Manufacturing with a 3d Printer
FDM Manufacturing
How It Works:
Process: FDM works by extruding melted thermoplastic filament through a heated nozzle, which deposits the material layer by layer to build up the final object. The filament is fed from a spool through the nozzle and is heated to its melting point before being extruded.
Materials: FDM uses a wide range of thermoplastic filaments, including PLA, ABS, PETG, TPU, and more.
Pros:
Material Variety:
FDM supports a wide variety of materials with different properties, including flexible, heat-resistant, and chemically resistant filaments.
Cost-Effective:
FDM printers and materials are generally more affordable compared to SLA, making it accessible for hobbyists and small businesses.
Ease of Use:
FDM is relatively easy to use and maintain, with straightforward post-processing that often involves simple support removal and minimal sanding.
Strength and Durability:
FDM prints can be very strong and durable, suitable for functional parts and mechanical applications.
Cons:
Lower Resolution:
FDM generally produces lower resolution prints with visible layer lines, which may require post-processing to achieve a smoother finish.
Print Quality:
FDM prints can suffer from issues like warping, stringing, and layer adhesion problems, particularly with certain materials.
Complex Geometries:
While FDM can handle complex designs, intricate details and fine features may not be as sharp or accurate as those produced by SLA.
Weak along the Z-axis:
Due to the way 3d printers work, each layer is just stacked on top of each other, meaning that there will always be one weaker axis on the part.
SLA Manufacturing
How It Works:
Process: SLA uses UV light to cure liquid resin into hardened plastic in a layer-by-layer process. The laser traces each layer’s cross-section on the surface of the liquid resin, solidifying it, and the build platform then moves down to allow the next layer to be traced.
Materials: SLA primarily uses photopolymer resins.
Pros:
High Precision and Detail:
SLA is known for producing very high-resolution prints with fine details and smooth surface finishes, making it ideal for detailed prototypes, jewelry, and dental models.
Surface Finish:
SLA prints have a smooth surface finish right out of the printer, reducing the need for post-processing.
Complex Geometries:
Can produce complex shapes and internal structures that are difficult or impossible with subtractive methods.
Material Efficiency:
Minimal waste since material is only used where needed.
Rapid Prototyping:
Quick turnaround from design to part, ideal for prototypes and custom parts.
Customization:
Easily allows for custom and on-demand manufacturing without the need for new tooling.
Tooling Reduction:
No need for custom molds or jigs, reducing upfront costs.
Cons:
Post-Processing:
SLA parts require significant post-processing, including washing in isopropyl alcohol and curing under UV light to fully harden the resin.
Material Costs:
Photopolymer resins used in SLA can be more expensive than FDM filaments.
Limited Material Properties:
SLA resins can be brittle compared to FDM materials, making them less suitable for functional parts that require flexibility or impact resistance.