3D Printing Process

3D Printing Process

This chapter is intended for those who are new to  production through 3D printing and are interested in learning about the 3D printing process from the design stage to the final product.

Preface

Many 3D printing technologies exist, but there are steps in the process that are common to all of them.

This chapter will focus on the general process, from the design stage to the final product. Even if it is a fast prototype or a final functional component that is ready to use, the overall process is similar.

Step 1: Computerized 3D modeling - CAD

Creating a computer model is the first step in the 3D printing process. The most common way to produce a computerized model is computer-aided design (CAD – Computer-Aided Design). There is a wide variety of CAD software that allows you to produce 3D files suitable for 3D printing. Some can even be downloaded for free from the Internet.

You can learn more in the chapter on CAD Software

Image - Impact Labs Design with CAD

Another way to produce a computerized 3D model is with the help of a 3D scan. This process allows an existing product to be used and edited in computer software without the need for modeling. For example, you can scan organic elements (like stone) and use them as a design raw material for a product. You can also scan engineering products (for example, airplanes) and add custom components using software. Read more about 3D scan

When designing a 3D printing model there are conditions that need to be considered. 3D printing is an AM technology based on adding layer-by-layer material. Therefore, its conditioning is different from traditional material-based design methods, such as CNC. Conditions vary depending on the printing technology. For example: geometric constraints, the need to create supports and / or create a drain hole to empty a trapped material. You can learn more in Chapter 7 about 3D CAD Design Conditions .

Step 2: Convert CAD files and file processing

Unlike other production methods, 3D printing requires the conversion of CAD files into a file that the printer software can lay out in layers and convert into a sequence of instructions for the machine called G-code. Computerized, which drives machining tools, such as milling machines, lathes and 3D printers.In addition, the layout software allows the designer to determine the parameters of the print, including: supports, layer thickness, and object orientation in the printer (position, rotation and scale).

There are several types of files that can be imported into 3D printing software. File types vary by software itself and by printing technology. The main file types used for 3D printing software are STL and VRML (WRL) files. These file types make up the object of triangles (polygons). Standard Triangle Language (STL) files do not contain color information and therefore cannot be used to print multiple-color models. But only one color. In contrast, Virtual Reality Modeling Language (VRML) files contain information about the color of the model and can be used to print models that contain a variety of colors.

Explain file types and conversion STL CAD file .

Before converting or creating a printable model there are a number of features to consider. Go to article on rules and general considerations To be considered before printing .

Step3: Printing

There are different types of technologies that allow for 3D printing in a variety of materials and resolutions for different needs. Each printer requires a routine maintenance process and advance preparation before printing, but the process varies depending on the type of printer and the technology it uses.

Step 4 : Finishing printing and processing the products

At the end of the printing, remove the product from the printer – some technologies are a simple operation, and some are a process that requires some investment. For example: disconnecting the product from a heated tray, or pumping powder in which the product is immersed.

In some cases, after removing the product from the printer, it is required to go through a cleaning process in which remnants of supporting material, if any, are removed. The method of cleaning depends on the printing technology and the amount of support material and can be performed by air pressure, rinsing, massing, and physical breaking of the support material.

There are printers whose immediate product has final strength, and there are those that require an essential processing process in addition to printing in order to bring the products to their final degrees of difficulty or strength.

After bringing the product to the required degree of difficulty, move on to the finishing stage. Different technologies provide products with different degrees of finish. Therefore, for certain needs the parts will have to go through an additional machining process in order to give them the desired finish, for example sanding or painting.

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