An intro to 3D printing

So what is 3D printing and how can Barras 3D help you or your business

3D printing, also known as additive manufacturing, is a process of creating three-dimensional objects by layering material on top of each other. Unlike traditional manufacturing methods that involve subtracting material through machining 3D printing builds objects layer by layer from the bottom up.

A good way to imagine this is if I was to get a Tomato and to slice it really thinly I’d have a lots of little slices of the tomato.

If you were then to stack these slices up in order then you would have a tomato again. So if you could create tomato slices by magic then you could make tomatoes

This is how 3D printing works is it creates objects one layer at a time. The software that makes these layers is actually called a slicer, but more of that later

However this isn’t how 3D printing is treated in the media

In the media 3D printing is a miracle box that you push a button and a fully formed object comes out of it. An example being the miracle 3D printed houses which will revolutionise the building industry. As the house can be printed in 12 hours

apart from

The foundations

The roof

The windows

The doors

The plumbing

The wiring

The floors

The internal walls

Etc and so on

And they fail to mention it takes a week to get the machine on site and running

So we shall put the 3D printing magic box in the trash where it belongs with other media miracles and air fryers (they are just small ovens!!!)

So where is 3D printing useful

Many many places

It allows you to make things far quicker then you could by traditional methods and in some case you can make things which are impossible by traditional methods.

A link to a Youtube playlist which goes into it in more depth

If you want to get a 3D print done then please head HERE FIX IT!!!!!!!!!!!

So what we know so far about 3D printing is it is loads of flat layers all stacked ontop of each other to make an object. These layers are printed one layer on top of another layer until you have the finished object.

To get to the finished object you first need that object to exist in a electronic space. The normal way to get here is to create the object in 3D design software. Be that CAD for engineering objects or a piece of sculpting software for more decorative pieces.

I have a good amount of experience in CAD but still have lots to learn. In 3D sculpting I have zero knowledge but there is lots of people out there who will happily made you a 3D sculpt.

Now you have the 3D model it needs to be sliced into the separate slices. This software is called rather unimaginatively a slicer. This is often custom to the 3D printer that is being used. Most of the slicing I do in Prusaslicer which is native to Prusa 3D printers

3D printing processes

Now you have your object sliced up it is time to have a look at the various processes that are common for 3D printing

FDM 3D Printing

Fused Deposition Modeling (FDM) is a type of 3D printing technology often used in additive manufacturing. The process involves creating a 3D object by depositing layers of material one on top of the other.

In FDM 3D printing, a thermoplastic material is fed through a heated nozzle, which melts the material. The nozzle moves according to the design specifications, extruding the melted material onto the build platform. As each layer is deposited and solidifies, the platform moves down, allowing the printer to build the object layer by layer.

FDM 3D printing is popular due to its versatility, low cost, and ease of use. It is commonly used in prototyping, product development, and small-scale manufacturing. Its simplicity and wide range of materials make it a preferred choice for many individuals and businesses in the 3D printing world.

The machines that Barras 3D uses are mostly FDM using Prusa printers and the following materials. PLA, PETG, ASA, PC-CF all of which give excellent results.

The Barras 3D logo is based on a FDM printer.

The top part is a typical hot end design which is what heats the material and extrudes it out.

The lines on the logo are the different layers

There is a wide variety of materials that can use this method of squirting out materials and letting them go solid and then putting another layer ontop. This is where the infamous 3D printed houses come from as they use cement.

There is another material that can be heated up, turned into a liquid and then printed and returned to a solid once it cools.

CHOCOLATE

Yes there is a 3D printer that works with chocolate but this isn’t in the Barras 3D plan……………Well not yet………..not that i need an excuse

Resin 3D printing

Also known as stereolithography (SLA) or digital light processing (DLP) printing, is a type of additive manufacturing process that creates objects layer by layer using liquid resin material. This liquid resin will go solid when exposed to a strong UV light source. This is normally done by having the resin in a container with a clear bottom. UV light is then shone through the bottom of the container. This can either by tracking a laser across the bottom or by using an LCD to mask off the a UV light source. This layer of solid resin is then lifted off the screen to get the next layer and the object slowly emerges from the resin.

This method allows for high levels of detail and accuracy in the final printed models. Resin 3D printing is often used in applications where intricate designs and smooth surface finishes are required, such as in the production of jewellery, prototypes, dental appliances, and miniatures.

The downside is it stinks and it is messy. Currently barras 3D has a small resin printer which is used mostly for producing casts for jewellery. It is what was used for the pawprint casts.

A better resin printer is firmly in the plan as some of the smaller industrial machines are excellent, but they still stink so it will be relegated to it’s own little corner of stickiness.

SLS 3D Printing: A Brief Overview

The two processes I have described above are turning a liquid into a solid to make the layers. SLS is a slightly different concept.

Selective Laser Sintering (SLS) is a type of additive manufacturing technology that uses a high-powered laser to fuse small particles of plastic, metal, ceramic, or glass powders into a 3D object. SLS printers work by spreading a thin layer of the powdered material over the build platform and then using a laser to selectively fuse the particles together based on the 3D model's cross-section.

One of the key advantages of SLS 3D printing is its ability to produce complex geometries and intricate designs without the need for support structures. This is because the surrounding powder acts as a natural support during the printing process, allowing for greater design freedom compared to traditional manufacturing methods.

SLS is widely used in various industries, including aerospace, automotive, healthcare, and consumer goods, due to its capability to create functional parts with high strength and durability. However, it is essential to note that SLS 3D printing can be more costly than other additive manufacturing technologies due to the specialized equipment and materials required.

SLS however isn’t a cheap process for either to buy the machine or to run the machine. So this isn’t currently in the Barras 3D fleet but who knows which way this business will go.