The top processes in Additive Manufacturing (AM) can be generally categorized as filament-based, resin-based, or powder-based. While there are some variations in these processes, the vast majority of materials fall within these three categories. Additive Manufacturing has a wide range of materials that fit many different applications and industries. From aerospace, engineering, automotive, medical, and so many more, looking at different properties can help you decide what material is best for you and your specific needs
1. Fused Filament Fabrication (FFF)
Filament-based materials are typically housed in a spool format. Filaments are commonly found in two diameters: 1.75mm and 3mm with the former being the most common. By far the largest variety of materials for AM are available as filament. The most common include:
- By far the most common material for filament-based printing. It is also available in a wide range of composite variations including carbon fiber and glass filled.
- This is a type of polyester made from fermented plant starch. As it is plant-based it is considered one of the most environmentally friendly plastics available.
- Very easy to print on most 3D printers. It prints at a relatively low temperature and is less prone to warping than other materials.
- Printed parts are dimensionally stable and more rigid than other polymers like ABS. Some PLA variations can also be annealed for greater strength.
- Offers a low-cost option for prototyping.
- Offers properties similar to ABS in terms of durability.
- It is not as easy to print with PLA as parts can shrink and curl off the print bed. Requires higher temperatures than PLA.
- Also available as a composite with other materials such as carbon fiber and glass-filled.
- PETG is fully recyclable and considered environmentally friendly.
- Great for prototyping parts that require chemical resistance and durability.
- Strong and durable with high-impact resistance.
- Popular for prototyping injection molded parts that will ultimately use ABS in production.
- It can be tricky to print with these materials on printers that do not have a heated chamber.
- Not as environmentally friendly as other materials, but can be recycled.
Filament-based materials are also available in some interesting variations including:
- ASA – (Acrylonitrile styrene acrylate)
- Igus Iglide
- a slippery material used for bearings
- BASF Ultrafuse 316L
- stainless steel powder in a binder that can be used to print metal parts
- PEI (Polyetherimides)ULTEM
- PAEK (Polyaryletherketone) family of polymers
- PEEK and PEKK (and other variations)
PEI and PAEK materials have exceptional thermal and mechanical properties making them ideal for aerospace and medical applications. They require very high temperatures in an enclosed environment in order to print well. They are also available as composites with carbon fiber and glass fiber.
2. Powder-Based Materials
These materials are available in fine powder. The powder is used in processes such as SLS (Selective Laser Sintering), MJF (Multi Jet Fusion), DMLS (Direct Metal Laser Sintering), and Binder Jetting.
The most common powder-based materials include:
- Nylon materials offer a wide range of characteristics, however, in 3D printing, the most commonly produce rigid parts in the form of PA12 and PA11.
- Excellent durability and chemical resistant.
- Perfect for prototyping parts that may ultimately be molded from the same material.
- With finishing, this material can produce injection-molded like quality for end-use parts.
- Lightweight, ductile, and chemically resistant.
- The only powder-based material that is watertight.
- It can be spin-welded.
- Uses DMLS to melt the powder into shape.
- A wide range of metal powders are available including Aluminum, Copper, Stainless Steel, and Titanium.
3. Vat Photopolymerisation Materials
These materials use a photoreactive resin that solidifies when exposed to a particular wavelength of light. The most common processes include SLA (Stereo Lithographic Apparatus), MSLA (Masked SLA), and DLP (Digital Light Processing). One of the challenging aspects of these resin-based processes is the classification of materials. Unlike filament and powder, resins derive their properties from chemical reactions that do not rely on heat. As a result, resin materials are generally classified based on the physical characteristics of their final (cured) state.
Elastomeric
- Parts with varying degrees of elasticity range in durometers as low as 40A.
- Behaviors similar to silicone.
- Some manufacturers offer pure silicone resins.
- Parts that are optically clear can be used in applications that require transparency including lenses
- Exhibits similar qualities to polypropylene.
- Dimensionally stable and rigid parts.
- In some cases glass filled.
- Often used for prototype mold tooling.
- Often equated with ABS.
- It can be used for end-use parts
For those who have worked with 3D printers in the early days of 3D printing over 30 years ago, their first exposure to 3D printed parts was likely a photopolymer part. In those days, the parts were extremely brittle and could barely be used for more than a visual representation of a part. Over the last few years, that has changed dramatically. Resin-based parts can hold their own when compared to other AM processes.
The amount of materials available for Additive Manufacturing is enormous and covers a wide gamut of performance, aesthetics, and practicality. That said, there is a narrow band of materials that are most popular. Manufacturers of these materials encourage AM users to explore beyond this narrow selection in an effort to promote end-use adoption of AM as a viable production solution. There are many cases where 3D-printed parts have matched (or even exceeded) the performance of parts produced using injection molding or machining. By selecting a material that can be used for both prototyping and end-use, the development and production processes can be seamless.
Do you feel like you’re constantly racing, trying to stay one step ahead of your competitors and barely keeping up with your product development timelines? The world of manufacturing never slows down, and it can sometimes feel like you’re caught in an endless, frenetic rat race. Staying ahead of the competition requires continuous innovation and the ability to bring new products to market quickly. Additive manufacturing (AM) is transforming the industry by offering unparalleled innovation through design flexibility and enabling rapid prototyping and low-volume production.
Design Freedom with Additive Manufacturing
One of the most significant advantages of additive manufacturing is the design freedom that you cannot get with traditional manufacturing methods. Traditional manufacturing methods often impose limitations due to the constraints of molds, tooling, and subtractive processes. Additive Manufacturing builds objects layer by layer, allowing for the creation of complex geometries and intricate designs that were previously impossible or too costly to produce.
Take the aerospace industry, where weight reduction is crucial for improving fuel efficiency and performance. Additive manufacturing enables the production of lightweight, high-strength components with complex internal structures, such as lattice designs, that reduce weight without compromising strength. This level of design freedom allows engineers to optimize parts for performance, leading to more efficient and innovative aerospace components. Similarly, in the automotive industry, companies like Ford are using 3D printing to produce parts with optimized shapes and reduced weight, improving fuel efficiency and vehicle dynamics. This ability to design and produce complex parts quickly accelerates the innovation cycle and brings cutting-edge automotive technologies to market faster.
Rapid Prototyping with Additive Manufacturing
Rapid prototyping is another one of the key benefits of additive manufacturing, enabling companies to quickly iterate on designs and test new ideas. Traditional prototyping methods can be time-consuming and expensive, often requiring specialized tooling and multiple production steps. AM simplifies this process by allowing designers to create prototypes directly from digital models.
In the consumer electronics industry, rapid prototyping with AM has become a game-changer. Companies can now develop and test new product designs in a fraction of the time it would take using traditional methods.
For instance, tech companies use 3D printing to create prototypes of new devices, from smartphones to wearable technology. This speed and flexibility enable them to refine their designs rapidly, bringing innovative products to market ahead of the competition. The healthcare field also benefits significantly from rapid prototyping. Medical device manufacturers use Additive Manufacturing to create prototypes of surgical instruments, implants, and other medical devices. This allows for quick validation of design concepts and functional testing, ensuring that the final product meets stringent regulatory requirements and performs as intended. By accelerating the development process, additive manufacturing helps bring life-saving medical innovations to patients more quickly.
Case Studies: Real-World Applications of Additive Manufacturing
To show the impact of additive manufacturing on product innovation, let’s explore some real-world use cases for different industries.
GE Aviation is a pioneer in using additive manufacturing for aerospace components. The company uses AM to produce fuel nozzles for its LEAP jet engines. These nozzles, made from a nickel-based superalloy, feature intricate internal geometries that improve fuel efficiency and reduce emissions. Traditional manufacturing methods would require multiple parts to be welded together, but with Additive Manufacturing, the nozzle is produced as a single piece, reducing weight and increasing durability. This innovation not only enhances engine performance but also simplifies the manufacturing process and reduces costs.
Bugatti, the luxury car manufacturer, has leveraged additive manufacturing to produce a high-performance brake caliper. This titanium brake caliper is the largest functional component made using 3D printing in the automotive industry. The complex geometry of the caliper, which optimizes strength and reduces weight, would be challenging to achieve with traditional manufacturing methods. By using AM, Bugatti was able to create a part that meets their exacting standards for performance and quality, showcasing the potential of 3D printing in producing critical automotive components.
Johnson & Johnson has embraced additive manufacturing to revolutionize the production of custom medical implants. Using patient-specific data from medical imaging, the company creates personalized implants tailored to the unique anatomy of each patient. This approach not only improves the fit and performance of the implants but also reduces surgery times and enhances patient outcomes. Additive manufacturing enables Johnson & Johnson to offer highly customized solutions that were previously unattainable with conventional manufacturing techniques.
Customization with Additive Manufacturing
Consumer demand for customized products is on the rise, and additive manufacturing allows this demand to be met. The ability to produce tailor-made items efficiently opens up new business opportunities and enhances customer satisfaction. In the fashion industry, Additive Manufacturing is being used to create custom-fit footwear and accessories. Companies like Adidas have introduced 3D-printed shoes that offer a perfect fit for each customer. Adidas can produce shoes that match the specific pattern of movement for athletes, providing superior comfort and performance. This level of customization attracts customers seeking unique products and sets a new standard for innovation in the fashion industry.
The dental industry is another area where customization through additive manufacturing is making a significant impact. Dentists and orthodontists use Additive Manufacturing to produce custom dental implants, crowns, and aligners. These products are created based on precise digital scans of the patient’s mouth, improving treatment outcomes. The ability to produce custom dental solutions quickly and accurately enhances patient satisfaction and streamlines the workflow for dental professionals.
Overcoming Challenges of Implementing Additive Manufacturing
While the benefits of additive manufacturing for product innovation are clear, successful implementation requires overcoming several challenges. These include material limitations, print speed, post-processing requirements, and ensuring consistent quality. Material limitations are being addressed through ongoing research and development, with new materials being introduced that offer improved properties and performance. Advances in print speed and scalability are also being made, with newer machines capable of producing larger volumes more quickly. Post-processing, such as removing supports and finishing surfaces, remains an important consideration, but automated solutions are being developed to streamline these steps. Quality control is crucial to ensure that 3d printed-produced parts meet industry standards and perform reliably. Implementing robust quality assurance processes, including non-destructive testing and in-situ monitoring, helps maintain consistency and reliability in AM production.
The Impact of Additive Manufacturing
Additive manufacturing is reshaping the landscape of product development. By offering design freedom, enabling rapid prototyping and production, and allowing for customization, AM empowers businesses to innovate faster and more efficiently. As companies continue to explore and adopt additive manufacturing, it is essential to address the associated challenges and invest in the necessary technology, skills, and processes. By doing so, businesses can unlock the full potential of AM and drive the next wave of innovation in manufacturing.
Embracing additive manufacturing today means positioning your company at the forefront of technological advancement, ready to lead in a rapidly evolving industry. The future of manufacturing is here, and it is Additive.
