4 - Technology

Technology: 3D Printing

Three-dimensional (3D) printing is the construction of a three-dimensional object from a digital model. It is an "additive" technology that does not require blocks of material or molds—it simply "stacks and fuses layers of material" to create objects (Protolabs Network). 3D printing has gained massive popularity in industries and among general hobbyists. For years, I have watched my brother fiddle with his 3D printers, experiment with different filament types, and find new designs to print for himself, our family, and his friends. He has taught me a lot about 3D printing, and I am always impressed by the level of detail 3D prints can achieve and the types of things you can create.

A Brief History
In 1986, American inventor Charles Hull patented stereolithography (SLA), one of the most widely used 3D printing processes. SLA printers use a curable photopolymer material that hardens when exposed to UV light. 

In 1988, Carl Deckard, a student at the University of Texas, filed a patent for selective laser sintering (SLS), a type of printing that uses a high-powered laser to form small polymer particles into solid objects. The first SLS printer became commercially available in 2006 after Dr. Adrian Bowyer founded the open-source initiative known as the RepRap project. Bowyer and his team developed a 3D printer made of plastic parts that could be printed by the machine itself, making it a successful "self-replicating" technology. Because the technology was open-source, it made 3D printing accessible to anyone with access to a computer. Since then, a surge of 3D printing manufacturers have entered the market, 

Source: The American Society of Mechanical Engineers

The Three Most Established 3D Printer Types (According to FormLabs)

• Fused deposition modeling (FDM) 3D printers “melt and extrude thermoplastic filaments, which a printer nozzle deposits layer by layer in the build area.”
• Stereolithography (SLA) 3D printers “use a laser to cure thermosetting liquid resins into hardened plastic in a process called photopolymerization.”
• Selective laser sintering (SLS) 3D printers “use a high-powered laser to fuse small particles of thermoplastic powder.”

FDM printing is the most widely used type of 3D printing for consumers and hobbyists. It is affordable and works well for basic models, making it easily accessible for beginners, schools, and businesses. 

Above: FDM extrusion printing

3D Printing & Modeling Software

Many helpful tools exist to assist users in developing and printing 3D models. Some examples of 3D modeling software include TinkerCAD, FreeCAD, Blender, and Autodesk Fusion (formerly known as Fusion 360). 

Above: 3D modeling in Blender

If you are unsure what to print or want to see other people's creations, Thingiverse is an excellent resource. It contains millions of ready-to-print designs, including shelves, animal figurines, fidget toys, katanas, and decorative items. My brother regularly uses Thingiverse, and even though I've never 3D printed anything myself, I enjoy browsing the website.

Popular Types of Filament for FDM Printers
3D printing filament is the "raw material that keeps you printing" (All3DP). FDM printers work well with various filament types, offering consumers a wide range of options for the structure and look of their prints. 

My brother mainly uses plastic materials but has experimented with carbon fiber and resin printing. Below is a list of filaments most commonly used in FDM printing:

Acrylonitrile Butadiene Styrene (ABS) 

• high heat resistance
• high-strength
• slight flexibility
• used in many consumer electronics

Polylactic Acid (PLA)

• one of the most commonly used filaments
• affordable
• easy to use and work with
• made from renewable materials such as corn starch
• biodegradable
• makes stiff, rigid designs

Nylon (Polyamide)

• suitable for weight bearing and parts subject to friction or flexing
• chemical and heat-resistant
• can be dyed

Polycarbonate (PC) and blends

• strong and heat-resistant
• ideal for objects that need strong impact resistance
• the type of plastic used to manufacture bulletproof glass
  

Learn about the properties of popular filament types here. 

Just for Fun!

Take a look at some of the wacky things made by 3D printers: