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Unveiling the Truth: How Long Does 3D Printing Really Take?

Blog Article  April 15, 2024  Share across your network:

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.

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)

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.

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.

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:

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

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.