Shapeways examined the current attitudes of manufacturers integrating 3D printing into their production processes. Working with Dimensional Research to gain a better understanding about their experiences, Shapeways found that while manufacturing stakeholders are confident about the future of 3D printing, their answers also pointed to the resounding need for more sophisticated accompanying software. Manufacturers are also finding that their own customers demand higher quality in products and materials, expanded and improved features, and greater customization. To download the full report, click here.

Presenting a Highly-Tuned 3D Printing Ordering System

Over the past decade, the evolution of OTTO has been an intuitive process. Built on continued inspiration from Shapeways customers, growing volume, and more complex requirements, OTTO is a highly developed digital manufacturing platform meant to advance workflow—and ultimately, revenues—for companies seeking to provide quality 3D printed parts to their own customers.

Not only is there zero up-front cost involved, but manufacturers are able to grow their business, retain full ownership of their end customers, and enjoy another stream of income while OTTO completely manages production. This powerful purpose-built software handles everything from expediting shipping to tracking orders, sending invoices, dealing with customer service issues like issuing refunds, and more.  

OTTO is Easy to Integrate and Use  

OTTO is a straightforward system, even for businesses that are just beginning to take on 3D printing prototypes or functional parts. OTTO eliminates the need for enormous capital investments, allowing manufacturers to provide advanced technology and advanced materials that are used in more than 90 percent of applications in over 40 different industries.

As a comprehensive 3D printing ordering software, OTTO bridges that common gap that many other manufacturers are experiencing between production and automation, and is easily integrated into any website, resulting in more sophisticated and streamlined services, faster turnaround with better quality, and an overall improved customer experience. 

Scaled to Your Needs

OTTO oversees everything from a personalized ordering site with company-specific branding. The seamless customer experience includes analyzing and fixing models, nesting, slicing, and printing, but also enhances the bigger picture too. By outsourcing 3D printing services, other manufacturers eliminate the need to buy equipment, materials, and more, and are not hindered by production issues or changes.

Shapeways 3D prints all parts and ships them, tracks deliveries, and offers transparency every step of the way. Parts can be delivered directly to customers if desired too, with white-label packaging.

Learn more about OTTO Software at www.ottosoftware.com. 

About Us

Shapeways spent over a decade using, improving, and building purpose-built proprietary software to scale, resulting in over 21 million 3D printed parts for over 40 industries. OTTO is now being offered to others to expand 3D printing for manufacturers everywhere. 

The post Shapeways Launches OTTO for Comprehensive Fulfillment in 3D Printing appeared first on Shapeways Blog.

Developed in the mid-80s, 3D printing began as a way for engineers to make small prototypes. For decades, it was also quietly embraced behind the scenes by research labs, aerospace organizations like NASA, and a handful of automotive companies with deep pockets who realized the immediate potential for prototyping, making spare parts, and manufacturing jigs and fixtures. As major patents began to run out around 2014, 3D printing was thrust into the consumer spotlight. Spectacular headlines began to take over the press, garnering worldwide attention over a technology that to the average layperson seemed nothing short of magic.

The 3D Printing Industry Continues to Accelerate

For designers and manufacturers, the floodgates were opened. Advances in applications like medicine were some of the most highlighted applications due to transformative medical models, medical devices and implants, and surgical tools leading to life-saving and cutting-edge surgeries. They were joined by companies engineering drones, robotics, embedded electronics, and a long list of others. Recent market research now projects that the global 3D printing market will reach $62.79 billion USD by 2028, with a 21 percent compound annual growth rate from 2021 to 2028.

With the advent of expiring licenses which had been held so long, accessibility and affordability were cited as the ongoing reasons for the explosion in 3D printing technology, materials—and captivating innovation. 3D printing at the desktop became much more common, quickly catching on in primary and secondary schools, as well as for college and university labs. Suddenly 3D printers were in common use at the professional level in design firms, as well as architectural offices and medical research labs.

Industrial Parts Still Require Industrial 3D Printing Hardware

Desktop and professional-grade 3D printers can be purchased painlessly, but that is often where the ease ends as the technology is not always as simple as it sounds or looks. Many of the cheaper models may draw in consumers with hype, including kits that could cost less than a typical grocery shopping bill, but often present challenges for operators without significant tinkering or engineering experience. While much can go right, and it is very exciting, much can go wrong too, including the level of quality in manufacturing for prototypes and parts.

Harkening back to Ken Olson, co-founder of Digital Equipment Corporation (DEC), who famously said “There is no reason for any individual to have a computer in his home,” parallel contradictions may certainly prove to be true within the 3D printing industry. Desktop units may continue to become more user-friendly and higher in quality; however, they cannot take the place of their industrial counterparts in most cases, which is why so many businesses reach out to Shapeways for 3D printing—rather than taking on challenges such as the following:

• The expense of purchasing expensive equipment, along with making room for such items, and providing ventilation too.
• Hiring staff knowledgeable about 3D printing or instituting training programs.
• Dealing with the limits of non-industrial equipment.
• Handling scalability issues—especially trying to use desktop printers meant for small production jobs when parts need to be 3D printed in larger quantities.

From a Prototyping Tool to Production of End-Use Parts

With so many modern professionals worldwide realizing the truly infinite potential in 3D printing for new products, and the ability to make complex geometries like never before, the collective whole has continued to experiment and push the limits. As a result, newer and more industrial hardware and materials continue to emerge, along with the ability to go far beyond prototyping, and onward to the production of customized, quality parts meant for long-term functionality and high performance.For example, technology like Selective Laser Sintering (SLS) at Shapeways allows the transition from low-batch volume to much higher production levels with machines that can 3D print thousands of end-use parts at once.

With durable, versatile materials like Nylon 12 [Versatile Plastic], Shapeways manufactures many different types of prototypes and end-use parts, ranging from consumer goods to jewelry to production parts built for those applications. With over 90 different materials and finishes to choose from, customers like beer-brewers Tilt and jewelry designers Groen and Boothman work with Shapeways to manufacture functional, high-performance parts, and luxury keepsakes for their customers.

3D Printing Services Make Manufacturing Much Easier

Although it is not unheard of, most businesses do not have the time to open up their own 3D printing factories, nor the desire to do so as they are busy focusing on their own core specialties. Expense is also a huge factor, and for many businesses, spending precious capital in the wide variety of industrial hardware, software, and human resources required for additive manufacturing may not be a sound investment. 

Shapeways offers the full range of additive manufacturing solutions, including a complete array of manufacturing capabilities to ensure seamless production of quality parts.  The services are reinforced by a global network of manufacturing partners to make custom solutions possible. Production truly spans from end to end too, beginning when a customer creates an account or speaks with a Shapeways business development manager, and continues with:

• Instant price quotes
• Automated printability checks
• Expert support on bulk and custom printing
• Comprehensive quality management 
• On-demand production to include assembly and direct-to-customer fulfillment with customized packaging

Shapeways acts as a reliable manufacturing partner to fulfill requirements in additive manufacturing, and many businesses have chosen to work with Shapeways because they seek a streamlined end-to-end production process. As scaling demands intensify, Shapeways also provides customers with access to traditional manufacturing offerings, including injection molding, urethane casting services, and more.

About Shapeways

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

The post Bolstering Manufacturing with 3D Printing appeared first on Shapeways Blog.

Consider the following as you look for a partner to manufacture your 3D printed prototypes and parts.

1. Ability to meet formidable production demands today—and tomorrow.

Does the manufacturer have a robust platform to serve your needs? Whether you are printing parts as an independent designer or as a business owner relying on bulk printing for your own customers, make sure the manufacturer you work with has the production capacity to fulfill your orders as you need them. Consider a working relationship for the future too. Can you grow together?

“I needed the parts ready ahead of the originally given date and Shapeways delivered on this. Quality of parts was as usual outstanding.”

2. Understanding of your business model and strategy

Seek a manufacturer that understands your innovative ambition and the type of business you are operating, as well as your strategy for the future with 3D printing or other types of manufacturing. Shapeways offers uniquely tailored manufacturing and fulfilment services, along with e-commerce opportunities and on-demand 3D printing integrated with Shopify and Etsy.

3. The potential for accuracy and repeatability in production

Accuracy in production means quality for your own customers, and repeatability means a lot less headaches, knowing you can rely on the manufacturer for consistency every time, no matter how many prototypes or parts they 3D print.

4. Expertise through experience

Don’t count a manufacturer out just because they are the new kid on the block; however, there is enormous advantage to working with a company full of people who have extensive knowledge in 3D printing and are able to talk brass tacks with customers when it comes to technical questions.

5. Strength and excellence in technology and material offerings

Here lies the key to accuracy and repeatability, as well as the opportunity for a successful working relationship. You are seeking a manufacturer with the resources to take over production of your designs, and it is critical that they can follow through with their promises. If you require considerable production capacity, make sure the manufacturer can keep up—and then some! Shapeways, as an example, offers over 10 technologies for manufacturing, and more than 90 different materials and finishes.

6. Versatility in production

Industrial applications present vast potential for 3D printed prototypes and components. While the manufacturer you seek to work with should be masterful at the production of parts, it is in your favor if they can pivot to other projects in the future; for example, currently your business may be making mechanical parts, but what if you decide to design lighting systems, architectural fixtures, antenna or drone components, or something more whimsical like jewelry? To be able to work with one partner who can handle all your manufacturing needs isn’t just advantageous—it promotes further innovation and advancement.

7. The reality for on-demand 3D printing of spare parts

This is a tremendous benefit for you, and one that will just keep on giving. First and foremost, if all of the above considerations are falling into line, you will have satisfied customers. Beyond that, the savings to your bottom line is exponential on several levels. You can slash inventory and limit or completely eliminate warehouse space as parts are maintained on digital files rather than sitting around gathering dust. With industrial 3D printing occurring at the manufacturer’s end, you can cut back on equipment, materials, headaches scheduling deliveries, and a handful of middlemen along the way.

8. Industry presence

An experienced 3D printing service company will have worked on thousands or even millions of projects over the years, and is able to monitor the pulse of the industry continually regarding new technology, materials, and important trends that are relevant to manufacturing. Shapeways is a shining example with over 20 million parts printed, and one million customers served!

9. Technical support

This type of assistance is a lifesaver when problems or questions arise. At Shapeways, 3D printing engineers are available to discuss issues centered around technology, materials, and applications, as well as extremely common questions related to printability.

10. Customer service

For most consumers, this is a priority in working with any company. The impact of good (or bad) customer service simply cannot be underestimated. While ordering 3D prints or embarking on a project, you should also be able to speak with a representative one-on-one to discuss material and technology options and understand how the manufacturer’s services can align with your needs.

“As a business owner, I order a lot on Shapeways. They deliver quality prints, and they guarantee it. If something goes wrong, they’ll go miles to set things straight. Superb customer service, which makes me come back every time. Thank you Shapeways for manufacturing our designs!”

Many designers who have been working with Shapeways for years or 3D printing on their own may be expanding into new roles with design firms, starting their own businesses, or working on various independent projects that require advanced technology and materials. Shapeways strives to cover each point on this list for existing and potential customers, along with offering excellent customer service and access to a User Application team that will connect customers with 3D printing engineers to discuss projects.

Shapeways’ digital manufacturing services have empowered more than one million customers worldwide to produce more than 20 million parts. Read about case studies, find out more about our solutions, and get instant quotes here.

The post 10 Things to Consider When Choosing a 3D Printing Manufacturer appeared first on Shapeways Blog.

Backtrack to the early days of 3D printing as Chuck Hull was presented with his own lab, and famously woke his wife out of bed late one night to see his first rudimentary 3D print in the form of a rapid prototype. Fast forward, and such a scenario could now be taking place anywhere in the world. Software, hardware, and materials are more accessible and affordable than ever, leaving the world ripe for change. The initial goal of bringing 3D printers forth into the world was to encourage creativity via stereolithography; however, SLA 3D printing was almost solely emphasized as a rapid prototyping tool for engineers in the beginning.

The secret was too big to keep

Patented in 1986, SLA 3D printing was soon followed by selective laser sintering (SLS) and then fused deposition modeling (FDM). 3D printing technology—and all the opportunity behind it—was quickly bursting at the seams as automotive companies, NASA, and other entities with deep pockets wanted to take a swift turn from the conventional world of subtractive manufacturing into the additive. A handful of inventive trailblazers in their own right most likely enjoyed 3D printing behind the scenes as long as possible, with the knowledge that such innovation would be impossible to hide forever.

It wasn’t long before interlocking and moving parts (along with the potential for integrating electronics) began to pave the way for a wide range of functional components in critical applications like aerospace, automotive, and medicine.

Critical industries began to invest

Progress was particularly impressive as industries embracing 3D printing were also heavily centered around the safety of human lives. No one wants to be responsible for a rocket engine failing, an automobile causing accidents due to a defect, or an implant being rejected or a device harming an individual seeking to get better with medical treatment. The fact that researchers and scientists invested so much faith in an alternative method of manufacturing quickly gained attention, with interest continuing to accelerate at rapid speed over the past decade.

The ability to prototype and create finished products—all from the 3D printer—has had a profound effect on manufacturing. Processes like selective laser sintering (SLS) can be performed at high speeds, producing strong and durable parts. Because supports are not required (due to unsintered powder bolstering parts during the printing process), design freedom is virtually boundless, thus releasing designers from the stress associated with adding supports, and removing them.

Post-processing takes on many forms, depending on the 3D printer and the materials involved, but finished parts may be left natural, polished, or even dyed. SLS 3D printing again, is a great example as 3D prints made with Nylon 12 [Versatile Plastic] can be processed for a smooth finish, or taken to a more refined level with a premium, scratch-resistant finish. A wide variety of hues are available too.

3D printing will continue to transform manufacturing

It’s obvious that business is booming within the billion-dollar 3D printing industry, offering a vast range of options for materials alone, to include thermoplastics, powders, metals, resins, and filaments. Factories are beginning to run on a whole new type of automation, to include technology propagating itself, from 3D printers made from 3D printed parts to 3D printed robots performing 3D printing activities (and let’s not forget, this could also be happening in space to build colonies and maintain and fix crucial parts).

Warehouse space may easily begin to dwindle as a requirement for many businesses, with on-demand production eliminating the need for inventory. Instead, high-performance, customized parts can be created on demand and completely to the preferences of the consumer. With 3D printing propelling consumer-driven personalized comfort, patient-specific treatment in medicine, and the potential for making intricately customized products—the drudgery of “one-size-fits-all” may disappear altogether, and quite soon.

Intense opportunity for customization is already stretching to a variety of applications, demonstrated through powerful case studies at Shapeways. Most of the incredibly talented and innovative customers have one thing in common: 3D printing began weaving its way into their manufacturing processes over the years and to this day is allowing them to improve with each model, part, or latest design generation. In some cases, other technologies are woven in with 3D printing too for maximum effect.

Shapeways customers have evolved in tandem with 3D printing  

In architecture, for example, the ability to offer a 3D printed model or mockup as well as a virtual tour has taken the experience between designer and consumer to an unprecedented level—allowing for better communication, quality—and in the end, satisfaction. The team at Verner Architects is able to make 3D printed prototypes on-site, test them, and then order customized parts on-demand.

“I’ve been aware of Shapeways since architecture school,” said architect David Swaim. “Once I graduated I worked at an architectural model shop where we would get little pieces of furniture that we could not build by hand printed and delivered to put in our models.”

Swaim’s previous positive experiences with 3D printing led him to introduce the technology into a recent high-end remodel in California. Ultimately, the project was much larger than the architects expected, and by the end also included a unique six-foot, 3D printed bathroom vanity inspired by the beauty of coral reefs. The results were outstanding, with the fixture meant to stand the test of time in terms of luxury and durability.

Additive manufacturing plays a role in many other unexpected areas too. Dutch design duo Hanno Groen and Joanna Boothman, Shapeways customers for years, relied on SLS 3D printing for their latest series of cuff bracelets. Many may be surprised to hear that industrial manufacturing plays such a large role in their work, but not only are the skilled designers able to create elegant, lightweight pieces of jewelry—their bracelets are durably, luxury items meant to be handed down over the years.

Each bracelet is “as unique as a fingerprint,” and the antithesis of mass-produced, disposable costume jewelry.

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

Both designers also appreciate the way the Shapeways platform complements their artistic spirit—aside from aiding in the actual creation of jewelry—as they are able to work whenever the mood strikes and then upload their models quickly.

Boston-based industrial designer Evan Gant offers an artistic bend with his 3D printing also, designing a distinctive 3D printed pendant light that adjusts with a simple twist. Aptly named the Twist Light, Gant was using paper towel rolls for prototyping. Not only did he discover the wonders of using 3D printing to test parts—he also began manufacturing his lights with small-volume manufacturing through Shapeways.

“My favorite part of the design process is iterating and seeing the reaction to ideas,” explained Gant. “In a traditional process (like injection molding), a large portion of your time is spent optimizing from a mold, finding a vender that will make you parts, doing quality control, etc. You often need to make a lot of compromises to your design in the end.”

For the medical professionals, compromise is usually is not a luxury, with patients’ lives at stake. As the COVID-19 pandemic struck worldwide and supply chains began to show massive and unexpected vulnerability, Shapeways reached out to help the medical community by printing face shields for hospitals, using a modified version of the Prusa 3D design. The shields are manufactured via SLS technology and can be repeatedly disinfected after each use. As the need for face masks with good filtration, fit, and some modicum of smile became apparent too, Luxmea Studio stepped up to partner with Shapeways in creating bespoke face masks, ordered through a smart fitting process online.

The need for organization never ceases for medical processes and equipment either, especially as the coronavirus has raged on. Considering the needs of everyone involved—from medical equipment suppliers to nurses and doctors and patients—Voytek Medical worked with Shapeways to 3D print medical cable clasps printed in Nylon 12 [Versatile Plastic].

“Voytek Medical has been using Shapeways in every stage of production, from concept to prototype and end-user products,” said the Voytek team.

3D printing can transform your business too

As prototyping becomes more of a given, the industrial spotlight shines front and center on 3D printing for the manufacturing of finished products. Businesses of all sizes now rely on AM processes for innovating, designing, optimizing, and revolutionizing.

3D printing services from Shapeways such as SLS allow you to reap the rewards of high-performance, quality materials without having to invest all your business capital in the powerful hardware, software, and materials required for your build. Enjoy the benefits of Shapeways advanced technology and wide range of materials for printing your creations with accuracy, complex detail, and no minimum or limits in terms of mass customization or single part orders. Read about case studies, find out more about our solutions, and get instant quotes here.

The post Far Beyond Prototyping: The Additive Manufacturing Revolution Continues to Accelerate appeared first on Shapeways Blog.

What is rapid prototyping?

Rapid prototyping, to put it simply, takes you from napkin sketch to final product rapidly. A major bottleneck in the product development cycle is in prototyping. Traditional prototyping workflows often include outsourcing the creation of each prototype, waiting weeks — and spending significantly — for every new iteration, however tweaked or overhauled design changes may be. With rapid prototyping, those weeks between iterations may become days, taking months or years for standard prototyping cycles down to weeks, and getting your new product to market in a much more agreeable timespan.

What Is 3D Printing / Additive Manufacturing / Rapid Prototyping?

Rapid prototyping today often means bringing in 3D printing technologies — or are they rapid prototyping processes, or is that additive manufacturing? It may help to understand just what additive manufacturing is (and Shapeways has a guide for that!) and how these technologies fit into the prototyping workflow.

What Is Additive Manufacturing?

Additive manufacturing (AM) is a digital manufacturing process in which a CAD model is used to create a solid object. A variety of technologies are defined as being additive, as these processes add material over the course of the build, rather than subtracting it as seen in many traditional manufacturing methods (e.g., CNC milling). Materials are deposited, often in a layer-by-layer process, using a 3D printer to build up the geometry of the model in three dimensions. AM processes can handle a variety of metals, from simple plastics to various metal alloys, from food pastes to biomaterials.

What’s The Difference Between 3D Printing, Additive Manufacturing, and Rapid Prototyping?

There are several ways of referring to these technologies, most commonly “3D printing” or “additive manufacturing,” though “rapid prototyping” is also used. For a fuller explanation, we dive into technology terminology in this article, but in short:

3D printing and additive manufacturing are often used interchangeably to refer to effectively the same processes. Additive manufacturing is recognized as a more industrial term, and tends to encompass expensive professional machinery being used in applications from prototyping to end-use product production. 3D printing can refer to the process of layer-by-layer building of an object, or more generally to refer to any usage of this technology, from hobbyists using inexpensive desktop systems to professionals using industrial equipment. Rapid prototyping was one of the first terms used for these technologies, which in the 1980s were geared toward the rapid production of prototypes and for a few decades so dominated usage that this application was synonymous with the tech itself.

For the purposes of this guide, 3D printing is a technology suite used for the application of rapid prototyping.

Rapid Prototyping Materials

Now that we know what rapid prototyping is, a good follow-up question is straightforward: What are some of the material options for rapid prototyping with 3D printing?

When using 3D printing from prototype to production, the same technology can be used throughout the product development cycle. That does not, however, mean that the same materials are necessarily the best choice at every step. Early stages of prototyping may focus more on speed and rough idea than on a “final look” quality, so inexpensive plastics are often the best fit here, when several iterations may be made in fairly quick succession. Each refinement in prototype may call for a better-quality material, and staging material selections can help cut costs, keeping the finer-detail options for only later-stage planning.

During initial prototyping stages, a low-cost material can be used with low infill and thicker layers, lowering material costs and speeding print time to create a rough-and-ready first look at a new design. Whether plastic or metal, 3D printing can quickly fabricate a product that will come to look and feel just like the desired end result.

By starting with a low-cost plastic material and moving after a few iterations to metal, for example, a product that will eventually be conventionally fabricated using metal can come to market much more quickly than would be the case by machining each iteration — a traditional pathway that ultimately costs much more in terms of time, money, and labor.

Material options in additive manufacturing may not run the full gamut available in traditional technologies, but new formulations are becoming available all the time.

Among Shapeways’ broad 3D printing materials portfolio, the most commonly used for rapid prototyping is Nylon 12 (Versatile Plastic). This material is a durable nylon plastic that can be used for a wide range of applications, both for prototyping and for end products. The SLS material can be 3D printed thin for flexibility — think hinges and springs — or thicker to build up structural components. Nylon 12 is affordable, has the fastest lead time (shipping as quickly as three business days from order), and is available in a wide range of colors. It can also be bonded with other materials, electroplated, or otherwise adaptable to your specific application’s needs.

Other well-suited offerings for rapid prototyping include Multi Jet Fusion Plastic materials (PA12 and PA12 Glass Beads) for added stiffness and durability, and SLA (Accura 60, Accura Xtreme, Accura Xtreme White 200) for fine details.

For more in-depth information on any of these materials, see Shapeways’ Materials Guide (pdf).

Benefits Of Rapid Prototyping

That’s all well and good, but when it comes down to it, is there an actual business case for prototyping with 3D printing?

This question gets a resounding YES! Using 3D printing from product concept to creation can help reduce the time and costs needed to get your new idea to market and into the hands of your eager customers.

In broad strokes, the product development cycle includes the need for physical prototypes at several stages of design including:

• Concept
• Assembly / Fit
• Functional
• Life Test
• Regulatory

3D printing these different iterations offers the benefits of digital manufacturing — think speed, agility, and lowered costs for one-off production — to every stage of product development.

Taking a 3D model directly to a 3D printer for fabrication speeds the process of prototyping. Digital models can be made quite quickly using a variety of 3D printing technologies, removing the needs for many steps in other, more traditional fabrication technologies. No tooling is needed, for example, nor is there a waiting period while molds are made and filled. It’s also much faster and more precise than hand-fabricating.

Following review of each prototype for the parameters necessary, subsequent versions can be made quickly to get to just the right look and fit before moving into more finessed prototypes. Tweaking a digital file to adjust for better look, fit, appropriate scale, or other needs can be done quickly, with a next iteration 3D printed potentially same-day.

Some 3D printing options, like HP and Carbon, enable the capability of prototyping and producing on the same system or family, as different materials and parameters can move ever closer to a market-ready product. By iterating on the same system that will be used for the final product, quality control can be kept in-hand every step of the way, meaning there are no surprises when the first end-use production begins.

When working with a service bureau like Shapeways, additional expertise and access to different technology suites comes into play for a high-quality experience every step of the way.

Shapeways’ rapid prototyping services offer:

• Fast Turnaround
• Variety of Materials
• Reliable Quality

We go over the full business case for 3D printing prototypes in this article for more depth.

Rapid Prototyping Pricing

Once the decision has been made to rapid prototype using 3D printing by engaging a service bureau, one large question remains: pricing.

Shapeways lays out clearly its pricing structuring, from engaging a designer to simply uploading a model for an instant quote.

Among the considerations for our pricing are:

• Materials:
  • Material Volume
  • Machine Space
  • Number of parts
  • Production
  • Bounding Box Volume
  • Support Volume
• Manufacturing Speed:
  • Priority
  • Economy
  • Rush
• Shipping cost
• Taxes

Bulk pricing is also available for large orders. For full details, see our pricing overview here.

Customer examples

As popular wisdom holds that “show, don’t tell” is the best way to prove a point, we’d like to share some examples of customer rapid prototyping achieved through the Shapeways platform.

Just a few of our customer successes include:

Atlas Games

Innovative tabletop gaming mainstay Atlas Games has plenty of decades of experience in creating card games, board games, and roleplaying games. The company turned to Shapeways to bring its new dice-based game to fruition for a release through Kickstarter, creating a realizable visual of Dice Miner for potential backers to see prior to sale. The 3D printed prototypes of game pieces helped carry the new game from early design through a playable final product.

Jeff Tidball, Chief Operating Officer of Atlas Games, says of working with Shapeways: “Dice Miner’s Deluxe Edition will have a plastic PVC mountain, so we used Shapeways to prepare early prototypes of that component. We used Shapeways for two purposes. First, to playtest using components as close as possible to the final version, to make sure they performed as we expected at the table. Second, to evaluate their producibility while holding physical objects, as opposed to needing to evaluate them only on screen, or in our imaginations.”

LuminoGO

Using 3D printing to prototype a comfortable, reusable new face mask helped the LUMINO team quickly respond to pandemic needs. Developing the LuminoGo mask for full facial visibility as well as wearer safety features including UVC light or an integrated filter to sterilize breathing air was no mean feat, requiring significant prototyping — and the team turned to Shapeways to 3D print almost every part of the mask to get it all ready for safe wearing on the market.

LUMINO CTO Bernhard Neuwirth says: “Almost all parts are 3D printed. The main reasons for us have been fast prototyping, fast production, choice of materials and colours, which is important for branding and personalization. The big difference with competitors is that we have already working prototypes.” And: “Shapeways was helpful in every way from early on in the project. I especially liked the very fast production options, the choice of materials and the amazing quality of the product. Traditional production methods would be injection moulding. We will certainly do that in the future. Meanwhile we produce already, while optimising the product. We use 3D-print as a production method.”

SNOOZ

Working with Shapeways to 3D print dozens (and dozens and dozens) of designs to reach the ideal sound system, the SNOOZ team cut substantial time and costs in their production process by rapidly prototyping. The savings over traditional machining was major enough that this Las Vegas-based startup has now been working with Shapeways for more than five years — and still has more product work with us in the pipeline for the next devices.

SNOOZ CTO and Co-Founder Eli Lazar explains: “Without 3D printing, I am not sure we could have ever developed a viable product, or at least one that people actually liked. Our fan blade is entirely custom, and small details make a huge difference. A 1-degree extra twist in the blades or 1mm extra length or width of the blades, and it generates a whole different set of tones. You can use software to simulate the acoustics for a fan blade design, and we did do quite a bit of this. However, these simulations can take up to a few weeks to run, and they are really not accurate enough to predict the subtleties that we were interested in. The best way I can explain this is that a stringed piano is always acoustically superior to a digital keyboard, because the timbre (perceived sound quality) of real sound is just better than any digital replica. With that said, we had to make actual parts. Having parts machined was always an option too, but from our experience, that is 10-25x higher cost, and perhaps 10x slower, which was just not an option for us.”

Please contact us today to learn more about our offerings and how we can help you every step of the way for your next project.

The post What is Rapid Prototyping? – A Complete Guide appeared first on Shapeways Blog.

What are the types of additive manufacturing?

At its simplest, additive manufacturing is the opposite of subtractive manufacturing. That is, rather than subtract material such as is often seen in traditional means of production — think CNC milling, cutting, carving — additive manufacturing adds material to build a shape.

3D printing is a part of the additive manufacturing workflow, though the two terms are often casually used interchangeably. Seven ASTM-recognized 3D printing processes are the most common forms of this technology suite, and include:

• Material extrusion
• Material jetting
• Binder jetting
• Sheet lamination
• Vat photopolymerization
• Powder bed fusion
• Directed energy deposition

The history of additive manufacturing began with rapid prototyping applications — but the future is squarely in end-use manufacturing.

Design for Additive Manufacturing

Design for Manufacturing (DFM) is a well-established discipline; Design for Additive Manufacturing (DfAM) is a new set of skills specific to additive manufacturing.

Simply using an existing design file to 3D print a part will not likely result in a successful product. New ways of making have new design parameters, and existing designs can be optimized to better fit those new parameters to create a product tailored to the manufacturing technology used to create it. Additive manufacturing offers a freedom of design unprecedented in subtractive or molding processes. Geometries can be more complex, mass customization is possible, and internal structures can be created for complex one-piece designs.

DfAM leverages the unique capabilities of additive manufacturing including lightweighting, part reduction, and reduction of material and labor time and costs. When properly applied, DfAM allows for new ways of design — holes don’t have to be round anymore, and lattices can help provide the right amount of strength with less material, for instance.

Working with experts to design files offers immediate access to DfAM know-how.

Additive Manufacturing Materials

Plastic, metal, ceramics, and even food and living cells are among the materials that can be 3D printed. Most often, plastics and metals are used for the prototyping and production of new products.

Plastics

From early prototype to finished product, plastics are the most common material set in the additive manufacturing toolbox. These polymer materials may come in the form of filament, powder, resin, or pellet, depending on the 3D printing technology being used.

Some of the more common 3D printable plastics include PLA, ABS, TPU, and nylon. Reinforced and composite materials offer versatility and additional capabilities, such as strength or flexibility. Engineering-grade polymers like ULTEM and other high-temperature plastics also allow for high-performance end-use product creation such as might be seen in the aerospace industry.

The choice of plastic for a given project should take into account characteristics like finish, color, feel, and flexibility. Shapeways offers a large variety of polymer materials, like Nylon 12 (Versatile Plastic), which meets needs from prototyping to finished product, and Fine Detail Plastic, an acrylic material capable of extremely high detail. Flexible TPU, reinforced MJF Plastic PA12 Glass Beads, rigid polyurethane,  and visually appealing Multi-Color Polyjet are just a few other options for extended capabilities.

Metals

An ever-widening selection of metals are also 3D printable, in the form of wire and, most commonly, powders. Metals like stainless steel, steel alloys, aluminum, and Inconel are becoming common in additive manufacturing. Metal-infused plastic filaments are also enabling metal production on desktop 3D printers. Metal materials require sintering after being 3D printed, and often smoothing processes to shine surfaces to the right finish.

Both directly 3D printing and lost-wax casting capabilities expand Shapeways’ portfolio to bring you the right choice in metal for your project. 3D printed stainless steel or aluminum offer the geometrical freedom to design in familiar metals, while lost-wax casting expands offerings to precious metals like platinum, gold, and more using 3D printed wax molds.

Ceramics

Whether for medical, high-temperature, or artistic applications, ceramic materials like porcelain are 3D printable. Ceramic materials are typically heat-resistant and/or biocompatible, lending their use to a variety of industries. Post-processing procedures like firing will generally be required to finish a ceramic 3D print.

Pastes

Paste materials can be extruded in often more experimental applications. Concrete 3D printing, for example, is becoming prominent in new construction approaches. Food such as chocolate or purees can also be extruded to create unique takes on food.

Bioprinting

While for the most part a future-looking area, bioprinting — that is, 3D printing using living cells — is a rising area of R&D. With an eventual goal of functional 3D printed organs for implant, to date most research has been on a much smaller scale, with successes seen with liver and kidney cells, as well as a small beating heart.

Additive manufacturing workflows

The full additive manufacturing workflow comprises design, print preparation, 3D printing, and post-processing. Design, leveraging DfAM know-how, creates the file from which the 3D printer will operate. Slicing prepares that file for the 3D printer, as each “slice” of the design will represent a layer of the additively laid-down material. The actual 3D printing is the stage in which a 3D printer produces the three-dimensional object, typically in a layer-by-layer process. Post-processing may involve very little work or a comprehensive several-stage finishing process to take the finished 3D print job to completed additive manufacturing project.

Post-processing/finishing

Often referred to as the “dirty little secret” of additive manufacturing, post-processing is a necessary step that follows the work of the 3D printer. Depending on the 3D printing process and material used, as well as desired end properties, any number of steps may be involved. Shapeways continues to expand on post-processing options for the right finish every time.

Among some of the most common post-processing steps are:

Unpacking

Powder bed 3D printing, as the name implies, uses a powder bed. Parts made in these processes must be unpacked from the full “cake” of powder, a process that generally involves manual excavation to “dig them out” as it were.

Powder removal

Once out of the powder cake, each part made on a powder bed fusion 3D printer must be cleaned of all excess powder.

Support removal

Supports are required for FFF and SLA 3D printing processes, allowing for the three-dimensional building of each part. These supports are needed only during the 3D printing itself, and must be removed cleanly from each part after the build is complete, including sanding down or otherwise smoothing the points of connection.

Curing

Resin-based processes like SLA require parts to be cured to “set” the resin completely following 3D printing. Parts are only complete once they have been fully cured, often with UV light.

Firing

Just as traditional ceramics must be fired in a kiln, 3D printed ceramics must be fired to firmly set and solidify design geometries.

Sintering

Metal 3D prints must be sintered to firmly fuse all metal content, as a “green” part comes off most metal 3D printing processes. Sintering in a furnace removes all non-metal content, shrinking the part down by a known percentage from the 3D print to the final size.

Assembling

Any multiple-piece builds 3D printed part-by-part must be assembled manually. This most often applies to large builds that exceed the size of a single 3D printer build volume and instead have to be broken down into parts to be put together after printing.

Polishing

Metal 3D prints requiring a “shiny” appearance require polishing to remove the look of layering or other surface roughness.

Smoothing

Similar to polishing for metal prints, chemical smoothing processes remove the look of layer lines from polymer prints, creating a smooth surface finish.

Dyeing / Painting

Color is typically the final step in post-processing, through batch dyeing, painting, or other application of colorfast dye.

Applications of Additive Manufacturing

Rapid prototyping was the first application area for 3D printing. So tied together was this application to the technology that it was frequently called “RP”. As the technologies have developed, so too have applications. “3D printing” often referred to the work of makers and hobbyists using desktop 3D printers to create projects outside of prototyping, from game pieces to functional household items. “Additive manufacturing” is often used for industrial usage including end-use part production.

When to Use Additive Manufacturing vs. Conventional Manufacturing

The best application for additive manufacturing is complementary to conventional manufacturing. While in some cases additive manufacturing may displace conventional processes, additive and subtractive or molding technologies work best together.

Additive manufacturing can be applied effectively to low-volume manufacturing, mass customization, and highly complex, high-value parts. Conventional manufacturing processes are still best suited for mass production of alike parts, for instance.

Just as sometimes a hammer is needed and other times a wrench, it’s all about using the best tool — or process — for a particular job.

Ideal use of each type of additive manufacturing technology

Each 3D printing technology has its best-fit application areas. While some are well adapted for individual usage to create one-off parts, others can be scaled to manufacturing applications. Where and when are some of the most common applications for each technology?

Material extrusion

Perhaps the most common 3D printing technology, material extrusion — often referred to as FFF, or fused filament fabrication — uses an extruder to lay successive layers of material, most often in the form of plastic filament. Many desktop 3D printers use this technology; it is the most widely available for personal use. FFF 3D printing is well-suited for all stages of prototyping, from rough idea to functional prototype; for making tooling, jigs and fixtures; and for use among makers, hobbyists, and designers. Engineering-grade polymers, metal- or ceramic-filled composites, and other advanced materials also make extrusion-style 3D printers appropriate for some end-use production applications.

Material jetting

Most material jetting processes use liquid photopolymer droplets, which are then cured layer-by-layer with UV light. This process is best understood as being somewhat similar to inkjet (2D) printing. Material jetting is an industrial additive manufacturing process typically requiring a large 3D printer, and can be used for prototyping and end-use parts. Some material jetting systems enable color 3D printing.

Binder jetting

Binder jetting uses a liquid binding material to bond powder materials. The process can be thought of as an intersection between SLS and material jetting technologies. Binder jetting can be done with metal or sand materials to create, respectively, prototype or finished parts, or sand molds.

Sheet lamination

Sheets of metal or even paper material can be bonded together using sheet lamination 3D printing processes. For metal materials, ultrasonic additive manufacturing uses ultrasonic waves and mechanical pressure to bond layers. Laminated object manufacturing uses an adhesive coating to bond sheets of paper or plastic. Especially when using paper, material costs are quite low for sheet lamination. Geometries are not often highly complex given the methodology in these processes, gearing them more toward prototyping usage.

Vat photopolymerization

Stereolithography (SLA) and digital light processing (DLP) processes are classified as vat photopolymerization processes, in which liquid photopolymer in a vat is selectively cured by light-activated polymerization. These processes can be quite complex, down to the micro scale (microstereolithography) and can create some of the most detailed 3D prints. Applications range from prototyping to mass production. Nearly every hearing aid and orthodontic aligner on the market today is produced using SLA technology, as are many jewelry molds.

Powder bed fusion

One of the most common industrial additive manufacturing processes, powder bed fusion (PBF) uses thermal energy to selectively fuse regions of a powder bed. PBF processes include selective laser sintering (SLS) — using a laser — and electron beam melting (EBM) — using an electron beam. Plastics, metals, and ceramics can be 3D printed using PBF processes, creating prototype and end-use parts.

Directed energy deposition

Directed energy deposition (DED) melts materials, generally metals, as they are deposited. This process has the capability to repair and maintain existing structures, as a laser mounted on a multi-axis arm can move around relatively freely to lay down focused material. Maintenance and repair (MRO) applications are the most common for this process, which often requires post-processing to smooth the generally large layers.

Additive Manufacturing Pricing

Once the decision has been made to use additive manufacturing by engaging a service bureau, one large question remains: pricing.

Shapeways lays out clearly its pricing structuring, from engaging a designer to simply uploading a model for an instant quote. 

Among the considerations for our pricing are:

• Materials:
  • Material Volume
  • Machine Space
  • Number of parts
  • Production
  • Bounding Box Volume
  • Support Volume
• Manufacturing Speed:
  • Priority
  • Economy
  • Rush
• Shipping cost
• Taxes

Bulk pricing is also available for large orders. See our pricing overview here for full details.

Customer Examples

As popular wisdom holds that “show, don’t tell” is the best way to prove a point, we’d like to share some examples of customer work achieved through the Shapeways platform. Just a few of our customer successes include:

Quantum Systems

Taking to the sky, drones are already high-tech — but 3D printing brings them to new heights. Quantum Systems specializes in making advanced eVTOL (electric vertical take off and landing) drones. These are anything but hobbyist toys, as the Quantum Systems team recently tested their Trinity F90+ to deliver medical samples. These machines must be robust, complex, and lightweight, lending their manufacture ideally to incorporating 3D printing.

Quantum Systems’ CEO, Florian Seibel, explains, “The complex geometry of 3D-printed parts saves weight by using synergy effects. With synergy effects we mean that with 3D-printed parts we are able to reduce the total number of parts by designing multiple-use parts with integral functionality.”

My Track Technology

“All-terrain vehicle” may not be the first application to spring to mind for 3D printing, but My Track Technology (MTT) used the technology to slash time and costs in their production process. Rapid prototyping and strong end-use 3D printed parts brought their eco-friendly, electric remote-controlled track vehicle to life for use in extreme terrains.

Michael Martel from MTT sums up the experience of working with Shapeways to develop the machine in three key benefits: “Speed, cost and simplicity. When our 3D drawing is finished we don’t have to produce fabrication drawings. We just upload the 3D file on Shapeways’ website. Very simple. We also do not have to build a mold for 1 up to 50 parts. It’s very great cost saving. Later when the design is perfect we can build a mold and be confident that the mold will meet our requirements. We are also not limited to a particular shape with 3D printing, practically every shape is possible. Finally, the precision, repeatability and tolerances are better than most of the others manufacturing methods.”

Cityscape Rings

Unique jewelry design is an excellent showpiece for 3D printing. The Cityscape rings emerged from designer and trained goldsmith Ola Shekhtman, who loves architecture and travel, and sought to capture iconic landmarks in a wearable way. She debuted her Cityscape collection in 2015, and has sold well over 6,000 rings through her e-commerce shops.

She says of 3D printing, “3D gives me three kinds of freedom: 1. Geographic freedom. I can live where I want and travel all year long, and the only tool I need to have with me is my laptop. 2. Freedom of creativity. Details rule! Customers adore buildings with columns and tiny statues, which I create in 3D software. It is tricky to pierce windows [by hand] and 3D lets me make it easily. And, 3. Freedom of time – To make 1000 rings by hand I would spend nearly 100 years. Shapeways can produce this amount in 2-3 weeks. Using 3D modeling I can make a city once and it is available to order in any quantity, forever, which frees me up for new designs.”

LuxMea

A standout design case for 2020 emerged from LuxMea Studio, which specializes in computational design and fabrication. The company developed its customizable Nuo Masks, intended for comfortable, durable, reusable fit for each individual’s face. Rapid prototyping and reliable bespoke mask manufacturing showcases 3D printing for mass customization — and for pandemic safety with style.

The LuxMea team explains: “We have been working with Shapeways since early 2016 and Shapeways has always been our trusted and go-to partner for commercial 3D printing production. We had a meeting last year and discussed the possibility for mass customization. The Shapeways API allows certain software platforms to export files directly to Shapeways, without the need of manually uploading each file. Without Shapeways’s API, we would have to limit the quantity and increase the cost to account for manually uploading and checking for each file.”

Please contact us today to learn more about our offerings and how we can help you every step of the way for your next project.

The post What is Additive Manufacturing? – A Complete Guide appeared first on Shapeways Blog.

Here are 5 drone projects that have pushed the boundaries with the help of 3D printing:

Disaster Relief X VEIN Drone by Team ROK

After the Great East Japan earthquake and tsunami brought disaster on a massive scale in 2011, Yuki Ogasawara and Ryo Kumeda of Team ROK were inspired to create a drone built especially for disaster relief and search and rescue. A few years later they used 3D printing and generative design to create their x-shaped X VEIN drone. Because disaster aid presents its own specific set of challenges, the team used 3D printing to be able to customize their drone based on their exact needs.

The design features freeform curves, and a 3D printed lattice-patterned body for maintaining minimal weight while still giving it the strength required to operate in difficult conditions. X VEIN is able to fly within a 500 meter range and can be equipped with thermographic and infrared-imaging and capture images that can be viewed in real time to access remote or obstructed areas and help locate survivors. Because many of its parts are 3D printed, if they are damaged on a mission they can be re-printed and replaced on site. 3D Printing was a crucial tool to be able to have the level of design freedom necessary to build a drone with these specific needs and it ensures that the drone can be further customized in the future depending on the situation at hand.

CargoCopter by KU Leuven Researchers

Built to deliver payloads over long distances, KU Leuven research team created the 3D printed CargoCopter, a hybrid drone that combines fixed wings and multi-rotors so that it can take off vertically, hover and then fly horizontally. It was designed to expand the range and speed of traditional multi-rotor drones and thanks to its hybrid nature can efficiently transition from take-off to long-distance flight. It can carry up to 5kg, has a range of 60km and can fly up to 100km/hour. The team used 3D printing to rapidly prototype over 3 years to arrive at this model and their designs were able to quickly evolve. Thanks to the customization flexibility of 3D printing they are able to optimize each new CargoCopter design based on the needs of its particular mission.

BLUEROV2 Submarine Drone by Blue Robotics

Aerial drones are not the only ones making use of 3D printing. When Blue Robotics set out to build their underwater drones, they needed parts that could withstand the harsh conditions of the ocean and had trouble sourcing ones that were durable enough and weren’t overly expensive. They then turned to 3D printing to be able to prototype their own parts at a much more affordable rate. Using 3D printing to prototype also led them to customize parts to fit their exact needs. The BLUEROV2 comes with a high definition, wide-angle low-light camera with two or four lights to illuminate the ocean around it. It can travel to a depth of up to 100 meters and is built to withstand currents. The ROV is designed with expansion and modification in mind, and is fitted with a customizable frame to accommodate a range of functions.

Piccolissimo The Tiny Drone by Matt Piccoli from UPenn

In 2016, Matt Piccoli from UPenn’s School of Engineering and Applied Science designed the world’s smallest steerable drone “Piccolissimo”. The tiny drone comes in two sizes: one weighs 2.5 grams and is the size of a quarter, and the other steerable version is 2 grams heavier and a centimeter wider. It was 3D printed using lightweight plastic. It has two moving parts, the robot’s body and motor, which spins one way 40 times per second, and its propeller spinning 800 per second in the opposite direction. Its motion is determined by how quickly the propeller and body are spinning, which can be controlled by infrared signals. The drone can carry a load of up to one gram, like a small camera or sensor. Its size suggests that it would be a fitting model for surveying or search and rescue missions, as a few hundred could be used to cover more ground than a single larger sized drone.

The Int-Ball by the Japan Aerospace Exploration Agency (JAXA)

The Int-Ball, or JEM Internal Ball Camera was built using 3D printing to float aboard the International Space Station taking video and photo documentation. The spherical drone arrived on the ISS in June of 2017 and weighs 1kg, has a 15cm diameter and moves with 12 propellers. The Int-Ball features both internal and external components produced using 3D printing and is designed to float in a zero-gravity environment with the ability to move autonomously or be maneuvered by operators on Earth. It is set to reduce the crew’s workload by 10% by taking on image capturing duties.

3D printing helps to redefine what is possible when it comes to exploring and achieving innovation in drone technology. Its efficiency in prototyping and customization make room for a higher level of productivity and imagination, improving the way drones are designed and manufactured. If you are looking to create the next innovative drone, 3D printing is essential to facilitating the most efficient and flexible production process.

See how Shapeways can help your drone business transition to 3D printing!

The post 5 Next-Level 3D Printed Drones That Are Pushing the Industry Forward appeared first on Shapeways Blog.

Consumers in today’s market expect more and more for their products and experiences to be tailored to them, and to have more control over what they pay for. The challenge in meeting that demand for mass customization is having to switch from producing hundreds to millions of the same item to efficiently producing small batches of personalized items within a similarly short time frame without costs going up astronomically. Additive manufacturing helps maximize efficiency in making large-scale personalization more accessible.

Customer-Led Designs

Companies that use 3D printing for customization set up design interfaces to allow customers to make their own design choices in regards to color, texture, material or fit. For example, some automotive companies have given their customers the ability to choose their vehicle’s colors or include personalized lettering on the interiors. Any product can potentially be customized according to what suits the buyer: cars, furniture, fixtures, jewelry and more.

3D Scanning for a Perfect Fit

With 3D scanning software becoming more prominent and user-friendly, it is easier than ever for customers to contribute to the design process themselves. The footwear industry is making use of 3D printing technology, allowing customers to make aesthetic choices for their shoes and also to personalize their insoles based on their specific foot shape, weight or running style. Customization is also becoming a standard in the tabletop gaming industry, with more and more companies offering customizable game pieces.

A smart-phone app can take a scan of a person’s face or other body part and generate a 3D file that can be used to create a product that fits them perfectly. LuxMea has used this technology to produce face masks that are not only aesthetically customizable but also provide a perfect fit for the individual wearer, making them safer and more comfortable.

3D scans can be used to personalize earphones, shoe insoles, eyewear and many more products thanks to 3D printing technology. This ability to creatively participate in the design process boosts customer satisfaction, as the ability to have more say in what they spend money on makes the process more fun and efficient for the users.

Customization to Improve Lives

Advances in 3D scanning technology contribute heavily to the medical industry, an area where personalization can be crucial. With the ability to scan specific parts of the body, more accurate and patient-specific improvements can be made to someone’s health and wellbeing. 3D printing allows for more affordable and personalized prosthetics, implants and other aids ensuring a higher level of comfort and support. This is an area where perfect fit as well as timely delivery can be of the utmost importance to the success of medical devices and equipment. 3D printing is able to surpass the limits of traditional processes because of its ability to produce highly complex parts quicker. Customization also improves the instruments and supplies that physicians use, making them more efficient and comfortable and improving surgical outcomes.

Understanding Preferences and Trends

By allowing customers to make more of their own choices, the process provides key insights into trends and consumer preferences. Customers’ tastes can be used to help companies evolve their products and make product developments to fit the needs of their customers.

On-Demand Manufacturing

Another benefit of using 3D printing for customized products is a shift towards more on-demand production. By placing more emphasis on smaller personalized products instead of mass-produced products before orders are received, inventories can be reduced and a substantial amount of waste can be avoided. This can save money in material costs and create a more sustainable manufacturing process.

The 3D printing industry is growing at a very fast rate, and is making it easier to transition to using 3D printing over traditional mass production methods as time goes on. However, the transition can still be expensive and time consuming. 3D printing services like Shapeways can ease that transition by giving you access to high quality manufacturing as well as tailored e-commerce support. Let us know how we can help with your mass-customization needs.

The post Why 3D Printing Is Key For Mass Customizable Products appeared first on Shapeways Blog.

To put this in perspective, all manufacturing factories require the help of production aids to manufacture and assemble the products. A production aid is any device type of tool, jig, fixture, or a device used to enhance, optimize, and assist or speedup the manufacturing or assembly process.

More often than not, production aids are customized to suit the product being manufactured but manufacturing such customized tools in limited quantities is always costly.

Considering the importance of production aids and its limited quantities, 3D printing can be a perfect fit in this scenario. Factories can leverage the capabilities of 3D printing to produce them at reduced costs. 3D printing can hand a powerful tool to organizations to improve its overall plant efficiency.

We’ll first look at the benefits of using 3D printing in creating production aids.

VALUE OF 3D PRINTED PRODUCTION AIDS

• Faster Time-to-Market

With 3D printing, production aids can be manufactured rapidly. This starts a chain reaction to also speed up the pace of production and assembly, thus cutting down the time-to-market to take your product from factory to customer.

• Improved Plant Efficiency

With faster production and assembly leading to faster output and delivery, plant efficiency can be considerably improved.

• Reduced Cost of Production

By improving part repeatability and accuracy, rejections can be reduced, leading to reduced cost of production. When manufacturing jigs and fixtures, 3D printing can eliminate the time needed for iterations before finalizing on the desired jig or fixture.

• Performance Improvements

By using the design freedom capability of 3D printing, innovative and complex fixtures can be designed and printed to improve the production and assembly performance with fewer constraints.

• Better Production Aids

Compared to traditionally manufactured production aids, 3D printed production aids can be more efficient. It can be made from lighter materials but still offer comparable strength and durability. Alternatively, the tools can be topology optimized to reduce weight and material usage.

• Part Consolidation

3D printing offers the capability to consolidate multiple jigs and fixtures into a single production aid thus operators are able to perform multiple operations at the same work station using a same fixture, saving costs, storage, and handling.

• Worker Safety

As factories are getting more advanced there is even more impetus on ensuring workers’ safety. By 3D printing customized safety aid solutions such as safety latches, casings, locks, and even obsolete safety parts, the workplace safety can be improved.

TYPES OF 3D PRINTED PRODUCTION AIDS

Let’s take a look at some of the different types of production aids that can be 3D printed to improve overall plant efficiency.

Jigs & Fixtures

Jigs and fixtures are customized tools used to hold, guide and control the movement of a workpiece while other operations are carried out.

Examples of customizable jigs and fixtures include guides for burr removal, dimensional accuracy testing, sticker pasting in packaging operations, etc. All can be manufactured on demand.

Guides

Drill guides are a commonplace tool on all shop floors. They ensure that holes are drilled in their intended center and are not deflecting from this position in either linear or angular terms and are staying within the prescribed tolerance limits.

Marking Tools

In traditional manufacturing a part travels from one work station to the other as different operators perform cutting operations and it is important that the cutting accuracy and repeatability is maintained in all parts. For this, a tool can be 3D printed to perfectly identify the marks to perform accurate cutting operation.

Safety Latches, Casings and Locks

Apart from making sure the production is carried out efficiently, the plant also has to ensure the safety of its workers. For this a plant employs multiple safety tools like latches, casings, locks and more. These safety tools help minimize on-site accidents.

Go / No-Go Gauges

Go / No-Go gauges are used in a manufacturing plants as a testing tool to test weather a finished part meets the dimensional standards. A Go/No-Go gauge can easily identify any deflection of the part in terms of its form, shape and dimension. It can rapidly conform or reject a part according to the fit in the gauge instead of using other measurement tools like calipers.

Maintenance Parts

Custom quality check and maintenance parts a can be rapidly manufactured. Simple customizable tools such as stopper tools used to tighten nuts and bolts can be kept in the individual machine’s toolbox, thus increasing maintenance efficiency while saving time.

3D PRINTING OF PRODUCTION AIDS

Production aids can be 3D printed through various 3D printing technologies. For industrial printing, the commonly used technologies include Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS) and Binder Jetting.

SLS 3D Printing

Selective Laser Sintering (SLS) is a powder-bed fusion technology. It uses a powdered material that is sintered via a laser to form the object. This technology offers greater design freedom than some of the other 3D printing technologies. For parts involving complex designs, SLS can be effectively used.

SLM & DMLS 3D Printing

FDM printing can offer cheaper production aids, SLA can offer aids with smoother surface finishes while SLS can provide greater design freedom but all these technologies print only with polymers. For industrial parts requiring heavy-duty jigs, metal 3D printing is recommended. Metal 3D printing technologies suitable for production aids include SLM, DMLS and Binder Jetting.

Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS) are both powder-bed fusion technologies but for metals. Both of these technologies can be used for small-size precision production aids.

Binder Jetting

Binder Jetting technology can be used in case of large parts. This technology also uses powdered metal material but uses a binder material to fuse the metal particles together. The greatest advantage of binder jetting is that it can manufacture parts at a fraction of the cost compared to DMLS/SLM and Material Jetting. Moreover it is suitable for low-to-medium batch production when multiple tools need to be mass produced for the entire factory.

CONCLUSION

Factories can leverage 3D printing to create high-quality production tools to improve their plant efficiency. With 3D printing’s wide applicability, range of materials, design freedom and manufacturing flexibility, this technology provides many benefits that should not be overlooked.

The post Improving Plant Efficiency with 3D Printed Production Aids appeared first on Shapeways Blog.

Flexibility in Design

When trying to create something using traditional manufacturing technologies, each new part has to have its own tool, mold, or die before it can be created. 3D printers, on the other hand, are much more flexible on the creation process. Each design is created in a CAD (computer-aided design) program and can be ready in hours instead of days or weeks. The 3D printer will be able to incorporate each new design on the very next run, which means reduced downtime for each iteration.

Complex Designs Done Fast

Advanced 3D printers have the ability to create one or more of the following features in one print job:

1. interlocking designs
2. Full colors
3. Multiple materials and colors

Having a 3D printer that can incorporate complex designs with multiple moving pieces and/or print in different material and color variations makes creating product varieties much quicker and easier than with traditional manufacturing. This increased flexibility eliminates the time and expenses needed for additional product assembly.

No Minimum Order Requirements

When printing in smaller quantities, the costs associated with 3D printing are far lower than those with traditional manufacturing options. One of the most significant savings comes from eliminating the need to create entirely new dies or molds for each project.

Because of this, there is no need to require large orders of a single part, which is typically necessary for traditional manufacturing. 3D printing can efficiently produce individual products, or small batches of products, without the added time in creating dies or molds. This makes 3D printing the ideal solution to produce high volumes of unique orders.

Reduced Waste

3D printing will typically have much less waste than traditional manufacturing technologies. Without the need to order hundreds or thousands of each part in advance, every product can be printed on demand. This helps eliminate the environmental impact when surplus products are produced and discarded, and reduces the need for additional storage.

Proven when it Matters Most

3D printing is a great manufacturing option that can meet rapidly changing demands. Find out how Shapeways can help with your product creation needs with efficient and high quality 3D printing.

The post Not Just Faster…Better: How 3D Printing Allows for Rapid Improvements appeared first on Shapeways Blog.