What is 3D printing?

3D printing is a generic term that covers several additive printing processes that can be used to create three-dimensional objects from a computer program. Technical drawings of the component to be produced are created in special CAD programs. These are sent to a 3D printer, which then carries out the printing using the layering process. 3D printing is therefore the opposite of conventional machining, in which objects are removed from a block of material. Additive processes play a particularly important role in the field of rapid prototyping, but also in the series production of objects.

The term 3D printing is a synonym for the umbrella terms additive manufacturing or additive production, which are also frequently used in the professional environment. However, the term 3D printing has established itself as a non-technical term in general usage.

The beginnings of 3D printing

The beginnings of 3D printing date back to 1984, when Chuck Hill developed the first additive process, stereolithography. Since then, a number of other three-dimensional printing technologies have come onto the market that print spatial objects and components from various materials such as plastics, metals, ceramics or acrylic resins. Initially used primarily in an industrial environment, 3D printers are increasingly also being used in the private sector. Everything from tokens to components for space travel can be produced using 3D printing.

The additive processes in 3D printing

There are three main differences between additive processes. There are processes that build up the three-dimensional object by extrusion. Here, the base material is applied almost in liquid form along the defined structures and then hardens. These processes include, for example, FDM (fused deposition modeling or chocolate printing). Stereolithography or the polyjet process use liquid photopolymers that are cured by UV light when the structures are printed. A third 3D printing principle uses material powders that are selectively bonded along the previously defined structures using heat or certain chemical processes. Both SLM (Selective Laser Melting of metals) and SLS (Selective Laser Sintering of plastics) are widely used – as is the case with FKM sintering technology.

How 3D printing works

Regardless of which method is used, the process steps in 3D printing are similar:

  • Creation of the 3D model on the computer with CAD program
  • Preparation of the digital model immediately before printing (e.g. by slicing)
  • 3D printing
  • Post-processing (polishing, coloring, removal of support structures, …)

How does a 3D printer work?

As 3D printing creates three-dimensional, three-dimensional objects, it requires 3D printers with sufficient build space. In the SLS and SLM processes carried out at FKM, this installation space is a closed system. This means that no foreign bodies can enter it during printing.

The end product, which is defined via CAD, is therefore built up layer by layer in a closed installation space. After each lowering, a thin layer of the selected material is applied in powder form. A powerful laser beam adapted to the base material fuses this powder along the desired contours and structures with pinpoint accuracy and according to CAD specifications. The machines available to FKM can, for example, produce construction volumes of up to 1000 x 500 x 450 mm. Larger components are printed in individual units and then assembled.

The advantages of 3D printing

There are many advantages to creating objects and workpieces using a 3D printer. Because parts are produced in a layering process according to exact specifications from the CAD program, material loss is extremely low. Powder that is not melted and remains can be reused for future projects. Material waste only occurs during post-processing – for example, when necessary support structures are removed during printing or the surface of a product is reground. Compared to machining, the loss of material is negligible. Additive processes are therefore significantly more cost-efficient and ecologically sustainable.

Another obvious advantage is that components with complex geometries, internal cavities such as cooling channels or loose parts within the object can be produced in a short time and in the course of a single process step. In machining production, separate work steps are required here.

The advantages at a glance:

  • Time and cost-efficient production of components
  • Complex and intricate geometries
  • Complex internal structures
  • Free-form geometries
  • Lower material consumption
  • Tool-free production
  • Flexible customization and fast adaptation
  • Prototype production during development
  • Fully automated production of fully functional workpieces

The materials in 3D printing

The variety of 3D printing processes enables the use of many different material groups. In addition to metals and plastics, materials such as ceramics, acrylic resin, plaster, concrete, certain foods, living cells and others can also be used. In the industrial sector, however, plastics and metals make up the largest proportion of materials used in 3D printing.

Areas of application for 3D printing

Additive manufacturing processes are finding their way into more and more areas, from industry to hobby DIY. Even the food industry is now experimenting with 3D printing.

Industry and construction

The industrial sector is the area in which 3D printing processes are used most frequently. Thanks to the latest printing technologies, functional, stable and high-quality components can be efficiently produced in series or as prototypes during the development phase of new projects. Individual workpieces or small batches can also be produced effectively using the 3D printing process. The construction industry is developing in such a way that entire building components are being produced using 3D printers.

Automotive, aerospace

Industries that particularly benefit from prototyping using 3D printing are the automotive and aerospace sectors. The variety of materials used makes it possible to print components that can withstand high thermal or mechanical loads. In addition, the workpieces can be made as light as possible and highly stable at the same time.

Medicine, science, research

3D printing has revolutionized medicine. Dental bridges, implants, prostheses, hearing aids and more can be customized for specific patients and produced comparatively inexpensively. In science and research, nano- and bioprinting are worth mentioning.

Art, fashion, jewelry, hobby

3D printing is also increasingly being used in art and for private applications. As far as it is technically feasible, sculptures and other three-dimensional objects can be created. Jewelry, fashion components (belt buckles, etc.) and model components are now also created using additive processes.

3D printing at FKM Sintertechnik

FKM Sintertechnik specializes in two additive processes – selective laser melting and selective laser sintering, each with a variety of materials in powder form. From rapid prototyping to the realization of small series, we at FKM implement your orders with precision and experience.