 3d printer is excels at printing carbon fiber reinforced filaments. Here are some features of the rapid one that allow it to print these challenging materials with ease:

      Integrated filament dryer

      A crucial feature that sets the RAPID ONE apart is the integrated filament dryer. This keeps the filament in optimal state for printing at all times, without humidity that can affect the performance and finish of the final product. This contributes to consistent and high-quality results.

      Closed print booth

      The RAPID ONE features a closed print booth, resulting in a controlled and elevated temperature during the printing process. This minimizes problems such as warping and delamination, which is crucial when printing complex parts with carbon fiber reinforced filaments.

      Tungsten nozzle

      The ability to install a tungsten nozzle eliminates nozzle wear concerns with abrasive fiber-reinforced materials. The RAPID ONE is prepared for the challenges of these materials and ensures long-term durability and reliability.

      Unleash the future of 3D printing

      Carbon fiber-reinforced filaments represent a revolution within the 3D printing industry, and the RAPID ONE is the appropriate printer to go along with this revolution. With advanced features such as integrated filament dryer, the ability to install a tungsten nozzle and an enclosed print booth, the RAPID ONE enables users to achieve superior results with ease with these challenging materials.

      Whether you are a professional looking to produce high-quality parts or a hobbyist looking to push your creative boundaries, the combination of carbon fiber reinforced filaments and the RAPID ONE 3D printer opens the door to unprecedented possibilities. Discover the power of this technology and take your 3D printing projects to a whole new level.

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