Additive Manufacturing 1.0

Any ‘2.0′ is preceded by a first version, like the ‘1.0’ era. And the beginning, as they say, is a very good place to start. Additive Manufacturing 1.0 as an era could more aptly be called Rapid Prototyping, as that was more typical terminology used from the early 1980s and into the early part of the 21st century. As 3D printing technologies matured, so did the terminology used to refer to them.

The first decade or two of 3D printing was primarily led by stereolithography (SLA) and fused deposition modeling (FDM) processes–before the non-trademarked FDM equivalent of fused filament fabrication (FFF) became more common. Rapid prototyping (RP) was found to be extremely useful  in speeding up product development, with some users evencreating jigs, fixtures, and other helpful tooling.

In the early 2010s, RepRap and other desktop 3D printers emerged, bringing more mainstream visibility to FFF 3D printing. This became the era of the Yoda head, as this design rose to popularity on many a 3D printer. People started to think 3D printers would become as ubiquitous as microwaves in households, allowing them to ‘make anything.’

3D printing isn’t quite so easy, though–nor was it especially user-friendly a decade ago. The disappointment and disillusionment led to the death of 3D printing as far as much mainstream media was concerned. At the same time though, technological developments continued within the industry. 3D printing processes expanded, and the full additive manufacturing workflow became defined across seven ASTM-defined processes.

Larger companies, like GE and HP, invested heavily in additive manufacturing. Pure-play 3D printing companies rose to prominence with new technologies, with some, like Carbon, Desktop Metal, and Formlabs, hitting unicorn status with billion-dollar valuations.

Efforts across software and materials continued as well. More robust software, from the likes of Autodesk, Dassault Systèmes, and Siemens, powered complex geometries and AI-enabled feature generation. Terms like ‘topology optimization’ and ‘generative design’ became part of the lexicon as biomimetic designs with nature-inspired lattice structures allowed for all-new designs that could only be made on a 3D printer. 

On the materials side, global chemical giants threw their hats into the additive manufacturing ring as well. Arkema, BASF, Covestro, DSM, Evonik, Henkel, Owens Corning, SABIC, and Solvay, dedicated resources to developing advanced and familiar formulations of materials suitable for 3D printing.

With new capabilities in hardware, software, and materials, the industry began to turn from prototyping to production, entering a new generation of additive manufacturing.

Additive Manufacturing 2.0

The first company to publicly and specifically label this new stage in 3D printing was Desktop Metal. In their announcement in the summer of 2020 about their intent to go public, the company explained the concept of Additive Manufacturing 2.0:

“The additive manufacturing industry grew at a 20 percent annual compound rate between 2006 and 2016 before accelerating to 25 percent compound annual growth over the last 3 years, a rate that is expected to continue over the next decade as the market surges from $12 billion in 2019 to an estimated $146 billion in 2030. This market inflection is being driven by a shift in applications from design prototyping and tooling to mass production of end-use parts, enabled by the emergence of what Desktop Metal refers to as ‘Additive Manufacturing 2.0,’ a wave of next-generation additive manufacturing technologies that unlock throughput, repeatability, and competitive part costs. These solutions feature key innovations across printers, materials, and software and pull additive manufacturing into direct competition with conventional processes used to manufacture $12 trillion in goods annually.”

The assertion that we’re at an inflection point tipping toward mass adoption of additive manufacturing is being proven over and over again. Border closures and plant shutterings during the height of the pandemic in 2020 first showed how quickly and thoroughly supply chains could break down. This presented a huge opportunity for additive manufacturing to step up as a solution, serving as a critical proof point of the value of digital manufacturing.

Further opportunities presented in the form of additional supply chain crises, from the Ever Given stopping up the entire Suez Canal–through which a full 12% of global trade is routed–to the catastrophic impacts of Texas’ wild winter weather. These and other breaking points to traditional supply chains demanded flexibility and a fast response: exactly the call to action to deliver on the promises of additive manufacturing.

As 3D printing delivered on its promises, offering need-it-now PPE and testing supplies for pandemic response, as well as spare and replacement parts and other stop-gap supply needs, it became clear that what we were dealing with was a new type of 3D printing–and not the type limited to Yoda heads!

The Next Generation of Additive Manufacturing is Manufacturing

Desktop Metal may have been the first to use ‘Additive Manufacturing 2.0,’ but the term has spread quickly and thoroughly. Especially as we get further into 2021, we can see that the overall 3D printing industry is changing. Market consolidation through mergers and acquisitions, as well as an increasing number of companies entering the public arena, is reshaping the market itself.

We’ve already been delivering; to date, Shapeways has already scaled up to deliver more than 20 million parts to over 1 million customers in more than 160 countries, and over 40 Standard Industrial Classification (SIC) industries served. We offer 11 different additive manufacturing processes, working with more than 90 materials and finishes. With purpose-built, proprietary software powering everything we do, we’re confident in our ability to continue to meet the new expectations of Additive Manufacturing 2.0.

Our technology- and material-agnostic approach has enabled us to always work with our customers to find the exact right combination for their specific needs. Quality is at the heart of what we do, as we can guarantee the work we do using technologies and materials we trust. We’re also expanding these offerings, as we’re set to work with supply chain partners to broaden availability to injection molding and sheet metal as well. The key here is always finding the best solution, not just one that might work.

With Additive Manufacturing 2.0 fitting neatly alongside traditional manufacturing technologies, complementary processes can now truly work together for solutions to fit every need.

Freelance author Sarah Goehrke is the founder of Additive Integrity, and sits on the Board of Directors for Women in 3D Printing.

The post Additive Manufacturing 2.0 Is Here appeared first on Shapeways Blog.

• The origins of stereolithography (SLA), and why it is still considered such a powerful form of 3D printing today.
• The scalability of 3D printing with advanced SLA technology and advanced materials.
• How Accura 60 possesses similar properties to popular materials like molded Polycarbonate (PC).
• Why Accura Xtreme is an excellent choice for creating master patterns used in injection molding.
• When to turn to materials like Accura Xtreme 200 for tough parts.

Stereolithography (SLA) is notably the oldest form of 3D printing, per the historical days of pioneers like Chuck Hull and other engineers looking for better ways to perform rapid prototyping and improve product development. Like Selective Laser Sintering (SLS), this is still one of the most respected and powerful forms of technology which has continued to advance along with the entire additive manufacturing industry, widely used for creating 3D models, master patterns, and functional parts.

For designers and engineers who understand how to lean into the many benefits of SLA, the results can be impressive for manufacturing precise, high-quality industrial parts that require smooth surface finishes and more intricate detail than others; in fact, that is one reason industrial users may use SLA as a go-to technology over SLS—when seeking intense detail and dimensional accuracy. SLA 3D printing can also be used as an accompaniment to more conventional manufacturing practices like injection molding, 3D printing the molds for making a versatile range of industrial parts.

Understanding SLA 3D Printing Technology

Settled into the vat polymerization category—along with direct light processing (DLP)—SLA relies on lasers and resin to build 3D printed structures. A powerful laser solidifies, or cures, each thin layer of liquid resin deposited onto the build platform at the top of the resin tank. As the platform moves up and out of the resin tank, the part is 3D printed in a repetitive process building the part layer by layer.

A high-powered laser beam traces or draws the design of the part in each layer, which then solidifies, or cures, due to the heat of the laser. The average layer height in SLA 3D printing is about 100 microns, with a minimum of 25 microns. The potential for accuracy and precision are hard to top—especially when enhanced by advanced materials from Shapeways. Strong adhesion is another huge benefit stemming from SLA, creating an excellent foundation from the start in each print, and eliminating worries over structural integrity later.

SLA 3D printing is also appealing to Shapeways customers because it is so scalable, offering the ability to manufacture small, intricate, but accurate parts—as well as larger structures with much greater build volumes and the same fantastic surface quality.

SLA 3D Printing Materials

Accura® 60

As trends continue toward highly industrial, critical applications, Shapeways customers turn to advanced SLA materials like the following: This clear plastic produces rigid and durable parts with similar properties to molded Polycarbonate (PC). It has the ability for fine details making it apt for tough, functional prototypes, lighting components, medical instruments and fluid flow and visualization models.

Accura® Xtreme

A material with similar physical properties to polypropylene and ABS, Accura® Xtreme is an ultra-tough grey plastic with outstanding durability, accuracy, moisture and thermal resistance and the ability for great detail. It is ideal for snap fit assemblies, enclosures for consumer and electronic products, master patterns for vacuum casting, and general purpose prototyping.

Accura® Xtreme 200

This white plastic is the toughest SLA material available and can replace CNC-machined polypropylene and ABS articles. It is perfect for projects that must withstand extreme, harsh conditions making it ideal for challenging functional assemblies. It can be applied to similar projects as Accura Xtreme as well projects that demand the highest durability like automotive parts, drill/tap applications, assemblies with self-tapping screws, enclosures for consumer electronic components, general purpose prototyping, and master silicone molding.

Applications Suitable for SLA Materials

All three of these SLA materials produce rigid, robust parts that resist breakage and are durable enough to create functional parts as well as provide excellent detail and accuracy. SLA Plastics are printed on large format 3D printers which is great for creating more sizable parts for visual prototypes, short-run production, and mass customization including specific applications such as:

• Master patterns for vacuum casting
• Shell investment casting patterns for metal casting
• Complex assemblies
• Wind tunnel models
• Rapid production of flow test rigs
• Mass customization production (orthodontic, dental)
• Custom assembly jigs and fixtures

These materials have a larger build volume than standard SLA technology, which means your projects will have less limitations. Following through on your latest innovations all begins with that first upload! Create an account with Shapeways and upload a 3D model now, along with receiving an instant quote.

Support Structures and Post Processing for SLA 3D Printing

SLA 3D printing does not end with the 3D printer. Support structures are always required for SLA 3D printing, but with proper design and part orientation, they can be reduced as much as possible. These types of structures are much thinner in SLA 3D printing, and although dealing with them in post-processing can be a slight hassle, their presence allows for greater latitude in creating complex geometries and expanding innovation.

Supports aid in stabilizing complex geometries during printing, along with protecting models that may include overhangs extending outward from the design. Supports keep models 3D printed with SLA in place on the print bed, offset high temperatures in some cases, prevent warping, curling, and sagging, and overall, reduce the potential for misshapen or collapsed prints.

Ultimately, post processing presents the opportunity to finish parts with impressive quality. Before removing supports, each SLA part is washed clean of extra material, typically employing a bath of one or more solvents to remove unwanted resin. Parts must dry completely, and then can be post-cured with UV light and higher temperatures to ensure the highest quality in finish and mechanical properties too. Supports are removed with caution, however, models may still bear marks left over from removal. They can be easily sanded away at the end of the post-processing phase though.

About Shapeways

Shapeways has worked with over 1 million customers in 160 countries to make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here. Contact Shapeways now to enjoy the benefits of advanced technology and materials for 3D printing with accuracy, complex detail, and no limits in terms of mass customization or single part orders.

The post SLA 3D Printing Materials: Focus on the Finer Details appeared first on Shapeways Blog.

Industrial 3D Printing Continues to Gain Traction

Brought to light by Chuck Hull in 1983, SLA 3D printing came about in response to the inventor’s need for more rapid prototyping of plastic parts. The long-ago desire to create higher quality products faster and with a more streamlined workflow still resonates with designers, engineers, and industrial companies, reflected in action as SLA 3D printing hardware and software continue to be refined, with a focus on the potential for mass customization.

Groundbreaking concepts like Shapeways on-demand 3D printing are taking hold too, fulfilling the manufacturing of customized products as needed in limited quantities, and carrying the process all the way to the end, even to include shipping in custom packaging. Businesses of all sizes are able to cut back on inventory, reducing the need for warehouses altogether, and enjoying small runs of high-quality products.

Since the 1980s, 3D printing has progressed into a billion-dollar industry that just continues to grow. As patents began to expire around 2014 3D printing continued to solidify its presence on nearly every level just as predicted, from the DIY market to the highest industries relying on additive manufacturing not only for test parts but also for high-performance, functional parts in applications like medicine, aerospace, automotive, and much more.

Why Stereolithography Is Still Such a Good Fit in Additive Manufacturing

Surprisingly, the original additive manufacturing methods have been hard to beat over the last few decades, and serious users continue to return to technology like SLA 3D printing, as well as selective laser sintering (SLS). For designers and engineers who understand how to lean into the many benefits of SLA, the results can be impressive for manufacturing precise, high-quality industrial parts that require smooth surface finishes and more intricate detail than others; in fact, that is one reason industrial users may use SLA as a go-to technology over SLS—when seeking intense detail and dimensional accuracy. SLA 3D printing can also be used as an accompaniment to more conventional manufacturing practices like injection molding, 3D printing the molds for making a versatile range of industrial parts.

Settled into the vat polymerization category—along with direct light processing (DLP)—SLA relies on lasers and resin to build 3D printed structures. A powerful laser solidifies, or cures, each thin layer of liquid resin deposited onto the build platform at the top of the resin tank. As the platform moves up and out of the resin tank, the part is 3D printed in a repetitive process building the part layer by layer. A high-powered laser beam traces or draws the design of the part in each layer, which then solidifies, or cures, due to the heat of the laser.

The average layer height in SLA 3D printing is about 100 microns, with a minimum of 25 microns. The potential for accuracy and precision are hard to top—especially when enhanced by advanced materials from Shapeways. Strong adhesion is another huge benefit stemming from SLA, creating an excellent foundation from the start in each print, and eliminating worries over structural integrity later.

SLA 3D printing is also appealing to Shapeways customers because it is so scalable, offering the ability to manufacture small, intricate, but accurate parts—as well as larger structures with much greater build volumes.

Advanced Applications Require Advanced Materials & Technology

As trends continue toward highly industrial, critical applications, Shapeways customers still turn to advanced materials made for SLA 3D printing.

SLA Plastic Accura® 60: Available in semi-clear, this rigid acrylate-based plastic material lends the transparency many designers seek for a wide range of parts to be used in important applications like medicine, as well electronics like lighting.

Relying on Accura 60 for high-performance products, medical professionals can order 3D printed medical instruments like forceps, clamps, or specialized handles on-demand. Even more popular are models 3D printed with SLA for pre-visualization of surgeries. In 3D printing medical models that are specific to the patient, surgeons can focus on diagnosis, treatment, and begin preparing for rare or altogether new procedures. Models and guides can also be used in the operating room, reducing time in surgeries, recovery time, and aiding in a better experience for the patient, ultimately, in terms of their treatment and comfort.

Other Shapeways customers use Accura 60 for a variety of impressive lighting components, designing 3D models for tough, functional parts that may be used indoors or outdoors, and in commercial or residential environments. Because it is possible to print with such thin layers of resin, Accura 60 offers the complete transparency often necessary for use with more utilitarian devices like casings or vents. SLA 3D printing also allows for intricate details like grooves, small holes to facilitate hanging or attaching, openings to expose keypads or screens, and countless other uses.

SLA Accura® Xtreme presents advantages that are required for serious industrial mechanical parts like snap-fit assemblies, enclosures whether engineers are designing parts for consumer products or electronics, as well as other more specialized applications like master patterns for vacuum casting, a process that uses a vacuum to draw liquid material into a mold where the desired structure is then formed.

Enhanced strength and durability along with water and heat resistance make Accura Xtreme even more appealing to industrial users, along with excellent surface texture that compares to parts made with conventional techniques. This rigid acrylate-based plastic is available in ultra-tough grey plastic, which is better for fine details, and suitable for 3D printing a wide variety of versatile parts, to include frames for eyeglasses, as well as both the front and back components of casings that must connect with tiny, intricate snaps, and parts that must twist and fasten together with precisely manufactured grooves. Cylindrical parts can also be 3D printed with a variety of detail, no matter what size.

SLA Accura® Xtreme 200 – This material is the toughest that Shapeways offers for industrial applications in SLA 3D printing. Available in ultra-tough white acrylate-based plastic—best for smooth appearances—this resin offers all of the best features, from durability to great dimensional accuracy and surface finish. Accura Xtreme 200 stands apart, however, due to its extreme strength. Taking industrial additive manufacturing to the next level, Accura Xtreme 200 is used for functional parts in automotive applications, able to withstand stress and strain, as well as exposure to the elements or other harsh environments.

Accura Xtreme 200 is also used for other mechanical parts requiring intensive durability, to include drill-tap applications, assemblies with self-tapping screws, enclosures for electronics, and also as SLA 3D printed master patterns for urethane casting, where silicone molds are filled with polyurethane to achieve a desired structure. Parts are not only strong, but they are also extremely accurate, making it easy to 3D print detailed areas for parts that snap or attach to other parts, areas for ventilation, and a variety of areas on parts that may be raised or indented, or require ornate features for functionality.

This material is also used to replace items which may have previously been manufactured through conventional techniques with CNC-machined polypropylene or Acrylonitrile Butadiene Styrene (ABS), a commonly used thermoplastic polymer.

Support Structures & Post-Processing Procedures for SLA 3D Printing

SLA 3D printing does not end with the 3D printer. Support structures are always required for SLA 3D printing, but with proper design and part orientation, they can be reduced as much as possible. These types of structures are much thinner in SLA 3D printing, and although dealing with them in post-processing can be a slight hassle, their presence allows for greater latitude in creating complex geometries and expanding innovation.

Supports aid in stabilizing complex geometries during printing, along with protecting models that may include overhangs extending outward from the design. Supports keep models 3D printed with SLA in place on the print bed, offset high temperatures in some cases, prevent warping, curling, and sagging, and overall, reduce the potential for misshapen or collapsed prints.

Ultimately, post processing presents the opportunity to finish parts with impressive quality. Before removing supports, each SLA part is washed clean of extra material, typically employing a bath of one or more solvents to remove unwanted resin. Parts must dry completely, and then can be post-cured with UV light and higher temperatures to ensure the highest quality in finish and mechanical properties too. Supports are removed with caution, however, models may still bear marks left over from removal. They can be easily sanded away at the end of the post-processing phase though.

Explore Expanded Options With Shapeways

For products like Accura Xtreme, it is possible to achieve enhanced optical clarity, but that option is not included for standard orders. Contact the Shapeways Sales Team to discuss additional post-processing options. Start by scheduling a one-on-one consultation with a 3D printing expert and let the Shapeways team provide the best solutions to fit your manufacturing needs!

Get Help from the User Application Team

The Shapeways User Application Team is available for extended help in 3D printing. In some cases, customers may be curious about pushing the limits of technology and materials to produce a unique part or for example, a high-end piece of designer jewelry. While 3D design and 3D printing are methods born from a refusal to accept limits in innovation, the reality is that parts simply are not printable if the proper materials are not researched ahead of time, and used with a suitable technology.

The UA team can be very helpful in exploring the compatibility of materials, as well as modifying print orientations to help improve the quality—and printability—of a model. Expert file fixers can offer advice on how to fix problematic files as well as sometimes working their magic on models that initially were not printable at all. Shapeways file fixers are also adept at helping customers tackle other unique issues that may stand in the way of successful 3D printing.

Upload Your 3D Model Now

Following through on your latest innovations all begins with that first upload! Create an account with Shapeways and upload a 3D model. The automated system performs a printability analysis, and also sends an instant quote.

About Shapeways

Enjoy the benefits of SLA 3D printing technology and materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 20 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Everything You Need to Know About SLA 3D Printing for Industrial Applications appeared first on Shapeways Blog.

Precise, specialized, and powerful.

As the original 3D printing technology, Stereolithography still reigns in the production of finely detailed, complex geometries. Chuck Hull produced his first part on an SLA 3D printer in his small lab in 1983, and that small, resin-based part set a revolutionary manufacturing trend in motion. Decades later, SLA 3D printing has made impacts in nearly every industry imaginable.

Shapeways offers a versatile range of advanced 3D printing services, continually expanding options for industrial manufacturers–whether resin-based, thermoplastics, steel, or precious metals. The goal is to ensure compatibility of 3D printing materials and technology for maximum printability and quality. Engineers tend to design 3D models for SLA technology when making smaller, detailed parts.

What is SLA 3D Printing?

Operating under the subcategory of vat polymerization, SLA technology relies on liquid resin to build 3D models. Objects are cured and solidified by UV light as each thin layer of material is deposited onto the build platform at the top of the resin tank. During the SLA process, a laser traces or draws the design of the part in each layer. 

Famous for accuracy and precision, this 3D printing process offers strong adhesion between layers, resulting in good structural integrity for parts and superior dimensional accuracy. The average layer height for SLA technology is 100 microns, with a minimum of 25 microns. 

Stereolithography technology has advanced over decades, always in step with the momentum of the 3D printing industry. Designers and engineers rely on SLA 3D printing for expedient low-volume production of complex master patterns for molds in traditional technology like Injection Molding, as well as additive manufacturing for 3D printed models and industrial parts.

SLA 3D Printing in Product Development

While it may have taken decades for SLA 3D printing to infiltrate the mainstream market, 3D printing played a continued role in success behind the scenes.. With advancements in SLA 3D printing, it is possible to make products that would have been impossible with traditional manufacturing, prompting innovation for complex prototypes for automotive and aerospace.

SLA 3D printing is more accessible now than ever, making it possible to create detailed, realistic products for a wide range of applications, many of which are within the medical industry:

“Stereolithography is particularly versatile with respect to the freedom of designing structures and the scales at which these can be built: submicron-sized structures as well as decimetre-sized objects have been fabricated. In the biomedical field, these developments have led to the fabrication of patient-specific models for mold-assisted implant fabrication, aids for complex surgery, and tailor-made parts such as hearing aids. More recently, biodegradable materials have been developed for the preparation of medical implants, such as tissue engineering scaffolds, by Stereolithography,” state researchers in ‘A review on stereolithography and its applications in biomedical engineering.’

Without 3D printing, traditional manufacturers remain stalled during prototyping and development, which can impact deadlines and overall cost. Shapeways customers are reliant on SLA 3D printing services for rapid prototyping to accelerate research and development, making it possible to garner feedback expediently. 

The Benefits of SLA in Additive Manufacturing

SLA 3D printing provides good mechanical qualities and a smooth surface finish, making it a popular choice for 3D models or prototypes requiring a realistic look.

Although SLA additive manufacturing technology is used for functional parts, manufacturers rely on 3D printed rapid prototyping services more than ever before. One important difference is that now they may use the same material and technology for both prototyping and functional use. This is made easier due to the ever-growing selection of advanced 3D printing materials and technology.

No lead time is required. Designers have the freedom to choose when they want to design, prototype, and manufacture. At Shapeways, the process is as easy as uploading a 3D model and getting an instant quote back along with file analysis to ensure quality SLA 3D printing. While some customers may create prototypes for intricate 3D printed architectural displays or for client presentations, others may be iterating their way to perfection. 

The 3D printed rapid prototyping process with SLA technology and materials could require a couple of different iterations before product development moves on to the final part, but there are some Shapeways customers who go through a much more intense process, prototyping, making changes after feedback, and then continuing to iterate over a hundred times.   

SLA 3D Printing Materials and Applications 

Manufacturers continue to be loyal to SLA 3D printing over other technology, including desktop 3D printing, because of the need for detail and accuracy as well as the versatility to make a variety of smaller parts like industrial jigs and molds. 

3D printing acrylate materials are extremely effective but present challenges too, and researchers have outlined their findings in recent work:

“Acrylate-based resins are common in the SLA process, as they exhibit high reactivities, which is advantageous for fast building speeds. Different types of acrylates are readily available to tune mechanical properties and thermal resistance for example by altering the number of reactive groups or by employing different oligomers such as urethane acrylates. One disadvantage of acrylate resins is their high-shrinkage during printing, causing potential distortion of the printed part. As a solution, the combination with methacrylates is often implemented,” state researchers in ‘Experimental Characterization Framework for SLA Additive Manufacturing Materials.’

Originally the number of materials may have been somewhat limited for SLA users, but Shapeways has remained dedicated to offering more as users are moving past using 3D printing as solely a prototyping tool and making high-performance parts for critical applications. 3D printing users have much higher expectations too as they make designs with greater complexity, requiring quality materials that promise higher performance and smoother surface finish.

SLA additive manufacturing materials and corresponding applications include:

SLA Plastic Accura® 60

Also referred to as Clear Plastic, Clear SLA, or Translucent Resin, this SLA 3D printing acrylate is semi-clear in color, rigid, and offers watertight properties. SLA Plastic Accura® 60 is recommended for SLA 3D printing projects that require complex functional assemblies which must also be transparent, to include industrial parts like:

• Technical accessories
• Lighting components
• Casting patterns
• Snap-fit assemblies
• Prototypes and models

SLA Plastic Accura 60 is offered in a standard, semi-clear finish, and 3D printed products are sanded lightly to remove any potential nubs that may be leftover from support removal. This material may also present slight variations in clarity and texture over the surface of the 3D model, depending on 3D printing orientation and post-processing procedures. It is possible to achieve further optical clarity in post-processing, but that level is generally not included with standard orders using this SLA 3D printing material.

For this material, 3D models must meet the following minimum and maximum bounding box sizes:

Bounding Box Min

3.8 x 3.8 x 3.8 mm

Bounding Box Max

609 x 711 x 457 mm

Find out more about SLA Plastic Accura 60 design guidelines here. 

SLA Plastic Accura® Xtreme

A gray acrylate-based plastic suitable for 3D printing a versatile range of prototypes and parts at any size, SLA Plastic Accura® Xtreme is also known as Gray SLA or Gray Resin. This material is also watertight, good for printing on the small and large scale, and is used for complex, functional assemblies for applications like:

• Tech accessories
• Mechanical components
• Snap-fit assemblies​

Using SLA technology, Plastic Accura Xtreme 3D printed parts are known for their high resolution and detail. Offered in a standard gray finish, this material is also good for 3D printing parts with smooth surfaces and limited layer lines–similar to the finish that can be achieved through injection molding–but without the added time or expense. 

For Plastic Accura Xtreme, SLA 3D models must be within the following minimum and maximum bounding box sizes:

Bounding Box Min

3.8 x 3.8 x 3.8 mm

Bounding Box Max

482 x 482 x 558 mm

Find out more about SLA Plastic Accura Xtreme design guidelines here.

Accura® Xtreme 200 

A watertight photopolymer resin, Accura® Xtreme 200 offers benefits like dimensional accuracy in parts, excellence in strength, durability, and surface finish. This versatile 3D printing material is a white acrylate also referred to as White SLA, White Resin, or Accura Xtreme White 200.

Accura Xtreme 200 is an ultra-tough material recommended for the following industrial 3D printed parts:

• Mechanical parts
• Display models
• Snap-fit assemblies
• Master patterns for vacuum casting

Offered in a standard white finish, products are sanded lightly to remove any nubs from support removal, although some markings from supports may remain. 

For this material, 3D models must be within the following minimum and maximum bounding box sizes:

Bounding Box Min

3.8 x 3.8 x 3.8 mm

Bounding Box Max

609 x 711 x 457 mm

Find out more about SLA Accura Xtreme 200 design guidelines here.

About Shapeways

Enjoy the benefits of this advanced technology and a wide range of materials from Shapeways for 3D printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Shapeways has worked with over 1 million customers in 160 countries to 3D print over 21 million parts! Read about case studies, find out more about Shapeways additive manufacturing solutions, and get instant quotes here.

The post The Expert Guide to Stereolithography (SLA) 3D Printing appeared first on Shapeways Blog.

“Deep Facade” from ETH Zurich Uses 3D Printing to Produce Complex Geometric Shapes

Deep Facade is a 6×4 meter aluminium structure composed of 26 sections of looping metal cast in a 3D printed open sand mold. It was created by students from the Digital Fabrication course at ETH Zurich in 2018 and evokes the folds of the cerebral cortex. This process makes use of the computational design method called topology optimization, where lightweight material can be used to create highly stable and efficient structures. They used binder jetting technology to fabricate the sand molds which allowed them substantial geometric freedom and sped up the fabrication process due to fast printing time, eliminating patternmaking and reducing material waste. The complexity of the geometric shapes of Deep Facade would not have been possible without the use of digital design and 3D printing. Each mold took under 12 hours to print and once printing began the facade itself was formed in less than half a week. The students’ work on Deep Facade demonstrated that the production of parts with 3D printed sand molds was faster and cheaper than traditional mold making methods, and also showed how efficiently one of a kind complex geometric designs could be produced.

FIT Additive Manufacturing Group’s “Facade 3000” Demonstrates the Potential for Mass Individualization with 3D Printing

In Lupburg Germany, FIT created a 3D printed aluminium facade for its boarding house made up of panels each with its own complex pattern of cavities to showcase how to use 3D printing in construction to favor economical individualization. The panels each have a unique arrangement of cavity shapes, each created using aluminium inserts in the molds. They were able to produce 20 different panels simultaneously in rotation. This method of producing unique panel pieces demonstrates that 3D printing is a key resource when it comes to the future of cost-effective mass-individualization and customization in construction.

1 South First Building by COOKFOX Architects Finds Higher Productivity and Durability with 3D Printed Molds

The new building at the site of the former Domino Sugar Factory in Brooklyn, NY. consists of two interlocking structures with facades of all-white concrete precast from 3D printed molds. The crystalline facades were designed to emulate sugar crystals and are self-shading with each piece shaped according to its solar orientation. The variations in the panels meant that over 100 different molds were needed, and creating each one took between 14-16 hours instead of taking 40-50 hours each if the molds were made traditionally. The efficiency of the molding process freed up substantial time and the 3D printed molds proved to be more durable than traditional wood and fiberglass molds (which can be used up to 10 times), as they were able to be reused 150-200 times.

Rainier Square Tower in Seattle by 3Diligent Corp x Walters & Wolf Use 3D Printed Parts for Better Accuracy and Reliability

In order to create an upward slope from the 4th to the 40th floor in the 59-story Rainier Square Tower in Seattle, Walters & Wolf and digital manufacturing company 3Diligent Corp printed aluminium nodes and wall curtains. 140 3D printed v-shaped nodes and square cut pieces of curtain wall were custom fabricated to geometrically accommodate a different angle for each section of the building. 3Diligent gave Walters & Wolf the option between investment casting and 3d printing and Walters & Wolf decided to use the 3D printed nodes because of their level of precision and structural integrity. Each node was created with varying dimensions up to a cubic foot, another testament to the efficiency and flexibility of 3d printing.

The “Fluid Morphology” Project in Munich Make Use of Fast Prototyping to Develop Functionally Integrated Facades

At the Technical University in Munich, Moritz Mungenast and Studio 3F began a project to create a 3D printed facade envelope that integrates ventilation, insulation and shading to become the new facade of the Deutsches Museum in 2020. The facade design is flowing and translucent, resembling Shapeways’ translucent material Accura 60. Studio 3F built a 1.6×2.8 meter section to test for a year to improve the design before making another polycarbonate prototype. The team was able to print 1:1 scale models and prototypes along the way with ease, meaning they were able to fully comprehend the viability of their design, determine production costs, communicate their ideas to their clients and continue developing what they hope to be a widely used facade technology that combines form and function.

In addition to these innovative projects, more and more architecture firms are utilizing 3D printing to achieve a higher level of freedom in design and as a way of making processes more time and cost efficient. 3D printed molds hold up better than traditional wood casts and have a higher range of possibility when it comes to complex geometric shapes. Because of the range of materials available, 3D printing also assures a level of structural reliability for the printing of end-use parts.

Shapeways can print with a variety of materials, including stainless steel, translucent and high strength plastics, and can help you get started with producing custom molds and parts.

The post 5 Benefits of Using 3D Printing in Facade Architecture and Construction appeared first on Shapeways Blog.

One of the first 3D printing technologies developed, Stereolithography (SLA) has been widely used for creating models, prototypes and patterns. To produce parts using SLA systems, a laser selectively cures liquid resin in a resin bath above it, moving up layer by layer until the part is complete. Using large format SLA technology, you will be able to produce much larger parts than other resin-based technologies while achieving similar fantastic surface quality.

Our SLA Plastic launch includes the following three acrylate-based materials:

Accura® 60

This clear plastic produces rigid and durable parts with similar properties to molded Polycarbonate (PC). It has the ability for fine details making it apt for tough, functional prototypes, lighting components, medical instruments and fluid flow and visualization models.

Accura® Xtreme

A material with similar physical properties to polypropylene and ABS, Accura® Xtreme is an ultra-tough grey plastic with outstanding durability, accuracy, moisture and thermal resistance and the ability for great detail. It is ideal for snap fit assemblies, enclosures for consumer and electronic products, master patterns for vacuum casting, and general purpose prototyping.

Accura® Xtreme 200

This white plastic is the toughest SLA material available and can replace CNC-machined polypropylene and ABS articles. It is perfect for projects that must withstand extreme, harsh conditions making it ideal for challenging functional assemblies. It can be applied to similar projects as Accura Xtreme as well projects that demand the highest durability like automotive parts, drill/tap applications, assemblies with self-tapping screws, enclosures for consumer electronic components, general purpose prototyping, and master silicone molding.

All three of these SLA materials produce rigid, robust parts that resist breakage and are durable enough to create functional parts as well as provide excellent detail and accuracy. SLA Plastics are printed on large format 3D printers which is great for creating more sizable parts for visual prototypes, short-run production and mass customization including specific applications such as:

• Master patterns for vacuum casting
• Shell investment casting patterns for metal casting
• Complex assemblies
• Wind tunnel models
• Rapid production of flow test rigs
• Mass customization production (orthodontic, dental)
• Custom assembly jigs and fixtures

These materials have a larger build volume than standard SLA technology, which means your projects  will have less limitations. We are excited to see what you create!

The post Introducing Three Tough SLA Plastic Materials appeared first on Shapeways Blog.