Additive technologies, such as 3D printing, are a method of layer-by-layer object development.
The first prototypes of 3D-printing technology and materials came in the 1980s, but the pinnacle of its success and appeal fall on the present. 3D printing’s capabilities and applications are expanding all the time. Additive technologies appear to be capable of almost anything, from printing blood veins to creating molds.
3D printing allows for the layer-by-layer production of objects based on a 3D computer model. Because of the step-by-step nature of manufacturing, this process of generating an object is often known as “growing.”
The essence of 3D printing is as follows: first, a 3D model is developed, then the item is built layer by layer, regardless of the technique employed.
Fused Deposition Modeling (FDM) is one of the most popular 3D printing processes. The popularity of FDM stems from the relatively low cost of the necessary equipment and a vast variety of raw materials used.
The quality of the final product is greatly reliant on the quality of the raw material used and the printing parameters employed, such as extrusion temperature, printing speed, layer thickness, filling percentage of each layer, filling manner, etc.
Before you can begin working, the 3D model in.stl format must be transferred to the 3D printer software. The model is placed on the work surface by the software automatically, or manually by the operator. The algorithm then produces supporting structure elements and estimates the amount of material and time needed to print the product. The model is separated into layers and the trajectory of the printhead is determined automatically before the printing process begins.
When providing detailed settings, it is possible to determine how contours and interior fills will be represented, as well as optimum extruder movements and their speed. This creates a.gcode file in the form of simple commands that the printer follows exactly.
The main feature
The main feature of the technology is that, unlike traditional manufacturing processes, where we start with a blank and then remove extra material or deform it, additive manufacturing creates a new product from scratch, or rather from polymer filament. The thing can be built from the bottom up or vice versa, depending on the technology, gaining different properties.
Advantages of 3D printing
Affordability. Because no additional expenses are required for tooling, additive technology is more advantageous than traditional technology when producing small batches or prototypes.
Production rate. 3D printers can drastically reduce the amount of time it takes to complete a project. In contrast to traditional manufacturing procedures, one can build things in a matter of hours using a 3D model, whereas creating an injection mold can take weeks.
Versatility.
3D printers can print a wide range of materials, and they can also make molds and dentures on the same machine. A 3D printer can also create a custom-designed object or one whose design can be changed without a significant financial investment, whereas modifying a mold for casting is difficult, if not impossible.
Disadvantages of 3D printing
The small size of the build chamber. A significant disadvantage of 3D printing is that large products need to be printed in parts and then assembled after manufacture.
Harmful emissions.
When multiple polymers are used for printing, hazardous compounds are released into the atmosphere, which may be detrimental to humans. It is necessary to use exhaust ventilation and air the premises more regularly to avoid this.
Precision.
3D printing products have lower precision compared to injection molded ones.
Conclusion.
3D printing is better for prototyping and small batch production, as well as the creation of custom-designed products with frequently changing designs. Injection molding is better for high-volume manufacture of high-quality polymer items that demand precision and consistency in each component.
3D printing at EnCata
Additive technologies are actively employed by our team of engineers, namely in IP-66 housing for a car-sharing company . In the industrial design phase, the selected mold is modeled in CAD and the prototype is printed on a 3D printer. The industrial design is validated with 3D printing and prototyping using silicone molds.
In another case, our engineers developed a removable electric actuator for the PowerDrive wheelchair. The wheelchair is designed for safe and comfortable driving. When required, caregivers are in full control and users can enjoy enhanced mobility without any restrictions.
The author of the PowerDrive, David Carson, approached us with a difficult but exciting task: to improve the prototype design (by reducing weight and adapting the enclosure design to the finished PowerDrive Industrial design concept) while lowering production costs.
Our engineers and designers successfully met the challenge. In the near future, the PowerDrive will be accessible on the market.
