3D printing and Additive Manufacturing are general terms that contain several processes. For years, unregulated terms and acronyms proliferation make the overall landscape quite confusing. Nowadays, ISO and ASTM have introduced a standard vocabulary to describe each available technology, though the situation is still pretty fluid given the high innovation pace experienced by the industry. To have a clearer view of the ongoing standardization process, look at our Tools and Resources section —you'll find the link at the bottom of this page.
If you ask yourself, "which is the right technology for my application?" take a moment to read this short summary. Be aware, though, that you'll not find a single answer. In fact, every 3D printing process has its benefits and limitations, and each is more suitable for specific applications than others.
On this website, you'll find several easy-to-use tools to aid you in selecting the proper 3D Printing process for your needs. Use the following lines as a quick reference to identify the best method for your design requirements, but we strongly suggest you look deeper at the solution we offer. Cost, performance, lead time, production volume... whichever is your driver, you'll have to consider a combination of variables that will make your choice exponentially complex. UltiMath AM gives you all you need to perform an in-depth assessment; if you are unsatisfied, we guarantee you a full refund.
First, we suggest you approach the choice from the right angle, according to your needs. There are several methods, but to keep things easy, start by replying to those three simple questions:
- Is the required material already known?
- Are the characteristics of the end part (e.g., has functional or aesthetic purposes) already defined?
- Are specific process capabilities (e.g., accuracy, build size) required?
Approaching the choice from a Material standpoint
3D printing materials usually come in filament, powder, or resin form (depending on the 3D printing processes used). Polymers (a.k.a. plastics, divided into thermosets and thermoplastic) and metals are the leading 3D printing material groups, while other materials (such as ceramics, composites, concrete, and sand) are also available.
If the required material is already known, selecting a 3D printing process is relatively easy, as only a few technologies produce parts from the same materials. The selection process usually becomes a cost versus properties comparison in those cases.
Approaching the choice from a Use-Case standpoint
It is vital to determine the primary design consideration early in the selection process. As a rule of thumb, you'll need to define if your component is a functional one (e.g., it will undergo mechanical stresses) or merely aesthetical. This will help immensely in choosing the most suitable approach.
As a rule of thumb, thermoplastic polymer parts are better suited for functional applications, while thermosets are best suited for visual appearance. Also, remember that due to the additive nature of the technology, 3D printed parts will often have anisotropic mechanical properties, meaning that they will be weaker in the z-direction. For functional pieces, this characteristic should be taken into account during design.
Additionally, tolerance level becomes focal when designing a part or prototype that couples with other components. Selecting a process with higher dimensional accuracy will increase the cost. Alternatively, finishing features with critical dimensions or small details after 3D printing (for instance, by drilling holes or tapping threads) is also an option. Again, everything will boil down to a balanced trade-off between costs and requirements.
Part strength and flexibility depend on different mechanical and physical properties. When high strength and stiffness are required, metal 3D printing or materials reinforced with continuous carbon fibers or glass fibers are viable alternatives. Since the spectrum of available materials is constantly widening, you should also keep an eye on materials with unique properties. Heat resistance, flame resistance, and chemical resistance materials are becoming widespread, and so are biocompatible or food-safe certified materials.
Flexibility can be defined as either high elongation at break (thermoplastics such as TPU are available in SLS and FDM) or low hardness (materials with a rubber-like feel are available for SLA/DLP and Material Jetting).
Approaching the choice from a Process standpoint
Finally, if your design is already finalized, then each 3D printing technology's capabilities will often constrain your options.
It is essential to have an overview of the fundamental mechanics of each process to fully understand their key benefits and limitations.
Now... there are hundreds of variables to be considered in this regard, and this is just an overview article —so forgive us in advance for oversimplifying a bit. That being said, three major aspects should at least be considered: dimensional accuracy, equipment build size, and post-processing requirements.
Dimensional accuracy refers to the level of detail each Additive Manufacturing process can achieve and its overall built quality. Processes with higher accuracy can usually create parts with more defined features, and industrial-grade machines have higher accuracy and repeatability than desktop printers.
The build size determines the maximum dimensions of a part that a printer can produce. Each process has its constraints, and so does each piece of equipment within a given technology family. Those kinds of coherence controls should always be run upfront.
Last but not least, the need for post-processing is a key element too. For instance, support structures determine the level of design freedom. Processes that require no support, like SLS, or dissolvable support, like Material Jetting or Material Extrusion (if at least 2 extruders are available), have fewer limitations and can produce free-form structures with greater ease.
Those aspects, and much, much more, are all taken into account by UltiMath AM algorithm. Try it now!