Whether customers are designing fine jewelry with handcrafted touches to be cast in precious metal or engineering critical parts for aerospace, Shapeways is dedicated to helping everyone translate their ideas into 3D print.

Matching Compatible Materials with Models for 3D Printing Success

Creating a successful product hinges on bringing together a quality design with the right 3D printing materials and technology. Shapeways makes this endeavor easier than ever with automated printability analysis, activated when a customer uploads a 3D model. 

The User Application team is also available to answer questions about potential issues with printing complex geometries–as well as offering assistance with larger 3D printing orders.

“We are there to help with any and all questions about design, materials for the 3D printing, or the processes that make our customers’ models come to life,” says Zach Dillon, User Application Team Lead at Shapeways.

Find out more below about popular materials for 3D printing at Shapeways, including a host of powerful technology options, colors, and finishes.

Nylon 12 [Versatile Plastic] is a 3D Printing Industry Favorite

Shapeways customers choose Nylon 12 [Versatile Plastic] for countless applications, whether 3D printing drone prototypes and then going on to make functional parts with the same materials–or manufacturing critical devices like detailed medical models and colorful 3D printed surgical training platforms.

Aptly named, versatility for this 3D printing nylon material is linked to the combination of Selective Laser Sintering 3D printing and the material’s high ductility, allowing for great flexibility in thinner pieces but a rigid structure with more substantial parts. Featuring other good mechanical properties like tensile strength and abrasion resistance, Nylon 12 [Versatile Plastic] is durable enough to withstand the iteration process, and will hold up over the long term serving in critical applications and even harsh environments.

Expanded design freedom in SLS offers a huge advantage, especially without any need to make support structures. Hundreds or even thousands of parts can be packed into one build via nesting, increasing efficiency while decreasing the potential for damage in post-processing.

Options for Nylon 12 3D Printing Finishes

Shapeways Premium Nylon 12 [Versatile Plastic] offers an upscale finish, elevating designs with a smoother and glossier surface, and resulting in a surface texture that is soft to touch. The Premium finish is recommended for the following:

• Interlocking parts
• Fine jewelry
• Home decor and art pieces
• Accessories like phone cases

Shapeways employs a multi-step tumbling, polishing, and dyeing process to create a consistent color and surface finish, while removing the grainy feel and layered look of 3D printed parts.  

Other finishes and colors for Nylon 12 [Versatile Plastic] include:

• Natural – This matte standard finish has a slightly rough surface.
• Processed – Some material is polished away to create a smoother surface.
• Smooth – Offering the smoothest surface, with a slight shine, this finish is attained via vapor smoothing.
• Colors: Versatile Plastic is naturally white. Shapeways also offers Black, Pink, Red, Orange, Yellow, Green, Blue, and Purple.  

For Nylon 12 [Versatile Plastic], 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • X + Y + Z ≥ 7.5 mm (Natural)
  • X + Y + Z ≥ 25.0 mm and axes must be ≥ 2.5 mm (Processed & Premium)
  • 10 x 10 x 10 mm (Smooth)
• Bounding Box Max
  • 650 × 350 × 550 mm (Natural White)
  • 180 × 230 × 320 mm (Natural & Smooth Black)
  • 200 × 150 × 150 mm (Processed & Premium)
  • 345 × 375 × 440 mm (Smooth White)
  • [Parts over 330 mm long in any direction may have a visible line due to our dual laser printer]

Find out more about the design guidelines for Nylon 12 [Versatile Plastic] here.

Addigy® P3001 is a Strong Performer in Footwear & Sports Protection

Addigy P3001 is another extremely versatile 3D printing material. Offering excellent mechanical properties like good ductility and high elongation at break, this thermoplastic elastomer is made up of both hard (Polyester) and soft (Polyether) segments. Addigy P3001 is popular with manufacturers due to its flexibility for 3D printing interlocking and industrial parts, while consumer goods and apparel companies are drawn to features like high energy return and biocompatibility.

Addigy P3001 meets ISO 10993 standards for biocompatibility, including cytotoxicity. This 3D printing material, regardless of finish, should not cause skin irritation or sensitivity. Because there are no plasticizers like PCBs in Addigy P3001, this material is also suitable for manufacturing toys. Another benefit is easy printability with little to no smoke or odor during production.

This thermoplastic is available in Natural and Smooth glossy finishes in black and white, and is suitable for interlocking parts, seals and gaskets, grips and handles, footwear, and protective gear.

For Addigy P3001, 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  •  X + Y + Z ≥ 15 mm
• Bounding Box Max
  • 190 × 190 × 290 mm

Explore the design guidelines for Addigy P3001 here.

Full Color Materials for 3D Printing

Color plays a vital role in 3D design, offering realism, vibrancy, and elevated style. This holds true in the case of full color 3D printed gaming miniatures, architectural models, and 3D printed medical models. Full color 3D printing may also be chosen for more utilitarian and industrial applications like electronics, where sensors must be different colors to delineate specific uses. 

Nylon 12 [Versatile Plastic] is available in an array of colors, but Shapeways also offers more expanded materials for 3D printing with color, to include:

High Definition Full Color is in demand by customers seeking more intense detail, and the ability to choose from ten million colors. The range of 3D print colors includes a full spectrum of eye-popping hues, achieved by using color profiles with specific data for characterization. High Definition Full Color allows for pre-visualization of models, exact color matches, shading, and contrast.

Shapeways High Definition Full Color prints are manufactured on the high-production Mimaki 3DUJ-553, featuring a build size of 508 x 508 x 305 mm. While other color printers offer a variety of benefits, the industrial-grade 3DUJ-553 is founded on Material Jetting (MJ) technology, employing eight unique piezoelectric print heads. Converting mechanical energy into electricity, the printheads deposit liquid photopolymer droplets to be cured with UV light. 

Speed and precision, along with the ability to produce robust colors and textures make MJ 3D printing uniquely powerful. While MJ 3D printing is popular for rapid prototyping, this technology is paired with High Definition Full Color for functional models, products, and useful applications.

Most designers choose High Definition Full Color when seeking fine detail with expanded gradients and textures. Designers can use 3D models with thinner walls for more complex designs, even at a minimum of 1 mm, which amounts to the thickness of a credit card.

For High Definition Full Color, 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 2.5 x 2.5 x 2.5 mm
• Bounding Box Max
  • 495 x 495 x 300 mm

Full-color models produced with High Definition Full Color are available in standard and matte finish.  

Find out more about High Definition Full Color 3D design guidelines here.

Nylon 12 in Full Color with Multi Jet Fusion possesses superior mechanical properties, dimensional stability, and good resistance to impact, as well as chemicals like oil and grease. Defined by the capacity to deform under tensile stress, Nylon 12 Full Color (MJF) is flexible for structures with a thinner design but becomes rigid for use with thicker parts, offering the durability and density required for end-use parts.

Manufacturers enjoy greater freedom in engineering and design of parts because (like SLS 3D printing) support structures are not required for MJF 3D printing. As a result, hundreds or even thousands of parts can be nested together in one build, manufactured with accuracy and repeatability every single time.

Operating as a subcategory of powder-based additive manufacturing, Multi Jet Fusion does not rely on a laser for heat or adhesion of the 3D printing layers; instead, this 3D printing technology uses an inkjet array that moves back and forth depositing adhesive agents onto the powder bed, where the nylon particles are melted with thermal heat. 

This highly adaptable material is available for Nylon 3D print in Natural and Smooth glossy finishes–suitable for products like jigs and fixtures, braces and casts, interlocking parts, medical models, and prototypes for testing.

For Nylon 12 Full Color Multi Jet Fusion, 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 4 x 4 x 1 mm or X + Y + Z > 9 mm (Natural)
  • 10 x 10 x 10 mm (Smooth)
• Bounding Box Max
  • 130 x 75 x 99 mm

Explore the design guidelines for Nylon 12 Full Color Multi Jet Fusion here. 

Heat Resistant Materials for 3D Printing

Using the same materials for prototyping and manufacturing means placing added emphasis on materials like Nylon 11 [PA11(SLS)], especially when seeking heat-resistance, impact-resistance, or corrosion-resistance.

Shapeways offers the following in heat resistant 3D printing materials:Nylon 6 Mineral Filled (PA6MF) 

This material is especially well-suited for automotive applications–including 3D printed auto parts in close proximity to the engine. PA6MF is 3D printed with Selective Laser Sintering (SLS) and offers great heat resistance, strength, and stiffness. Filled with mineral reinforcements, this 3D printing material is imbued with enhanced impact resistance, featuring isotropic rigidity and properties similar to injection molded parts without causing added time and expense. Designers and engineers choose materials like PA6MF for 3D printing for structural parts and high-performing, functional prototypes.

The heat deflection temperature for PA6MF is 209°C. 

For PA6MF, 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • X + Y + Z > 10 mm
• Bounding Box Max
  • 375 x 375 x 440 mm

Find out more about this industrial 3D printing material and accompanying design guidelines here.

Nylon 11 [PA11(SLS)] offers durability and heat resistance, 3D printed with Selective Laser Sintering (SLS). Often targeted for use in automotive, aerospace, and drone applications, this material is well-known for its ability to hold up to rigorous conditions like heat and weather. Excellent impact resistance makes this 3D printing material suitable for parts like sports protection equipment. Nylon 11 [PA11(SLS)] is also resistant to a wide range of chemicals. 

The heat deflection temperature for this material is 180°C. 

For Nylon 11 [PA11(SLS)], 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 0.7 × 0.7 × 0.7 mm
  • X + Y + Z ≥ 7.5 mm
• Bounding Box Max
  • 200 × 200 × 300 mm 

Find out more about Nylon 11 [PA11(SLS)] and accompanying design guidelines here.

MJF Plastic PA12 is 3D printed with Multi Jet Fusion. A heat-resistant thermoplastic meant to support complex geometries and detailed parts, MJF Plastic PA12 is in demand for dimensionally accurate products with finely tuned mechanical properties. This material offers great strength, durability, and stiffness. Suited for a wide range of applications, MJF PA12 is 3D printed for durable end-use goods, including high-performance industrial parts, smaller components like mounts, brackets, and consumer goods.

The heat deflection temperature for MJF Plastic PA12 is 95°C. For this material, 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 4 x 4 x 1 mm or X + Y + Z > 9 mm (Gray and Black Natural)
  • 10 x 10 x 10 mm (Smooth)
• Bounding Box Max
  • 284 x 380 x 380 mm (Gray Natural and Black Smooth)
  • 210 x 210 x 360 mm (Black Natural)

Note: Parts covering the exact maximum bounding box dimensions might not be printable due to printer limitations.

Find out more about this popular 3D printing material and accompanying design guidelines here.

MJF PA12 Glass Beads (MJF PA12GB) 

3D printed with Multi Jet Fusion, MJF PA12GB is an excellent choice for applications like large, flat parts that may be prone to warping with other materials. This material is suitable for high-performing 3D printed parts that require high strength and dimensional accuracy. Engineers rely on MJF PA12GB for 3D printing robotics, drones, medical, housings and cases, and tooling. 

The heat deflection temperature for MJF PA12GB is 114°C. For this material, 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 4 x 4 x 1 mm or X + Y + Z > 9 mm
• Bounding Box Max
  • 284 x 380 x 380 mm

Note: Parts covering the exact maximum bounding box dimensions might not be printable due to printer limitations.

Find out more about this popular 3D printing material and accompanying design guidelines here.

Aluminum – Relying on Selective Laser Melting (SLM) technology, Aluminum alloy AlSi10Mg provides good heat resistance, as well as offering a lightweight material that is strong, durable, and accurate. This Aluminum 3D printing material provides excellent corrosion resistance, high electrical, and thermal conductivity. 3D printed Aluminum can be machined, milled, and tapped, making it ideal for outdoor applications.

The heat deflection temperature for Aluminum 3D printing material is 570° C. For this material, 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • X + Y + Z > 30 mm 
• Bounding Box Max
  • 250 x 250 x 200 mm

Find out more about this material for 3D printing and explore the accompanying design guidelines here.

Stainless Steel 316L – This extremely heat-resistant metal is 3D printed with Binder Jetting technology. Offering excellence in corrosion resistance and tensile strength, this metal 3D printing material is a single alloy, 100% Stainless Steel. Shapeways customers rely on Stainless Steel 316L for 3D printing mechanical machinery and parts like heat exchanges, fasteners and brackets, and surgical tooling for medical applications.

The heat deflection temperature for this metal 3D printing material is 1375-1400° C. For Stainless Steel 316L, 3D models must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 15 × 7.5 × 3 mm 
• Bounding Box Max
  • 127 × 127 × 76.2 mm

Find out more about this popular metal 3D printing material and accompanying design guidelines here.

3D Printing Precious Metals with Wax Casting

Wax casting is a multi-faceted process for creating metal parts that has been in use for thousands of years, requiring expertise and sophisticated tools. At Shapeways, this technique includes 3D printing molds which are injected with molten metal. 

With the ability to 3D print any type of complex mold, this modern twist to wax casting allows for unique master patterns to be easily customized and manufactured, adding sprues so that metal materials flow through after the initial wax has melted and drained. Metal structures detach easily from the plaster molds and can then be tumbled for polishing.

At Shapeways, this type of manufacturing is used for making prototypes, home decor, jewelry, and marine accessories. Wax casting allows for superb finishing, while metals like Copper offer good corrosion resistance.

Following are precious metals for Wax Casting:

Bronze is a Copper-Tin alloy made of 10% Tin and 90% Copper. This material is often used for jewelry with a vintage appearance, featuring a deep red color, marbling, and silver highlights. Bronze jewelry at Shapeways is made via Wax Casting, and is suitable for bracelets, earrings, and cufflinks—all available in natural matte or polished finishes. 

For Bronze, designs must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 2.4 × 2.4 × 0.6 mm
• Bounding Box Max
  • 89 × 89 × 100 mm
  • 75 × 75 × 40 mm for interlocking parts

Find out more about this popular 3D printing material for jewelry and accompanying design guidelines here.

Brass – An alloy made of 15% Zinc, 5% Tin and 80% Copper, Brass is popular for jewelry designs requiring intricate detail in manufacturing. Made via Wax Casting, Brass jewelry from Shapeways is available with a natural matte finish or a shiny polish.

For Brass Wax Casting, designs must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 2.4 × 2.4 × 0.6 mm 
• Bounding Box Max
  • 89 × 89 × 100 mm
  • 75 × 75 × 40 mm for interlocking parts

Find out more about Brass and accompanying design guidelines here.

Gold is another precious metal from Shapeways. Both 14K and 18K gold are available in yellow, white, and rose. Gold is one of the highest quality materials Shapeways offers. Capable of showcasing intricate details, Gold offers a professional, finished look. 

For Gold, designs must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 2.4 × 2.4 × 0.6 mm 
• Bounding Box Max
  • 89 × 89 × 100 mm

Find out more about Gold for making jewelry, and view accompanying design guidelines here.

Platinum is one of the highest quality materials available. A white metal used for high-end men and women’s jewelry, Platinum products like cufflinks, tie bars, rings, bracelets, and necklaces are made via Wax Casting. 

For Platinum, designs must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 2.4 × 2.4 × 0.6 mm 
• Bounding Box Max
  • 89 × 89 × 100 mm

Find out more about Platinum for making jewelry, and view accompanying design guidelines here.

Silver is a high-quality alloy used with Wax Casting to make cufflinks, tie bars, rings, bracelets, and pendants. This metal tends to be more malleable and is always a favorite for jewelry makers. Shapeways offers Silver with the following finishes: natural, polished, fine-detail polished, and antique.

For Silver, designs must meet the following minimum and maximum bounding box sizes:

• Bounding Box Min
  • 2.4 × 2.4 × 0.6 mm
• Bounding Box Max
  • 89 × 89 × 100 mm
  • 75 × 75 × 40 mm for interlocking parts

Find out more about this material and view accompanying design guidelines here.

Shapeways offers over 90 materials and finishes. We are also willing to source additional products when possible due to unusual 3D printing project requirements. 

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 Materials Used in 3D Printing appeared first on Shapeways Blog.

1. Choose Straightforward Software

There are many different versions of free 3D modeling software available. Depending on project requirements and level of experience, designers often look into and and end up using a variety of different 3D modeling programs; for instance, CAD software like Tinkercad or SketchUp is great for users on every level and easy to use for most design projects, while Blender is a powerful tool and a mesh modeler, offering a variety of add-on tools for intensive customization. 

Other software involves more of a learning curve but is worth it in the end due to the ability to create much more complex 3D models. No matter what type of 3D modeling software is used, it is key to be apprised of specific guidelines; for instance some programs may offer automatic features, while others are manually set.

2. Set Your 3D Model up for Success from the Start

While the modeling process may often be fun and exciting, efficiency is critical for optimizing any product for successful 3D printing–whether the intention is to make high-performing parts for sleek drones, an architectural model for an important client meeting, or a prototype that could serve as one of a hundred iterations during product development. 

Once a customer uploads a 3D model to Shapeways, it is automatically checked for common issues; however, the modeling process should be used to perfect a design as much as possible before analysis, avoiding thickness or strength issues, and compensating for any possible areas of vulnerability ahead of time. Turn in a model that is above the basic requirements for printability, rather than picking up the slack after analysis.  

3. Configure the Basic Layout for Good Adhesion and Support

Creating a successful design for a 3D printable shape means planning for the printing process in terms of successful adhesion. Although layer adhesion can become tricky due to issues with temperature, cooling, or layer height, mistakes in modeling could also be the culprit. Avoid problems ahead of time by designing a 3D model that will stick to the print bed easily, creating a flat surface to build upon layer by layer.

Plan for overhangs too–and try to avoid steep ones–as well as adding support structures if necessary. While this is not required for powder-based technologies like Selective Laser Sintering or Multi Jet Fusion, other 3D printing methods like Stereolithography (SLA) rely on supports to maintain the integrity of the part during manufacturing. 

4. Design 3D Printable Shapes that Can Support Their Own Weight

Rather than facing disappointment after the fact, preliminary considerations for size and weight of the 3D model are imperative to success. If not scaled properly, 3D prints may be surprisingly small–but worse, if they are too heavy it may be impossible to position them upright as intended or they could fail completely during production. 

Refer to bounding box information to avoid these problems; for example, in 3D printing with Nylon 12 [Versatile Plastic], one of the most popular materials at Shapeways, these details are readily available. Models should be scaled within the listed dimensions of the bounding box, a 3D imaginary outline of a box enclosing the smallest area occupied by a 3D model. 

Note: printing orientation will be restricted if the 3D model size is close to the maximum dimensions.

Following is an example of the bounding box dimensions for Nylon 12 [Versatile Plastic]:

• Bounding Box Max
  • 650 × 350 × 550 mm (Natural White)
  • 180 × 230 × 320 mm (Natural Black)
  • 200 × 150 × 150 mm (Processed & Premium)
  • 345 × 375 × 440 mm (Smooth)
  • [Parts over 330 mm long in any direction may have a visible line due to our dual laser printer]
• Bounding Box Min
  • X + Y + Z ≥ 7.5 mm (Natural)
  • X + Y + Z ≥ 25.0 mm and axes must be ≥ 2.5 mm (Processed & Premium)
  • 10 x 10 x 10 mm (Smooth)

5. Choose Suitable Materials and Technology for Your 3D Model

Along with preparing for issues with scaling and size, researching materials and technology ahead of time will also save a lot of time and headaches, especially when designers are working with more complicated geometries. Again, design guidelines should be considered, but stretching the limits of a particular 3D printing material or technology can present obvious problems; for example, a part cast in metal with intricate engraving may be rejected for use with a material like Steel, due to a weak geometry or other specific details. 

Research materials to match models with project requirements whether using metal for fine jewelry or perhaps a more flexible material 3D printed with Nylon 12 [Versatile Plastic] using SLS 3D printing technology for interlocking parts.

6. Pay Attention to All Guidelines

With the inception of a design, or a project involving comprehensive product development, all guidelines should be considered, no matter what level of expertise the designer has achieved. Guidelines begin with software, and should be in line with project requirements. This is why so many designers are proficient in numerous types of 3D modeling software programs, and may find one appealing over the other depending on what they are working on at the time. 

Considering design guidelines is critical while creating a model, as well as moving forward to choose the proper materials and technology for 3D printing. This is why Shapeways offers design guidelines for every material description, whether you are wondering about designing for materials that rely on Multi Jet Fusion technology or Selective Laser Melting. While many designers do need different features such as flexibility or hardness, other factors come into play such as the ability to offer desired textures that may work as well for materials with rougher surface finishes.

7. Design for Suitable Wall and Wire Thickness

Think of walls as the flat surfaces in a model and wires as strands. Issues with wall thickness are extremely common, and usually caused by areas of the 3D model that are too thin, with the potential to break during 3D printing. This can be compensated for in automated slicing programs, but in many cases designers may choose to use customized settings. A common example would be a structure with walls that suddenly become too thin in curved areas, leaving the 3D model open to vulnerability. If the walls are too thick, however, designers and engineers may find that they are using too much material and opening up the potential for cracking. Upon printability analysis at Shapeways, a 3D model must have walls and wires that are sufficient to survive 3D printing, post-processing, and packing and delivery.

8. Create a Compatible File  

Many models emerge from 2D drawings which are then extruded into 3D, or they may be built from basic to more complex 3D structures using a variety of different software programs. Compatible files include the following:

• File types: DAE, OBJ, STL, X3D, X3DB, X3DV, WRL, 3MF, STP, STEP
• Full-color printing: OBJ, MTL, DAE, WRL, X3D, X3DB, X3DV
• Maximum file size for all types: 64 MB and/or 1 million Polygons

9. Prepare for Prototyping, Testing, Iterating

Many designers and engineers rely on Shapeways to help them perfect prototypes and parts during the product development process. This means experimenting with numerous materials and technology, along with editing them along the way for form and fit; in fact, some Shapeways customers may 3D print well over a hundred iterations before they take a product to market. With rapid prototyping, the process is fast–and results in a high-performing, tested product that ultimately enhances the consumer experience. 

Shapeways customers may also work with the User Application team in testing parts for the proper materials, sometimes requesting the PITA (Print It Anyway) method. Although sometimes risky and often working outside material guidelines, PITA allows designers to see what might happen–but without any guarantees! 

10. Prepare for Cost, Printability Analysis, and Customized Feedback 

Once a 3D model is ready for 3D printing, the Shapeways customer uploads their design and receives an instant quote. The model undergoes file analysis to ensure its printability. Sometimes things do not go exactly as planned during the modeling process, despite all efforts, and a design may require customized feedback or more complex file fixing via the User Application team at Shapeways. While they do everything possible to regenerate files which may be problematic, for more challenging issues the UA Team may need to work directly with the customer regarding necessary changes. 

Download our Infographic, 10 Printability Tips for Your 3D Model.

About Shapeways

Working with Shapeways ensures your part will be printed with the highest quality materials in the most efficient manner possible.

Enjoy the benefits of 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 Ten Ways to Ensure Printability of Your 3D Model 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.

Vapor Smoothing

Accompanied by new choices with Nylon 12 [Versatile Plastic] Smooth, Shapeways customers can design for even more complex structures—whether in product development or for end-use parts. Shapeways achieves this unique finish for Nylon 12 [Versatile Plastic] Smooth with vapor smoothing techniques. With this post-processing method, rough surfaces that may be present after SLS 3D printing can be smoothed with chemical solvents as parts are placed into a sealed chamber filled with vapor.

Vapor smoothing chemicals cause a melting process which improves the surface and the performance of the part—including those with internal cavities—sealing in a soft shine. The Nylon 12 [Versatile Plastic] Smooth finish is watertight and suitable for use with functional 3D printed products as long as they do not have interlocking parts.

Nylon 12 [Versatile Plastic] – A 3D Printing Standard

3D printing was once a wild frontier of innovation, initially offering advanced but limited materials and technology in a futuristic, emerging industry. Quickly though, 3D printing exploded into a billion-dollar machine, bringing forth a new and exciting world for design and production; in fact, with 3D printing, parts could suddenly be produced through additive manufacturing that simply were not possible before.

With such an incredible buffet of choices available now, choosing the correct material can sometimes be the most difficult part of the process. Thermoplastics like Nylon 12 [Versatile Plastic] continue to play a starring role in the additive manufacturing realm whether for production of rapid prototypes or high-performance products. Suffice to say that this particular material is aptly named, with Nylon 12 [Versatile Plastic] surpassing a large volume of other 3D printing materials despite a wide range of selling points for most.

Recommended for a wide range of applications, there is a lot to know about Nylon 12. The overall appeal stems from excellent mechanical properties to include tensile strength, durability for long-term use, and resistance to abrasion, fatigue, and stress. And while the new White Smooth Versatile Plastic and Black Smooth Versatile Plastic offer the smoothest results yet, other very popular 3D printing finishes are available too—including Natural, Processed, and Premium.

Shapeways Customers Inspire with Nylon 12 for So Many Applications

Demonstrating the wide array of uses for Nylon 12 [Versatile Plastic] and all the choices in finish, Shapeways customers choose this material for 3D printing with Selective Laser Sintering (SLS) to make products like medical models, supplies, drones, luxury jewelry, and more—all taking advantages of the optional finishes.

3D Printed Medical Models

Uruguay-based Armor Bionics has channeled 3D printing into a technology capable not only of improving the quality of life for patients around the world, but saving lives too with their unique specialty: creating intricate 3D designs for medical models that are then 3D printed by Shapeways and used for diagnosis, training, and treatment. Armor Bionics CEO Bruno Demuro is dedicated to offering medical professionals better solutions for surgical planning:

“We’ve seen the benefits and how much treatment affects the patients,” said Demuro. “It betters the outcome of every single surgery where it is applied.”

3D Printing in Drone Technology

The aerospace industry leads in the use of 3D printed parts also, and has for decades—far before anyone even knew what the technology was about. Drone technology has taken off in recent years, with a special push via additive manufacturing—allowing engineers not only to create innovative designs but also use lightweight, durable materials with complex geometries. This is especially true for companies like Munich-based Quantum-Systems, specializing in advanced eVTOL (electric vertical take-off and landing) drones. Using 3D printing for prototyping and manufacturing of functional parts since their inception in 2015, Quantum Systems is able to make lightweight parts, while also taking advantage of ‘synergy effects’ in reducing part counts and assembly.

“Only because of the fact that we have integrated this manufacturing method into our manufacturing and development process, have we been able to significantly reduce development time. For injection molded parts, we save around 10 weeks by using 3D printed samples to release the CAD data,” said Florian Seibel, CEO of Quantum-Systems.

“The probability that these parts need a second loop of corrections is quite low in this way. For CNC-manufactured parts it is the same. We often just skip the first round of samples with 3D printed parts, which saves us three to four weeks. In general, I would say 3D printing saves us 20 to 50 percent of time, depending on which parts we design.”

3D Printing in Jewelry Applications

3D printing has a long history with jewelry makers too, and especially at Shapeways. Again, demonstrating the wide range of popularity amongst industrial designers, customers like Groen and Boothman continue to use Shapeways services for 3D printing luxury jewelry like their custom Creatures design series, featuring unique cuff bracelets. The designers rely on the lightweight quality of Nylon 12 [Versatile Plastic], along with the strength and durability of the material.

“3D printing gives us a chance to explore new avenues and get away from the mass production paradigm,” said Joanna Boothman.

Selective Laser Sintering with Nylon 12 [Versatile Plastic]

Selective Laser Sintering (SLS) is one of the originals in 3D printing technology, and remains one of the most powerful—especially with the ability to nest hundreds or even thousands of parts within any build. The average build size of an SLS 3D printer is around 300 x 300 x 300 mm with a layer thickness of 100 to 120 microns. Using materials like Nylon 12 [Versatile Plastic], the process begins as a thin layer of nylon powder is dispersed onto the build plate and then sintered layer by layer until the desired structure is complete.

Supports are not required in SLS 3D printing, and this means that designers are granted incredible freedom when creating 3D models because they don’t have to compensate for support structures. The lack of supports also makes the job of 3D printing engineers much easier at the other end as models can be nested easily within each print build and there is not the potential for damaging parts in post-processing with support removal.

Dyeing of 3D printed parts is possible too, along with choosing finishes and different options in post-processing for Nylon 12 [Versatile Plastic]. The material is naturally white but also available in the following hues: Black, Pink, Red, Orange, Yellow, Green, Blue, and Purple.

About Shapeways

Shapeways offers over 90 materials and finishes, and is always interested in sourcing other materials customers may be interested in using too. Contact Shapeways now to enjoy the benefits of advanced technology and materials for manufacturing 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 make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

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Nylon 12 [Versatile Plastic]

Nylon 12 [Versatile Plastic] currently tops the list in terms of popularity, and epic versatility. Reinforcing one of the greatest benefits in 3D printing with the ability to create complex geometries not possible in traditional manufacturing, Nylon 12 [Versatile Plastic] is used with Selective Laser Sintering (SLS) for 3D printing everything from detailed medical models and surgical planning tools to fine jewelry. Because no supports are required in powder-based SLS 3D printing, designers are afforded greater freedom in creating, and production departments are able to nest hundreds or even thousands of parts together in each build.

Used for rapid prototyping as well as high-performance, functional parts, Nylon 12 [Versatile Plastic] is unique because in its thinner form it is flexible, making it suitable for springs and interlocking parts—and in its thicker state, strong enough for end-use parts in critical applications like medicine. Shapeways offers Nylon 12 [Versatile Plastic] in standard white, but it can be dyed in eight different colors, and is available in Natural, Processed, and Premium finishes. Find out more in the design guidelines here.

PA11

PA11 is also used with SLS 3D printing technology, but many are surprised to learn that it is derived from castor beans, making it environmentally friendly and easy to recycle. Not only is PA11 a flexible material, but it is also known for durability, good tensile strength, and impact resistance with high elongation at break too, meaning that it will be less likely to break under stress. This nylon material is also biocompatible, making it suitable for 3D printed exterior medical devices like knee braces or prosthetics.

High ductility also makes PA11 an excellent choice for end-use parts that must hold up during rigorous conditions, to include offering protection in sports with customized equipment, as well as during harsh weather conditions—and especially heat. Because of its high impact resistance, PA11 is also excellent for use in industrial applications like automotive and aerospace. Shapeways offers PA11 in white, with a slightly rough surface as a standard finish, as well as matte. Find out more in the design guidelines here.

MJF Plastic PA12

MJF Plastic PA12 is another popular 3D printing material that is similar to Nylon 12 [Versatile Plastic]. Used with HP’s revolutionary Multi Jet Fusion technology—a powder-based method relying on inkjet technology—MJF PA12 is unique because it is printed at a lower layer thickness and provides higher resolution for intricate features, as well as overall uniformity. MJF PA12 also offers flexibility in its thinner material form and is known for greater elasticity and less breakage, while offering strength and durability for thicker designs.

Used in many industrial applications due to its ability to support sophisticated geometries, MJF PA12 is known for low porosity as well as possessing excellent mechanical properties, and is recommended for applications like drone technology, medical devices like prosthetics, and mechanical parts. Offered in gray or black with a slightly grainy finish, MJF PA12 is available in natural, smooth, and a slightly glossy finish. Find out more in the design guidelines here.

MJF Plastic PA12 Glass Beads

MJF Plastic PA12 Glass Beads is definitely a unique material, employing glass beads to add strength and stiffness to parts. Although 40% of this material is infused with glass beads, MFJ PA12GB still offers good flexibility like its MJF PA12 counterpart. PA12 Glass Beads are also relied on to ensure structural integrity and dimensional accuracy for industrial parts, along with offering continued accuracy and repeatability whether using Multi Jet Fusion to 3D print customized parts in volume or on demand.

MJF PA12GB are recommended for large pieces, especially when issues like warping must be avoided in high-performance parts. This material is recommended for applications like robotics, drones, medical devices, mechanical devices, and tooling. Shapeways offers MJF PA12GB in gray and dark gray. Find out more in the design guidelines here.

Thermoplastic Polyurethane (TPU)

Thermoplastic Polyurethane (TPU) is a well-known material used in numerous types of manufacturing, to include injection molding. Created in a German lab in 1937, TPU is made up of both thermoplastic materials and rubber. Shapeways offers TPU in standard white for use with SLS technology using EOS 3D printers, as well as Ultrasint TPU01 material from BASF, available in gray, using Multi Jet Fusion 3D printers.

Offering great opportunity for versatility and customization, TPU is known for resistance in terms of chemicals, heat, and abrasion, along with excellent load-bearing capacity, good elongation at break, and high tensile strength—defining the amount of strain a part can handle before fracturing. TPU is suitable for applications like automotive, robotics, medical devices, sports gear, and even footwear. Find out more in the design guidelines here.

Great Durability

Materials like Nylon 12 [Versatile Plastic] rate at the top for durability, exemplified by work with Shapeways customers like 67 Designs. With an ongoing dedication to 3D printing—even for high-volume printing—SLS technology was the perfect fit for their luxury off-roading accessories like the MagMount, a device meant to hold tablets in place during outdoor adventures.

MJF PA12 and MJF PA12GB offer greater durability too due to the deep absorption of thermal energy during 3D printing with Multi Jet Fusion. The addition of glass beads to MJF PA12GB allows for further strength and stiffness. Materials like PA11 are suitable for products requiring durability also due to a wide range of material characteristics making it suitable for sturdy end-use parts, as well as prototypes that won’t break down over time.

Flexibility

Several popular 3D printing materials are strong and durable, yet in some cases also offer great flexibility. This is true of Nylon 12 [Versatile Plastic], as well as PA11; however, TPU is the clear stand-out in terms of elasticity due to its composition of thermoplastic material and rubber, making it highly suited for medical devices like braces, prosthetics, and implants. Soft robotics are another popular application for TPU, as flexible parts are required for actuators, simulated digits and limbs, and flex grippers.

Heat Resistance

Resistance is often a key factor in making a choice between materials. Heat resistance is particularly important in applications like aerospace and automotive where parts are consistently exposed to high temperatures.

Materials like PA11 are suitable for these types of environments, as well as harsh weather conditions, making it highly attractive for industrial applications. PA11 is also resistant to a wide range of chemicals. MJF PA12GB offers stiffness and strength for larger, flat parts, with thermal resistance helping to avoid warpage.

Waterproofing

Many functional parts require sealants for waterproofing. Again, materials like Nylon 12 [Versatile Plastic] top the list. Although this material is moisture-resistant, a variety of different sealants or coatings can be used to make it completely waterproof. Shapeways customer Verner Architects designed a six-foot-long vanity for a children’s bathroom in a luxury re-modeling project. After Shapeways 3D printed the vanity and shipped it to Verner Architects, they coated it with polyurethane to ensure continued water resistance over the years.

About Shapeways

Shapeways offers over 90 materials and finishes, and is always interested in sourcing other materials customers may be interested in using too. Contact Shapeways now to enjoy the benefits of advanced technology and materials for manufacturing 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 make over 21 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post Shapeways 3D Printing Materials: Checking Out the Top Five appeared first on Shapeways Blog.

Additive Manufacturing Offers More Choices and More Freedom in Design

Relying on popular methods like Selective Laser Sintering (SLS), for example, to heat up powder particles and meld them together into a prototype or part, or Binder Jetting for fusing together stainless steel particles via a binding agent, additive manufacturing offers many new and exciting options in manufacturing. With the ability to create complex geometries previously impossible through traditional methods, unprecedented freedom is available in design and production, from the small to the large scale. In comparison to traditional manufacturing, there are minimal restrictions with a multitude of options for materials as well as a wide range of choices in terms of affordability, whether choosing thermoplastics or metal.

Maximizing customization while also minimizing the need for inventory is another benefit many businesses never considered possible, along with the possibility of cutting out warehouse space altogether. With on-demand 3D printing, custom parts can be produced based on need, in small volumes with the same accuracy and repeatability.

Traditional Manufacturing Empowers Repeatability and Mass Production

Conventional methods continue to stand the test of time, offering undeniable power in production. With the ability to manufacture thousands—and even millions—of parts in mass production without any deviation in quality or detail, traditional manufacturing is often the most proficient route for satisfying customer demand.

Similar materials may be available also for customers who were previously engaged in additive manufacturing but have grown to the point where moving up to a different process is more suitable. This is evidenced in methods like CNC machining and injection molding especially.

Computer Numerical Vontrol (CNC) Machining

Pre-programmed computer software controls the subtractive manufacturing of industrial parts, issuing instructions centered around a 3D file. Performed through a variety of methods such as milling, drilling, turning, and cutting, CNC machining offers outstanding dimensional accuracy in parts, capable of surpassing 3D printing or other manufacturing processes—often making it a better fit for customers seeking more fine-tuned precision.

Shapeways offers a range of materials for use with CNC machining, some of which are used in additive manufacturing too, like thermoplastics, nylons, and metals.

Injection Molding

Patented in the 1870s, injection molding is commonly used for mass production of parts, relying on the use of molds which are typically made with plastic or steel.

Often heavily customized, depending on the requirements for specific applications, the molds can be used with materials like thermoplastics, nylons, or metal. The materials are heated to a molten state and then left to cool inside the molds, solidifying into the desired industrial part. There is generally little need for post-processing, with the molds being used over and over, offering incredible repeatability in parts for productions on the large scale. 

The Journey: Transitioning from Additive to Traditional Manufacturing

For most businesses, the manufacturing goal is to make quality parts that last. Weighing out the pros and cons and making a final decision can be overwhelming at first, not to mention dealing with budget concerns over investments in hardware, software, and materials. Shapeways is a world leader in digital fabrication, but also remains agnostic in terms of all technology.

“Our focus is on working around customers’ needs in terms of matching the correct materials and processes to a specific application,” says Zach Dillon, User Application Team Lead.

Key points in choosing additive manufacturing usually boil down to the infinite level of innovation possible in 3D design, along with the ability to customize products intensively. Many Shapeways customers are dedicated to AM processes, and tend to use them as long as possible, especially because they are able to 3D print hundreds or even thousands of parts in one run. If customer demand has increased exponentially though, it could make greater economic sense—as well as increasing speed and efficiency—to scale up to mass production, using traditional methods for large volumes of identical parts.

Today, many businesses also rely on different types of hybrid technology. This could mean that they rely on a mixture of AM processes and CNC machining, for example, at one facility, or they may have turned to machinery that encompasses both AM and traditional manufacturing all in one. For businesses requiring true versatility, hybrid technology can be the answer in terms of having it all in terms of retaining all the benefits possible, with AM complementing traditional manufacturing, and vice versa.

Learn More about Working with Shapeways

Contact us now to find out more about which technology suits your needs, enjoying the benefits of 3D printing and traditional manufacturing without having to spend precious business capital on advanced hardware, software, or material inventory.

Find out more about manufacturing 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 make over 20 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.

The post When Does it Make Better Sense? Additive Manufacturing vs. Traditional Processes appeared first on Shapeways Blog.

3D Color Plays an Important Role in Design

The option to 3D print with High Definition Full Color can be considered at any point in the design and ordering process at Shapeways. 3D print colors play a vital role in design, whether for style or for utilitarian use in functional devices like 3D printed sensors and housings. No matter what types of parts you are making though, figuring out how to color 3D prints is critical to your brand.

High Definition Full Color is in demand by customers seeking more intense detail, and the option to choose between ten million colors. The range of 3D print colors includes a full spectrum of eye-popping hues, achieved by using color profiles with specific data for characterization. High Definition Full Color allows for good pre-visualization of models, exact color matches, along with incredible shading and contrast that previously were not possible without meticulous hand-painting.

Amazing shading and contrast options are available for applying color and design details. Most designers choose High Definition Full Color when seeking fine detail with expanded gradients and textures. Designers can use 3D models with thinner walls for more complex designs, even at a minimum of 1 mm, which amounts to the thickness of a plastic credit card.

For High Definition Full Color, 3D models must meet the following minimum and maximum bounding box sizes:

Bounding Box Min

2.5 x 2.5 x 2.5 mm

Bounding Box Max

495 x 495 x 300 mm

Full-color models produced with High Definition Full Color are available in standard and matte finish. Some staircasing may be noticeable in hard light conditions. Final parts can be coated, and hardware like screws can easily be attached.  

Find out more about High Definition Full Color 3D design guidelines here.

Mimaki 3D Printing

For over 25 years, Mimaki has specialized in full color inkjet printing. They hold numerous patents, maintain a large presence in signage and graphics, industrial printing, and textile printing. In 2017, the Japanese company entered the 3D printing industry with great momentum–and so far, no one else has come even close to offering such exciting, and vast, options in color.

Josh Hope, Senior Manager for Digital Imaging and Innovation at Mimaki, has worked with Shapeways closely and is clear about what makes full-color 3D printing with Mimaki so different:

“We’re coming at it from a very different perspective, and that perspective is that we have many many years of experience in how to reproduce color accurately, how to manage that color, and how to provide a workflow that allows for the most accurate reproduction of color possible.”

Shapeways High Definition Full Color prints are manufactured on the high-production Mimaki 3DUJ-553, featuring a build size of 508 x 508 x 305 mm. While other color printers offer a variety of benefits, the industrial-grade 3DUJ-553 is founded on Material Jetting (MJ) technology, employing eight unique piezoelectric print heads. Converting mechanical energy into electricity, the printheads deposit liquid photopolymer droplets to be cured with UV light. The eight printheads are capable of four different print modes, with seven different droplet sizes. Greater control drop size and drop placement means greater accuracy and resolution.

Speed and precision, along with the ability to produce robust colors and textures make MJ 3D printing uniquely powerful. While MJ 3D printing is popular with many Shapeways customers for rapid prototyping, this technology is paired with High Definition Full Color for functional models, products, and useful applications.

“Shapeways is known for their quality and consistency,” said Josh Hope, Senior Manager for Digital Imaging and Innovation at Mimaki. “Our expertise in 2D color printing allowed us to approach the 3D printing world differently by starting with color. Offering High Definition Full Color to the customer base of Shapeways made sense because it can be used in so many ways.”

3D Printing Applications for High Definition Full Color

With the capability to present minute details accurately, customers choose High Definition Full Color for the following applications:

• 3D printed tabletop gaming figurines – High Definition Full Color is famous for 3D printed miniatures featuring incredibly realistic details. Unlimited customization is available for creating gaming characters with skin tones, facial hair, and details like feathers on animal figurines. Gamers have a tendency to be serious about the characters in their games, and throw themselves into the opportunity to bring them to life. With High Definition Full Color and 3D printing they can collect remarkable, personalized figurines and statuettes of their own design, manipulating texture, color contrast, and gradations.
• 3D medical models – 3D printed medical models can be extremely helpful to the medical profession, but more so to the individuals receiving patient-specific treatment as 2D data like MRIs or CTs are converted to 3D data. These realistic representations are used for surgeons to diagnose and treat conditions, and then navigate the ensuing medical procedure by using the 3D printed medical model to train. In fact, a surgeon may work with a corresponding 3D printed medical model for weeks before performing a surgery. It may also be used as a guide in the operating room or to train medical students. Further, 3D printed medical models are used as visual aids for patients and their families.
• 3D printed architectural models – Architecture is another popular application for use with High Definition Full Color, allowing clients to see every tiny detail of a new home or office, or envision large endeavors like luxury hotels on the verge of construction. 3D printed architectural models can be made on the large scale, representing entire city blocks and including every conceivable detail in miniature like landscaping and infrastructure. Customized, tangible models in robust colors may help land that new client after an impressive presentation–but they also encourage better communication and customer feedback—all leading to an acceleration in final project production.

Part of the allure and intrinsic magic of 3D printing is that creativity can take infinite, perpetually customizable forms. Those endless possibilities can also make it challenging to choose the best avenue for additive manufacturing. 

Built on years of experience and integration of features based on designer feedback, Shapeways provides a streamlined process for customers, making AM processes easier and more successful–every step of the way. This includes printability analysis to ensure that materials and technology are compatible with sophisticated geometries. If you are wondering how to color 3D prints, it is critical to understand what is available, and how that matches with your project requirements.

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 3D Printing Materials Spotlight: High Definition Full Color appeared first on Shapeways Blog.

Today, scientists from the Shapeways Top Secret Development Lab are releasing information that has been highly privileged up until now. They have spent over a decade exploring methods for 3D printing a real dog on demand; however, as time went on, they realized their vision went far beyond the ability to 3D print just one type of dog.

With the potential to customize and personalize nearly anything using additive manufacturing, researchers at Shapeways have taken advantage of futuristic proprietary technology and advanced materials—not to mention access to millions of colors—for 3D printing the perfect pup. This is a momentous time for dog lovers around the globe, whether they seek a teacup Poodle or a robust Rottweiler.

“We’ve investigated every aspect of how to make what Shapeways customers have been hounding us about for years,” explained Dr. Richard D. McPooch, lead researcher at the Shapeways Top Secret Development Lab in New York City. “Customization in designer canines is the wave of the future, and we are thrilled to be a part of helping prospective dog owners figure out the parameters of exactly what they want, especially for a companion that will be with them for many years. We believe dogs can now be designed to fit their owner’s needs better, adding to their lives, without bringing any chaos–or allergies.”

In confidential interviews performed over the last decade at the Shapeways Lab, a select yet diversified group of dog lovers told Dr. McPooch what they desired most in a dog:

1. Doesn’t make a mess on the carpet, or chew on shoes.
2. Stays when told, and never runs away.
3. Offers unconditional love, and is always there.
4. Sleeps in a designated area, and doesn’t have to go out in the middle of the night.
5. Presents minimal cost in terms of vet bills, food, and accessories.

“Whether Shapeways customers want a dog they can fit into their purse, or enjoy on the larger 3D printed scale, our goal is to make sure they have every resource possible in terms of size, shape, color, texture, and human-to-canine personalization,” said Dr. McPooch, a champion of dog aficionados everywhere.

Developing the perfect dog in the pack was certainly no walk in the park, but as Shapeways scientists toiled under shrouded secrecy for years, they constantly reminded themselves of four powerful words:

“Happy April Fool’s Day!”

All joking aside, Shapeways will help you bring all your canine designs to life in miniature with versatility in materials and technology, and full color. Check out some of the following great choices:

High Definition Full Color – Say goodbye to hand painting, and choose from over ten million color choices. This is one of your best options for incredibly vibrant, detailed miniatures. High Definition Full Color is 3D printed with the industrial-grade Mimaki 3DUJ-553, using eight unique piezoelectric printheads for maximum accuracy, resolution, and photorealism via material jetting.

Multi-color Polyjet – Also one of our most popular materials for figurines, Multi-Color Polyjet material is printed on the Stratasys J750. Over 500,000 color combinations are offered for translucent or opaque, full-color products.

Sandstone – Another great choice for multi-color printing, sandstone has been a favorite of many Shapeways customers for 3D printing quality miniatures. Binder jetting is used to manufacture miniatures in sandstone, offering incredible speed, precision, and quality in 3D printed products.

Create an account and upload your 3D models now, receive instant quotes, and instant printability checks too.

About Shapeways

Enjoy the benefits of 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 20 million parts! Read about case studies, find out more about Shapeways solutions, and get instant quotes here.  

The post From the Shapeways Secret Lab: Scientists Successfully 3D Print Designer Dogs appeared first on Shapeways Blog.

Aerospace “Engineers” have been around forever

Although there is certainly plenty to keep people busy and firmly tethered to the ground, historically the temptation and curiosity have always been too great. Humans have gone to wild extremes trying to simulate flight throughout time, from donning home-made wings to eventually constructing an ongoing evolution of kites, hot-air balloons, gliders, and eventually—an entire industry centered around aircraft.

Drone technology: The benefits have barely been touched on yet

Drones continue to grow in popularity on the corporate and hobbyist level, presenting a unique trend. While human beings are responsible for controlling drones, they are not actually flying in them—thus the unmanned aerial vehicle (UAV) moniker. This doesn’t mean there aren’t safety concerns though, especially as traffic in the skies increases and drones—although now allowed to fly in daylight hours while in the sight of the operator—are fairly unregulated and can do plenty of damage if they hit a plane or interrupt airport operations.

The vast benefits in using these smaller aircraft are impossible to deny though. While there are numerous, topical pluses like being able to send retail deliveries to thrilled customers within minutes, drones also offer enormous advantages in times of disaster since they can fly into places that may be difficult to get to or would be potentially unsafe for humans. Drones are also programmed to be adept at collecting aerial data, performing surveys and inspections related to infrastructure, real estate—and flying into sites well-known for hazards, like oil fields.

Drones can be vulnerable

As any pilot will tell you, it’s not the flight that’s dangerous, it’s the crashing. In relation to drones, luckily this means human lives aren’t at stake (assuming UAVs aren’t interfering with other flights), but no one likes to see their technology smashed up either. Advanced technology requires advanced materials and in the case of a drone, prototyping is critical to avoid as many “crash and burn” scenarios as possible while navigating through the elements.

While there are obvious parts that can’t be 3D printed—such as complex electronics—housing accessories can be fabricated—along with making everything from propellers to landing gear, and a long list of other parts and cases.

Shapeways offers a variety of materials and finishes

 
Here are some of the materials Shapeways commonly offers for 3D printing drones:

• Nylon 12 [Versatile Plastic] – It’s hard to imagine a material more aptly named, as Nylon 12 [Versatile Plastic] is also used in applications like architecture, mechanical devices, and even designer jewelry. Larger drone parts can also be printed with Nylon 12 [Versatile Plastic], and are popular due to both the strength and lightweight nature of the material as well as affordability (a huge benefit during the prototyping process too). This material is available in a wide range of colors for dyeing parts, as well as a premium finish.

• PA11 – Another extremely versatile material, PA11 is popular for high-impact applications like aerospace and drone technology. Offered in a natural white finish, PA11 is strong, offers high ductility (the ability to stretch without breaking) and like Nylon 12 [Versatile Plastic], is highly suited for interlocking parts.

• Multi Jet Fusion PA12 – this nylon plastic is also preferable for drones due to its strong and lightweight nature, featuring superior mechanical properties, and good support for intricate structures. MJF Plastic PA12 is available in black or gray, with the option of a smooth and glossy finish.

• Aluminum – while metal 3D printing continues to trend upward for industrial 3D printing, materials like aluminum are suitable for high-performance parts required for aircrafts like drones due to incredible strength and durability. Even better, aluminum is lightweight enough to allow for maximum flying speed in UAVs.

Depending on the type of drone, technology like stereolithography (SLA), selective laser sintering (SLS), multi jet fusion (MJF), or binder jetting may be used. For obvious reasons, the technology must be superior and the materials must be tough, able to handle the elements, and survive the inevitable collision too.

Kespry 3D prints drones for surveying and mapping

Customers like drone manufacturer Kespry (Menlo Park, CA) have worked with Shapeways to 3D print prototypes, as well as lightweight, functional drone parts using industrial technology. Kespry has also been embracing the parts-on-demand system, allowing their company to retain capital while manufacturing customized drones as needed. Due to 3D printing, speed and delivery have improved and their business has been growing.

Known as “The Best Drone Company You’ve Never Heard Of,” Kespry has worked with Shapeways since they began on their journey to create their Aerial Intelligence Platform for surveying and mapping with drones. They have also been the subject of a Shapeways case study thoroughly outlining why 3D printing works so well for their applications.

“When we started with Shapeways, it was before we even had our first customer, and now we have hundreds of drones going out every quarter. And it’s been a smooth transition to get to that point. That’s definitely not true of all of our vendors. Shapeways is one of the few that’s held out throughout that scaling process,” said Jordan Croom, Kespry’s lead mechanical engineer.

Quantum Systems 3D prints drones for eVTOL technology

Another Shapeways case study features Quantum Systems, a Munich-based company using drones for advanced eVTOL (electric vertical take-off and landing) technology. Founded in 2015, Quantum Systems began using 3D printing right away for prototyping.

“Only because of the fact that we have integrated this manufacturing method into our manufacturing and development process, have we been able to significantly reduce development time,” said Florian Seibel, CEO. “For injection molded parts we save around ten weeks by using 3D printed samples to release the CAD data.”

“In general, we order Versatile Plastic and HP (Multi Jet Fusion PA12), sometimes colorized. The material properties are perfect for building light and strong drone parts. We prefer HP at the moment, but for some parts, especially big ones, we order Versatile Plastic due to the price.”

Quantum’s Trinity F90 has successfully delivered medical samples, again making it clear that drones have the potential to be very helpful in making deliveries to remote areas or in dropping supplies during disasters.

Shapeways offers over 10 different technologies for manufacturing, and 90 different materials and finishes. Find out more about custom drone 3D printing with Shapeways here. Upload up to 20 models at a time, receive instant quotes—and look forward to consistent, quality drone parts that are durable and meant to last in tough conditions.

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Forward AM by BASF is directed under the guidance of its mother company BASF in a charter to offer advanced materials, service solutions, and affordability through scale to enable taking additive manufacturing from simply a prototyping tool to production. 

“The development of Polypropylene grades for powder based additive manufacturing was our logical step towards industrial production with 3D printing, especially in the automotive industry,” commented Christian Reinhardt, Global Automotive lead for BASF Forward AM. “From now on engineers can finally work with materials they are used to and don’t have to find workarounds for 3D printed applications anymore.” 

Economics and Sustainability

The Forward AM PP is highly recyclable in both SLS (Selective Laser Sintering) and MJF (Multi-Jet Fusion) processes.  This supports sustainability, limits waste, and keeps part costs very low.  

BASF 3D Printing Solutions is committed to the industrialization of 3D printing for manufacturing.  The affordability of 3D Printing materials will drive industrialization, and BASF has the capacity to manufacture powder at large scale, driving affordability.  This dramatically moves the needle in the favor of AM for higher and higher volume runs where historically injection molding might have been chosen outside of prototyping.  

“The ability to validate Polypropylene prototypes in the same base material as production enables cost and time saving opportunities for all customers,” said Aaron DeLong, Solutions Architect for HP. “Further, this breakthrough provides enhanced saving opportunities in bridge production, full production, and service applications.”

PP can also be an effective replacement for PA12 prototyping parts to bring about savings of 25%- 50%. 

Performance

“In combination with Digital Printing, we see the BASF PP material as a game changer in the automotive industry to give OEMs more flexibility, leading to a greater focus on product-level features and increasing the speed of innovation.” – David Tucker, Director of Digital Solutions at Forecast3D. 

BASF PP printed parts provide key advantages:

• Chemical Resistance.  The material produces durable production parts for automotive applications. 

• High ductility and toughness.  Industrial applications benefit from the ability of the PP to provide damping and shock absorption. 

• High burst pressure resistance.  Unlike most printed powderbed technologies, the Forward AM PP powders are not inherently porous.

• Water resistant and watertight.  Because PP is naturally water resistant, and the printing process makes parts watertight, it can be used in outdoor applications or where water tightness is needed. 

Functionality

Forward AM PP printed parts can be welded just as IM parts are welded.  This enables the opportunity for a multitude of functional production parts like tanks and reservoirs, tubes, and piping systems. 

You can combine AM parts with IM parts or with custom fittings. Large parts that extend beyond a normal AM build volume can be produced by welding pieces together.  PP enables light-weighting because of its low density which is often a driver in the transportation industry for fuel economy.

Applications

• Prototype bottle – this can be used in automotive test applications, printed in two parts and plate welded together.  Passed pressure tests and brought development time from four weeks to four days.

• Grab handle — meant for design validation applications for low volume premium vehicles.  Printed complete sets for testing and production line acceleration.  Saved estimated $15,000 tooling costs for design validation. 

• Respirator fastener – completed a Covid response project.  The customer was able to scale quickly, producing 28,000 parts in 3 weeks saving an estimated $10,000 in tooling.  The strength and ductility of PP made the “Christmas tree” fastener functional.

• PP wrist casts — promote comfortable healing. The cast is produced at a clinic or hospital without the challenges of a traditional gypsum cast; it can be slipped off and on and allows for ease of maintaining bandages underneath.

• Remote control inspection device – product development.  Developed from prototype to production with all custom parts printed in PP for manufacturing.  SLS PP saved 12 weeks in design time and $33k in IM tool costs.

Industrialization

BASF strives to leave the equipment choice to the customer by providing powders that work well across powderbed technologies.  We think that this is another step in the right direction towards industrialization of AM.  Users can process our PP powders on either HP’s MJF technology or a variety of SLS systems depending on what your preferences and specific needs are.

Many of our customers prefer to outsource their printing to service bureaus either in the ramp up stage or for long term manufacturing.  This can be a huge benefit to limit capital expenditure, increase flexibility in manufacturing volumes, or simply to harness expertise that might not be a core competency.  The network of service bureaus able to offer the BASF-manufactured PP powder is being built up at service providers like Peridot, Extol, and Forecast3D to start.  For one-stop shopping, it is also possible to access PP and many other BASF materials through the Shapeways BASF portal.

How can we help you industrialize your application with PP?

https://powered-by.shapeways.com/basf/model-iq

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