What is Matel 3D Printing? How it works?

What is 3D Printing? How it works?

3D Printing Overview:

3D printing is an innovative method of production: a three-dimensional object is visualized in detail using computer software, the data is sent to a 3D printer, and the printer creates it. Almost all consumer printers can only print in plastic, but that won’t be true much longer.

In real terms, however, the beginning of 3D printing can be move to 1986, when the first patent was provided for stereo lithography apparatus (SLA). This patent belonged to one Charles (Chuck) Hull, who first design his SLA machine in 1983.

What is 3D Metal Printing?

3D printing is a technology which has captured the headlines, with stories about the increasingly sophisticated projects that can be built. However, further developments have seen 3D metal printing go from strength to strength and it now has the ability to be used practically for a great range of projects and functions.

 Metal 3D printing has become increasingly popular. One reason metal 3D printing has become such a hot topic is that parts are often serially 3D printed for production. In fact, some parts made with metal 3D printing are already just as good, if not better, than those manufactured by traditional methods.

In traditional manufacturing, making metal and plastic objects is a wasteful process. Plenty of chunky parts are produced and surplus material used. While making aircraft manufacture metal parts, up to 90% of the material is cut away. 3D printing metal parts uses less energy and reduces waste of material to a minimum. And finished 3D printed products can be up to 60% lighter than their machined counterparts. The aviation industry alone saves billions of dollars through this weight reduction, mainly due to fuel.

How does a 3D metal printer work?

Metal 3D printing is a type of additive manufacturing technology, not subtractive which means that material is gradually added to get the finished result rather than being taken away (such as in turning or milling).

The 3D metal printing process

A 3D metal printer needs a CAD design to start the process, creating a detailed image from all angles of the desired design. Once the CAD software has been used to complete the design, it then needs to be converted into a .STL format to enable the 3D metal printer to interpret the instructions.

The metal printing process is a multi-layered approach, just like other forms of 3D printing and requires the design to be sliced very finely on the horizontal plane before it can start to be built. The 3D metal printer receives its instructions from the computer which instructs the Laser what shape to trace out across the powder. The Laser then pulses and heats up the powder which creates a solid form. This is how 3D printing in metal begins.

Once this initial base has been laid out the 3D metal printing process begins again, each layer typically no more than 0.1mm thick. This very gradual process is how metal 3D printers create the final product, with the heat from the Laser forming a solid shape. This process is known either as Direct Metal Laser Sintering or Selective Laser Melting, depending on the heat used and whether the powder is melted completely or just heated enough to fuse together.

What can be made?

The possibilities which open up with 3D printer metal techniques are almost limitless and designs which were either impossible or extremely expensive to make are now far more viable.

With 3D printing, metal can be shaped far more easily, and incredibly complex and intricate designs are far more achievable. This could be as complex as tubes within tubes, hollow middles with undercuts and overhangs, or just superfine layers previously too delicate to cut. The 3D print will take on the shape which the Laser is instructed to form, which means the only real limitation is what you can design.

What are the benefits of 3D printing?

With 3D printers’ metals and other materials have far more flexibility and the ability to create cheaper and more complex moulds becomes possible.

There are benefits of using a 3D printer or rapid prototype machine:

1. Greater range of shapes and designs possible. The complexities which are possible with 3D printing couldn’t be achieved via other methods.
2. More cost-effective. For low volumes of manufacturing, 3D printing provides an economical option which can be individually tailored to meet requirements.
3. Strong and robust finish. As the design is created as a continuous piece rather than having multiple welds and joins, there are no weak spots making it stronger overall.
4. The ability to work with such eye-wateringly small slices at a time means designs can be created which are super-thin, or hollow even, reducing the weight of a product. This is particularly beneficial in industries such as aerospace, which crave for lightweight products to improve aero-dynamics and reduce fuel consumption
5. No waste. Almost all the powder left unused in the process of 3D printing can be saved and used again (apart from a little dust residue). Unlike traditional machining methods, there’s zero waste which means it’s an eco-friendly choice With traditional subtractive methods, an object is manufactured into shape from a solid block, with the waste materials cut and drilled out, which are often wasted
6. Although a mould may still take a couple of days to print – for more complex designs at least – this is an extremely rapid process by comparison to other methods.
7. Easy to tweak. If you need to change the design, the process is simple and only requires a few buttons to be pressed rather than an expensive and lengthy re-design.
8. No need to stock expensive designs. With 3D printing, providing you have the materials to run the machine, there’s no reason for any item to be out of stock. All you need is the .STL file and you can print a product whenever you need one.