Advanced Applications of Desktop 3D Printers
By Erick Wolf
Types of 3D Printing Technologies
Type Technologies Materials
Extrusion Fused deposition modeling (FDM)Thermoplastics (e.g. PLA, ABS), HDPE, eutectic metals, edible materials
Wire Electron Beam Freeform Fabrication (EBF3) Almost any metal alloy
Granular
Direct metal laser sintering (DMLS) Almost any metal alloy
Electron beam melting (EBM) Titanium alloys
Selective heat sintering (SHS) Thermoplastic powder
Selective laser sintering (SLS)Thermoplastics, metal powders, ceramic powders
Powder bed and inkjet head 3d printing, Plaster-based 3D printing (PP)
Plaster
Laminated Laminated object manufacturing (LOM) Paper, metal foil, plastic film
Light polymerizedStereolithography (SLA) photopolymer
Digital Light Processing (DLP) photopolymer
Model
• A Model is made with CAD software • Or from scanned images
gCode
• Model is “sliced” into layers• X, Y, Z coordinates
Object
• 3D Printer uses gCode• Deposits plastic, layer by layer
The Basics: How it works
Model is made
Design a model with CAD software such as: Solidworks, AutoCad, SketchUp
From a 3D scan of an object Download a free 3D model from many
sources
Many ways to a 3D model
gCode is Generated
A 3D model is saved as an STL format The STL file is “sliced” gCode is X Y Z coordinates, speed,
temperature and more
gCode
3D Printer Deposits Plastic
3D Printer takes gCode Melts plastic Deposits layer by layer
Additive manufacturing
Each layer of plastic is deposited on top of the previous layer
The warm plastic bonds to the prior layer With each layer, an object slowly materializes
Filament
Materials: Called filament Standard size is 3mm and 1.75mm Looks like Weed Wacker wire Typically available in 1 or 2 pound spools. 1 pound of ABS filament = $48
ABS PLA PLA 4043D Nylon 618 Nylon 645 Bridge Nylon LayWOOD HIPS Soft PLA TPE
LayBrick BendLay T-glase Colorfabb XT PVA Polycarbonate PET BronzeFill PC/ABS TPU
25+ Materials That Are Readily Available For Desktop 3D Printing
Impact resistance and “toughness”◦ Most commonly used thermoplastic◦ Legos, automotive trim components, automotive bumper bars,
enclosures for electrical and electronic assemblies◦ Useful characteristics within a temperature range from −20 to
80 °C (−4 to 176 °F) 3D Printing
◦ Stronger, more stable (long term), and less brittle than PLA, handles higher temperatures
◦ General rule/design consideration – printed parts have 30% the strength of injection molding
Available in all colors, including gold, silver, fluorescent hues and glow in the dark
ABS - Acrylonitrile Butadiene Styrene
Parts For 3D Printers“We use this material to make almost every plastic component on the Airwolf 3D printers because of its ease of printing and resistance to high temperatures.”
-Airwolf 3D
ABS Example
ABS Has many Post Processing Possibilities
Prints well straight on glass with Wolfbite (www.aw3d.com)
Print Temperature: 240-250°C
ABS – Optimal Settings
Heat bed REQUIRED◦ Capable of at least 120C necessary for proper adhesion◦ Risk of curling without proper surface preparation
Large Prints will crack if not designed carefully or if enclosure is not present◦ Tall prints need to printed quicker◦ Add perimeters for strength
Heated build volume◦ Can quickly wear components (motors, bearings, plastic)◦ Servicing inconvenient
ABS – Considerations
Environmentally friendly◦ Made from starch rich plants such as corn, wheat, and sugar
beets Starch is separated and dextrose goes through fermentation process
◦ Bio-degradable and compostable Commercial compost – 30-45 days
Easy to print◦ Fun, smells pleasant (like waffles)◦ Little-to-no warping
Available in all colors, including gold, silver and fluorescent hues (even hybrids)
PLA - Polylactic Acid
30” Batmobile
PLA Example
Does not require a heated bed◦ Prep surface with Airwolf red tape for best adhesion
Fans on the extruder are mandatory◦ Fans on extruder reduces chance of jams◦ Fans on print surface can help cool printed surface for
appearance benefits Minimize excessive retraction Melting point: 195° - 220°C
PLA – Optimal Settings
Perfect for large demonstrative models◦ Little surface tension, so minimal chance of cracking◦ No need for heated build chamber
Print time is not an issue◦ We have printed for 5 days straight with PLA without warping/cracking
However, will change form in direct sunlight◦ Cellphone cases left in car will distort in less than a day
Functional prototypes should be treated
PLA – Considerations
Taulman 3D 618, 645, Bridge Nylon Filament Nylon based co-polymer Excellent surface bonding Reduced water absorption and tear resistance Color: white/clear Dyeable Bridge
◦ Tends to be more flexible, but less susceptible to warping◦ Print at 270C with bed at 60C◦ Pet tape with glue stick for adhesion ◦ Used for Airwolf gears
Nylon – Co-Polymer
Polycarbonate is an extremely strong, impact resistant thermoplastic
Bleeding-edge technology and is currently experimental
Used in Airwolf extruders for heat resistance Unlike acrylic or plexiglass (they shatter and
crack), Polycarbonate tends to bend and deform and after much effort will eventually stretch like very hard rubber until it eventually breaks
Hygroscopic and will absorb moisture from the air
Polycarbonate– Experimental Thermoplastic
Polycarbonate – Sample Part
Extruded at or above 300C for best layer-layer adhesion
Many current 3D printer extruders are not compatible with temperatures above 250C Make sure your printer is capable of these temperatures or your extruder may fail
Print surface is PET tape and then glue stick on top of that
The faster and hotter an object is printed the more clear the end results
Polycarbonate – Optimal Settings
Combination of Polycarbonate with ABS Extruded at or above 280C for best layer-layer
adhesion (advanced extruder needed) High heat distortion is an improvement over ABS Low temperature impact resistance gives it an
advantage over polycarbonate. Works excellent for small/midsize prototypes that
need to “function” Heated chamber preferred for large, complex builds Print surface is PET tape and then glue stick on top
of that
PC/ABS – Plastic “Alloy”
The printed wood will appear rough, similar to MDF (Medium-Density Fiberboard)
Paintable, grindable, carvable and stainable Heated bed is not necessary Available in two shades of brown Similar thermal durability as PLA
LAYWOO-D3 – Co-Polymer with recycled wood
LAYWOO-D3 – Example
Heated bed ideally at 60C Print Temperature: 175°C to 200°C Prep surface with blue painters tape Adding extra extrusion to the beginning of your print
will help prevent dry extrusion during the initial layers Increasing the retraction setting of your part during
slicing will reduce 'leakage' while the hotend is moving between sections (especially over open areas)
LAYWOO-D3 – Optimal Settings
LAYWOO-D3 will harden over time, for delicate parts allow 30-60 min for your print to set
Alternating the temperature during your print (even by as little as 10 degrees) will vary the coloration, giving it a 'grained' look
High Impact Polystyrene is very similar to ABS in its printing properties, but works with different solvents (Limonene for HIPS vs acetone for ABS)
Easy to paint and glue When printing, best to keep bed temps at 100C
or lower, but extrusion at normal ABS temps works fine
Color: White Use for support material on HD2x and use
solution to remove support material from part
HIPS – High Impact Polystyrene
Water-soluble synthetic polymer It prints very easily and can be used as wash away
support structure when using more than one extruder
Can be used with a dual extruder 3D printer to add support materials
Best printing comes with a 100C heated bed and slightly lower temps than ABS (190-210C)
Color: Off white Dissolves in water !!! (quickly) Like Elmer’s glue
PVA – Polyvinyl Alcohol
Soft PLA is a flexible 3D printing material that feels and acts much like rubber
Support built into prints can be easily removed (unlike traditional PLA)
Can be used to make parts that can bend or must flex to fit their environment - stoppers, belts, springs, phone cases and more
Biodegradeable
SOFT PLA – Polylactic Acid
SOFT PLA – Sampled Part
Layer height is best kept down to maximize layer-to-layer bonding because the parts need to be extra strong as they are flexed in use
Recommended Extrusion Temperatures: 200C-215C Sticks well to a bed that is layered with blue
painters tape Slow print speed for best results Keep bed at 60C
SOFT PLA – Optimal Settings
Also referred to as “thermoplastic rubber” High elasticity: Extremely flexible and strong 3D printed TPE feels much like rubber and
bounces back into shape REACH and RoHS 2002/95/EC Directive Compliant Filament shore hardness of approximately 85A Available in Red, Blue, White and Black
TPE – Thermoplastic Elastomer
Sample PartWashers
TPE
Prep platform with blue painter’s tape
Recommended extruder temperature: 240°C
Recommended platform temperature: 40°C
TPE – Optimal Settings
Has a grey stone color Allows you to give your prints a smooth or stone-
like texture Ideal for jumbo-printers Objects are paintable and grind-able Contains super-fine milled chalk and harmless co-
polyesters
LAYBRICK – Mineralic Fillers and Co-polyesters
Sample Object
LAYBRICK
You can print LAYBRICK in a range of about 175°C to 210°C
In the lower range, the print will come out mostly smooth, whereas at higher temperatures it will begin to have a sandstone-like texture
Prep surface with blue painters tape It is recommended to use a fan when printing at
higher temperatures (always to avoid jamming)
LAYBRICK – Optimal Settings
Extremely translucent (91% of light passes through) and is also flexible
Print nearly clear items Safe for household and food products Compared to ABS it also absorbs far less
moisture from the air and thus cuts down on warping significantly
Soluble in brake cleaner
BendLay – Modified Butadiene
Sample Part
BendLay
It sticks great to a bed that is layered with blue painter’s tape or on PET film with Elmer’s glue stick
Print it at a slower speed (around 20-30mm/s) than normal materials
Compared to ABS it also absorbs far less moisture from the air and thus cuts down on warping significantly
Extrusion Temperatures: 230°C-240°C
BendLay – Optimal Settings
A low temp (212C) industrial 3D printing material Considered “water-clear” and “optically correct” A low TG means that parts printed in T-glase,
should not be exposed to high temperature use or applications. The measured TG of T-glase is 78C
Made of FDA approved polymers for direct food contact/containers
Not biodegradable like PLA however it is a considered 100% reclaimable
There are supposedly no odors or fumes when 3D printing with T-glase
T-glase
T-glase– Sample Parts
Optimum temperature is about 212c to 224C, but will print down to 210C and up to about 240C (depending on speed)
T-glase easily sticks to heated acrylic and glass print tables (with PET film) for the smoothest bottom surface possible
Very low shrinkage makes printing large flat surfaces a breeze
Prints to acrylic, glass, Kapton and other platforms
T-glase – Optimal Settings
Concept: Photos of your feet are turned into 3D
models Select FeetZ shoe elements and shoe
is custom made to form and function needed
FeetZ 3D prints shoes in TPE
Leading the SizeMe Revolution
"Tests are good so far," Lucy Beard says, holding up an example of a cute,
very flexible and comfortable looking ballet
flat. Source: SAN DIEGO CITY BEAT
Pioneering intercontinental robotics: Uses 3D printers in its design and
manufacture of telepresence robots Large build platform of 12” x 8” and
heated bed enables Orbis to print larger parts of the robots with a 3D printer
The face of telepresence
“Our low overhead approach to design and manufacturing
permits us to respond quickly to the ever changing
market of robotics.” -CEO Steve Gray
Questions?
Erick Wolfwww.airwolf3d.com
(949) 478-2933
?