Unveiling the Truth: How Long Does 3D Printing Really Take?
Blog Article | April 15, 2024
Introduction
In today's fast-paced product development world, getting prototypes and final parts into your hands quickly is crucial. Traditional manufacturing methods can take weeks or even months, hindering your ability to iterate and refine your designs. This is where 3D printing steps in as a game-changer.
The Power of 3D Printing
3D printing, also known as additive manufacturing, has become an indispensable tool for product designers and engineers. It allows you to create physical models from a digital 3D file, layer by layer, in a matter of hours or even minutes. This rapid prototyping capability empowers you to:
Test & Iterate on Designs Quickly
Quickly See your ideas come to life faster, identify potential issues early, and refine your design before investing in large-scale production.
Reduce Development Costs
By eliminating the need for expensive tooling and minimizing material waste, 3D printing allows for cost-effective prototyping and small-batch production.
Unlock Design Complexity
Create intricate geometries and functional parts that would be impossible or prohibitively expensive with traditional methods.
Understanding 3D Printing Speed
While 3D printing offers significant advantages in terms of speed compared to traditional manufacturing, the actual print time can vary greatly depending on several factors. Here's what you need to understand:
TECHNOLOGY MATTERS
There are several 3D printing technologies available, each with its own strengths and weaknesses when it comes to print speed. The two main factors affecting print speed are layer height (the thickness of each layer) and speed per layer (how fast the machine can trace or expose each layer).
Fused Filament Fabrication (FFF)
This is the most common type of 3D printer, using a single nozzle to extrude molten plastic filament layer by layer. Larger layer heights lead to faster prints, but compromise on detail. Complex designs with intricate features take longer to print due to the nozzle needing to trace all the details.
Stereolithography (SLA) & Digital Light Processing (DLP)
These technologies use a laser or projector to cure liquid resin into solid layers. SLA offers the highest resolution with the smallest layer heights, resulting in longer print times. DLP works similarly but exposes the entire layer simultaneously, making print times less dependent on complexity.
Selective Laser Sintering (SLS) and Multi Jet Fusion (MJF)
These powder-based technologies use a laser or light to fuse powdered plastic particles together. SLS and MJF require cooling and post-processing to remove excess powder. MJF offers faster printing speeds due to simultaneous layer fusion and is well-suited for production volumes.
Fused Filament Fabrication (FFF)
FFF, also commonly known as Fused Deposition Modeling (FDM)™, is the most widely used 3D printing technology, particularly at the consumer level. Here's a breakdown of its key characteristics:
Printing Process
FFF utilizes a single nozzle that acts like a hot glue gun, extruding molten thermoplastic filament layer by layer to build the desired object.
Material Compatibility
FFF works with a wide range of readily available thermoplastics like ABS, PLA, and Nylon. This variety allows for customization based on the project's needs, such as strength, flexibility, or heat resistance.
Print Speed
FFF offers variable layer heights. Larger layer heights translate to faster print times, but with a trade-off in detail and surface finish. Conversely, smaller layer heights create smoother, more intricate parts but take longer to print.
Complexity & Print Time
FFF print times are highly influenced by the model's complexity. Since the nozzle needs to trace the outline of every feature, intricate designs with many details will take longer to print compared to simpler models.
Post Processing
In FFF printing, if support structures were included during the printing process to maintain overhangs or intricate features, removing these supports is an essential step in post-processing. Typically, supports are designed to be easily detached from the printed object, either by hand or with specialized tools, ensuring a smooth and clean final result. This process contributes to the overall refinement of the printed part, enhancing its aesthetic appeal and functionality.
Stereolithography (SLA)
SLA offers exceptional detail and resolution, making it ideal for applications requiring high precision. Here's a closer look at SLA technology:
Printing Process
Unlike FFF, SLA doesn't use filaments. Instead, it employs a focused laser beam to cure liquid resin into solid layers, meticulously building the 3D object.
Material Compatibility
SLA printers primarily use photopolymers, special resins that harden when exposed to light. These resins come in a variety of properties, offering options for clear parts, flexible parts, or even castable resins for creating metal molds.
Print Speed & Resolution
SLA boasts the capability for the smallest layer heights among common 3D printing technologies, resulting in unparalleled resolution and detail in the finished parts. However, this precision comes at the cost of print speed. Similar to FFF, complex models with intricate features will take longer to print due to the laser needing to trace every detail.
Post-Processing
Once the printing process is complete, SLA parts require post-processing steps. This typically involves washing away excess resin and then curing the part with additional light exposure to ensure its strength and durability. Additionally, if support structures were utilized during printing to uphold overhangs or intricate features, removing these supports is a crucial aspect of post-processing to achieve a refined final product.
Digital Light Processing (DLP)
DLP shares many similarities with SLA but offers some distinct advantages in terms of print speed. Here's how DLP technology works:
Printing Process
Similar to SLA, DLP utilizes a vat of liquid resin. However, instead of a single laser beam tracing each layer, DLP employs a projector that exposes the entire layer of resin to light simultaneously.
Material Compatibility
DLP printers are compatible with a wide range of photopolymers similar to SLA resins. This allows for versatility in choosing the material properties best suited for the application.
Print Speed
DLP's key advantage lies in its significantly faster print times compared to SLA. Since the entire layer is exposed simultaneously, print speed becomes less dependent on the model's complexity. However, DLP parts may exhibit slightly lower resolution and detail compared to SLA prints due to the nature of light projection.
Post-Processing
One essential aspect of post-processing for DLP-printed parts is the removal of any support structures that were included during the printing process. These supports are essential for maintaining overhangs and intricate features but need to be carefully removed after printing to ensure a smooth and clean final product. Proper support removal contributes to the overall quality of the printed part, enhancing its functionality and appearance.
Selective Laser Sintering (SLS)
SLS is a powder-based 3D printing technology well-suited for functional prototyping and even low-volume production runs. Here's what you need to know about SLS:
Printing Process
SLS utilizes a laser to selectively sinter (fuse) powdered thermoplastic particles together layer by layer, building the 3D object. The surrounding unsintered powder acts as a natural support structure, eliminating the need for additional support materials.
Material Compatibility
SLS commonly uses nylon-based powders, but other materials like metals and even some ceramics are also printable with SLS technology. This broadens the application possibilities for creating functional parts with desired mechanical properties.
Print Speed & Post-Processing
While not the fastest printing technology, SLS offers reasonable print speeds compared to some other methods. After printing, the parts require cooling before handling. Additionally, parts must be bead blasted to remove excess powder surrounding the printed object.
Multi Jet Fusion (MJF)
MJF is another powder-based technology that builds on the principles of SLS while offering some significant advantages. Here's a breakdown of MJF:
Printing Process
Combining aspects of SLS and inkjet printing, MJF utilizes a printhead that jets droplets of fusing and detailing agents onto a bed of powder. The fusing agent allows the powder to absorb the infrared light from the lamp and that causes it to selectively fuse wherever the fusing agent is dropped. The detailing agent helps reject infrared heat, giving the part a crisp edge.
Material Compatibility
Similar to SLS, MJF primarily uses nylon-based powders. However, ongoing advancements may expand its material compatibility in the future.
Print Speed & Post-Processing
MJF boasts the fastest print speeds among common 3D printing technologies, primarily due to its ability to fuse the entire layer at once. This simultaneous fusing process significantly reduces the time required for each layer to solidify, resulting in accelerated printing times. While MJF offers remarkable speed advantages over traditional methods, it still requires certain post-processing steps. After printing, excess powder must be removed through bead blasting to ensure the final part's cleanliness and structural integrity. Moreover, a cooling period is necessary to stabilize the printed parts and optimize their mechanical properties. Despite these additional steps, MJF's faster printing capabilities and streamlined post-processing contribute to its reputation as a highly efficient and effective 3D printing technology.
Ready to Explore the Power of 3D Printing?
At Saratech, we stay at the forefront of 3D printing advancements. We offer a variety of 3D printing technologies, materials, and expertise to help you leverage this transformative technology for your business. Whether you're a seasoned designer or just starting your 3D printing journey, our team can guide you through every step of the process.
3D Printing Expertise
Our team of experienced engineers can help you choose the right 3D printing technology for your project, optimize your designs for printability, and ensure successful printing results.
Advanced Printers & Materials
We have a variety of high-quality 3D printers capable of producing parts with exceptional detail, strength, and functionality.
Rapid Prototyping Services
Get your prototypes in your hands fast with our rapid turnaround times. We can help you iterate on your designs quickly and efficiently.
On-Demand Manufacturing
Need small batch production runs or custom parts? Our 3D printing capabilities can fulfill your needs on-demand, eliminating the need for traditional manufacturing lead times.
Comparing 3D Printing Technologies
|
|
FFF |
SLA |
DLP |
SLS |
MJF |
|---|---|---|---|---|---|
| Print Speed | Slow | Slow | Faster | Faster | Fastest |
| Strength | Anisotropic | Isotropic (weaker in Z-direction) | Isotropic (weaker in Z-direction) | Isotropic (weaker in Z-direction) | Isotropic (weaker in Z-direction) |
| Support Structures | Yes | Yes | Yes | No, powder bed supports parts | No, powder bed supports parts |
| Layer Height (Microns) | 50-300 | 25-300 | 25-300 | 50-200 | 80 |
| Resolution | Lowest | Highest | Very high | Good | Good |
| Infill | Recommended | Optional | Optional, but no effect on print time | Can be used to reduce print time and cost | Can be used to reduce cost but no effect on print time |
| Post-Processing | Support removal | Support removal and curing | Support removal and curing | Abrasive bead blasting | Abrasive bead blasting |
| Materials | Thermoplastics | Photopolymers | Photopolymers | Thermoplastics | Thermoplastics |
| Best Use Case | Single prototypes | Single prototypes | Single prototypes | Single prototypes | Medium volume production |
Optimizing Print Time
There are ways to optimize print time for each technology:
Increase Layer Height (Most Technologies)
While sacrificing some detail, using a larger layer height is the most universal way to reduce print time across all technologies.
Sparse Infill (FFF)
For FFF prints, consider using a sparser infill pattern to reduce the amount of material printed inside the part, thereby reducing print time. This reduces overall part strength.
Hollow Parts with Drainage (SLA and SLS)
For SLA and SLS prints, consider designing hollow parts with drainage holes. This reduces print time and material usage because the laser does not need to make as many passes to complete a layer.
Reduce Overall Print Height (DLP and MJF)
Since DLP and MJF print times are less affected by complexity, focus on reducing the overall print height of the part whenever possible.
Estimating Print Time Accurately
Obtaining precise print time estimates is crucial for effective project planning and execution in 3D printing. While 3D slicer software offers print time estimates, it's essential to recognize that lower-cost or hobbyist-level software may not provide accurate estimations. However, higher-end software solutions typically offer more reliable print time predictions by considering various factors such as layer height, infill density, and model complexity.
- Variable Settings: Factors like layer height and infill density have a significant impact on print time, but lower-cost slicer software may not adequately account for these variables. As a result, print time estimates generated by such software may be imprecise and may not accurately reflect the actual printing duration.
- Complexity Matters: Intricate models with numerous details often require longer travel distances for the print head, leading to extended print times. However, lower-cost slicers may underestimate the time needed for these complex prints, potentially leading to delays or unexpected results. In contrast, higher-end software solutions are designed to analyze model complexity comprehensively, resulting in more accurate print time estimations.
By utilizing advanced slicer software capable of considering a broader range of parameters, users can achieve more accurate print time estimates, enabling better planning and optimization of 3D printing projects.
Tips for Better Estimates
- Online Resources
Search online communities for print times of similar models or materials.
- Experiment with Settings
Run test prints with different settings to see how they affect print time and quality in practice.
- Experience Matters
As you gain experience, you'll develop an intuition for estimating print times based on model complexity and settings.
The Future of 3D Printing Speed
The world of 3D printing is constantly evolving, with advancements happening at a rapid pace. Here are some exciting developments that are pushing the boundaries of speed:
- Faster FFF Printers:Recent advancements in FFF (Fused Filament Fabrication) technology are revolutionizing the landscape of consumer-grade 3D printers. Manufacturers are continuously innovating to develop printers capable of significantly faster print speeds compared to their predecessors. These improvements in FFF printers are attributed to various factors, including enhanced extrusion mechanisms, optimized slicing algorithms, and improved materials. As a result, users can now enjoy shorter print times without compromising print quality, making rapid prototyping and production more accessible and efficient than ever before.
- Hybrid SLA/DLP Printers:In the realm of resin-based 3D printing, a groundbreaking development is emerging with the advent of hybrid SLA/DLP printers. These innovative devices integrate elements of both Stereolithography (SLA) and Digital Light Processing (DLP) technologies, offering a unique blend of high resolution and swift print speeds. By harnessing the precision of SLA and the rapid layer curing of DLP, these hybrid printers are capable of producing intricate, high-quality prints in record time. This convergence of technologies opens up new possibilities for designers, engineers, and hobbyists seeking to balance speed and detail in their 3D printing projects.
Conclusion
3D printing technology is rapidly transforming product development workflows. Gone are the days of waiting weeks or months for prototypes – with 3D printing, you can have physical models in your hands within hours, allowing for faster design iterations and quicker time-to-market.
While print times can vary depending on several factors, 3D printing offers a significant speed advantage compared to traditional manufacturing methods. This makes it an invaluable tool for a wide range of industries, from product design and engineering to healthcare and even aerospace.
Looking ahead, the future of 3D printing is brimming with exciting possibilities. Advancements in materials, printing speeds, and multi-material capabilities are constantly pushing the boundaries of what's achievable. We can expect even faster print times, a wider variety of printable materials, and potentially even full-color printing capabilities on the horizon.