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3D printing is also called "additive production", since it works in the opposite direction to traditional mechanical processes, which make the piece by removing material from the raw material. With this technology, the part is made by superimposition of layers. Each layer corresponds to the cross section of the object. In this way it is possible to create very complex geometries.
It starts from a 3D project created using CAD design software, which is then saved in STL (point cloud) format. This file is passed to the "slicing" software, which dissects the component into layers. At this point, the 3D printer is able to reproduce the various sections of the object.
The advantages of industrial additive printing over traditional processing methods are different:
3D printing owes its enormous diffusion in industrial processes thanks to the ability to reproduce objects with extremely complex shapes. This aspect represents a very important advantage: it is possible to make parts with internal ducts, holes of complex shapes and undercuts that cannot be made with other methods.
Compared to more traditional techniques, the 3D printer does not require additional tools or external equipment (moulds, fasteners, etc.). The only parameters to be considered are, for example, the maximum dimensions of the piece, the material or the timing of construction.
In addition, the modification of the piece can be carried out in a short time by modifying the 3D model and launching the print again to create a second prototype. Today, based on the different 3D printing technologies, it is possible to work with the most varied materials: polymers, plastics, metals, but also concrete or organic fabrics.
3D printing ensures rapid workpiece creation, with the possibility of making changes while reducing time and costs.
It is important to consider the nature and complexity of the projects to be replicated in series.
Compared to injection moulding, for example, 3D printing is cost-effective for complex projects. On the contrary, if it is a question of geometrically simple parts, a traditional mechanical machining could be more suitable.
In addition, the 3D printing process is sufficiently automated not to require long labour and maintenance times.
From prototypes to finished products with particularly complex shapes and geometries. Low production times, reduced production costs and reproducibility are the characteristics that guarantee that 3D printing becomes an excellent tool for both on-demand and mass-produced products. It also allows you to work with a wide variety of materials and leaves plenty of room for creativity.
The limits consist in the characteristics of the project:
Each printer has its own workspace and production capacity. In this case for particularly large objects it will be necessary to evaluate suitable machines.
In ErreBiLab, the maximum possible dimensions are equal to a 500x500x500 mm working cube.
As already mentioned, the 3D printer is economically advantageous only in the case of complex projects. If, on the other hand, prototypes or models are geometrically simpler, traditional techniques may be more convenient.
Depending on the quantity of parts to be produced, 3D printing may not be convenient for large numbers (medium and large series).
With regard to plastic materials, there are different 3D printing methods:
POWDER BED FUSION: this is the most popular technique in the field of metal 3D printing. These machines distribute a thin layer of metal powder on a work plate and then melt the areas corresponding to the cross section of the part. There are two main technologies in this field:
DIRECT ENERGY DEPOSITION: in this case, instead of using a powder bed, the material is supplied directly by the print head, which simultaneously melts it on the part to be built. This technology, unlike the POWDER BED FUSION, can be used to repair damaged parts. In this area there are two types: POWDER DED and WIRE DED. In the first case the print head distributes and melts dust particles, in the second the metal is in the form of wire.
BINDER JETTING: This innovative and new technology could replace SLS for large-scale applications and high productivity, thanks to its speed and scalability. In these machines, first a layer of powder is deposited on the work plate, then a print head (similar to those of inkjet printers), distributes a structural binder polymer at the cross section of the piece. However, these machines require a second sintering process in suitable furnaces, in which the binder polymer is eliminated and the part actually becomes metallic. The advantages consist in a high speed and modularity of printing, in the fact that many pieces can be sintered in huge furnaces; unfortunately at the moment these machines have very high costs.
BOUND POWDER EXTRUSION (atomic diffusion additive manufacturing): this latest technology does not use metal powder, but uses powder already mixed with binder polymers. This eliminates the risks associated with handling potentially hazardous powders. A filament of metal powder and polymer is extruded, creating a "green" part. At this point two post-production steps are necessary: first the polymer is "washed" away and then the part is sintered in a furnace. The costs of these machines are lower, but the process requires more steps in post-production.
ErreBi Lab is the online prototyping service for those who need to develop a model (simple or complex) quickly and at competitive costs.
We have designers who can design your model and/or direct you in the production phase: from design, to the choice of materials, up to the realization.
A few simple steps to achieve your project:
For large quantities and additional processing we advise you to request a personalised quote. If you need assistance we are at your disposal: fill out the form or contact us at the reference number. We will handle your request quickly.
