How to choose the right 3D printing material?

How to choose the right 3D printing material?

by | Oct 4, 2024 | Blog

If you decide to 3D print a design, one of the first questions you need to ask yourself is; which filament am I going to use? There is a wide range of filaments available and as a beginner, it can be overwhelming. This blog will help you choose the right filament for your application, so you can be sure you’re getting started with the right filaments.

Who will use the 3D printer?

One of the first considerations when choosing filament is the user of the 3D printer. This is because not every filament is easy to print. For beginners, we recommend PLA or ABS. PLA is the ultimate entry-level material. A print with PLA can hardly fail. If you use the default settings of our dddrop RAPID ONE, it delivers perfect results. ABS is also suitable for beginners, but it is advisable to gain some experience with PLA first before switching to ABS.
Serial production in 3d printing
Filaments such as PETG and FLEX, on the other hand, are more suitable for experienced users. These materials require precise adjustments, where small adjustments can already have a big impact on the print. We therefore recommend gaining a sufficient understanding of the printing process before working with these more complex filaments.

How warm is the environment in which the design is used?

When printing objects exposed to high temperatures, you need to choose the right material that can withstand heat. Each filament has a specific glass temperature – the point at which the material starts to soften. This is crucial when choosing the right filament.

For applications where your object will encounter heat, such as near a heat source or in direct sunlight, ABS is a good choice. It has a high glass temperature of 110°C, which makes it resistant to boiling water and other heat sources. PETG is slightly lower with a glass point of 90°C and is less able to withstand extreme temperatures. PLA and FLEX are the least heat-resistant, with a glass temperature around 60°C.

What are you going to print?

Ultimately, everything revolves around the application of your printed object. What you will print determines which filament is best to choose. Each material has its own strengths and weaknesses, suitable for different purposes. Below, we briefly discuss three popular filaments.

PLA (Polylactic Acid)

PLA is strong and rigid, allowing it to withstand large forces without stretching. The downside is that PLA can break on impact, just like glass. It is therefore mainly suitable for visual models, but not for mechanical parts. PLA is easy to print, energy-efficient thanks to its low print bed temperature of 60°C, and a perfect choice for visual models.
pla filament 1.75mm 5kg

ABS (Acrylonitrile-Butadiene-Styrene)

ABS is more flexible than PLA and is less likely to break when dropped. It is therefore ideal for functional parts and industrial applications. For example, ABS is widely used in the automotive industry for parts such as dashboards and bumpers. One drawback is that ABS emits an unpleasant odour during printing. For use in office environments or at home, we recommend using a well-ventilated room, or choosing odourless filaments such as PLA or PETG.

abs filament kopen

PETG (Polyethylene Terephthalate Glycol)

PETG is both strong and flexible and can be stretched up to twice its own length without breaking. This unique combination makes it suitable for parts that move repeatedly or are under pressure. PETG is also approved for applications in the food industry, making it perfect for packaging, for example. Moreover, PETG can withstand high pressure without deforming, making it an ideal choice for various functional applications.

Conclusion

Which filament you choose will depend on your experience, the environment in which the object will be used and your print requirements. As a beginner, it is best to start with PLA because of its easy print settings and versatility for sight models. For functional parts or applications where heat resistance is important, ABS is a good choice. PETG offers flexibility and strength, ideal for moving parts or food applications. Want to work with flexible materials? Then choose FLEX, but make sure you have gained enough experience, as printing them requires more precision. This way, you will always have the right filament for your project!
10 tips on designing for additive manufacturing (FDM 3D printing)

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

by | Jul 29, 2024 | Blog

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. Conside 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 appropiate 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!    
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.

5 advantages of large print volumes within industrial 3D printing

5 advantages of large print volumes within industrial 3D printing

by | Aug 11, 2023 | Blog

In the exciting world of industrial 3D printing, the technology has made significant advances and the possibilities have grown exponentially in roughly 10 years. One of the key developments that is attracting attention is the emergence of large print volumes in industrial 3D printers. This innovation has the potential to dramatically change the way we produce and manufacture. In this article, we take a closer look at 5 benefits of large print volumes in industrial 3D printing.

1. Increase in scale and efficiency

One of the most obvious advantages of large print volumes is the ability to print larger objects at one time. This offers significant advantages for industrial manufacturing, where efficiently producing large numbers of parts is crucial. With a larger print volume, manufacturers can produce larger components or multiple smaller parts simultaneously, shortening the production cycle and increasing overall efficiency.

2. Complex designs and prototyping

Large print volumes in industrial 3D printers open the door to creating complex and detailed designs that were previously impossible to achieve. This is especially valuable for prototyping, where engineers and designers can experiment with innovative designs without worrying about print volume limitations. This results in faster iterations and shorter time-to-market for new products.

3. Less assembly and material waste

Large print volumes allow manufacturers to print larger parts that might otherwise consist of multiple smaller parts. This leads to a reduction in assembly time because fewer parts need to be assembled manually. It also minimizes the need for intermediate joints or fasteners, resulting in a stronger end product. This ultimately provides a reduction in material and lowers labor costs.

4. Cost savings at scale

Although the initial investment in an industrial 3D printer with a large print volume can be significant, it can lead to significant cost savings in the long run. The ability to print larger parts or multiple parts simultaneously reduces the need for expensive mold manufacturing or CNC machining. This allows companies to streamline their manufacturing processes and save costs on both labor and materials.

5. Diversification of applications

Another advantage of large print volumes is the ability to address a wider range of applications. From large-scale prototyping and industrial components to custom production and even art and architecture. The possibilities are endless. This diversification allows companies to tap new markets and adapt to changing customer needs.

dddrop Rapid One’s scalable frame

The emergence of large print volumes in industrial 3D printing opens new doors for efficiency, complex designs, cost savings and diversification of applications. This technological development has the potential to transform the manufacturing industry and drive innovation on multiple levels.

The dddrop Rapid One is the first industrial 3D printer with a scalable print volume. Are you looking for a printer for large prints, a large batch of parts or complex prints? Request a free quote or contact us for more information!

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