3D printing processes and technologies

Detailed information about 3D printing technologies.

Process Technology
Extrusion Fused Deposition Modeling (FDM), Fused Filament Fabrication
(FFF)

Vat Polymerization Stereolithography (SLA), Digital Light Processing (DLP)

Powder Bed Fusion (Polymers) Selective Laser Sintering (SLS)

Material Jetting Material Jetting (MJ), Drop on Demand (DOD)

Binder Jetting Sand Binder Jetting, Metal Binder Jetting

Powder Bed Fusion (Metals) Multi Jet Fusion (MJF), Direct Metal Laser Sintering (DMLS);
Selective Laser Melting (SLM); Electron Beam Melting (EBM)

Stereolithography 3D printer in the laboratory prints a structure from a photopolymer.

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3D printing processes and technologies

Process Extrusion
Description Extrusion is one of the 3D printing processes that requires a filament of solid material
passing through a heated nozzle. The material is melted as it goes through the nozzle
and is deposited on a platform forming layers with the shape of the object that is being
produced. The material starts hardening after being extruded from the nozzle, and the
layers will bond to create solid 3 dimensional objects.
The most common 3D printing extrusion filament materials are plastics (ABS, PLA, etc.)
but this process can be used to produce objects from other materials.

Technologies The main technology is Fused Deposition Modeling (FDM). This technology is also called
FFF (Fused Filament Fabrication).

Features / Pros ▪ Best surface finish

▪ Full color
▪ Multi-material available
Cons ▪ Brittle
▪ Not sustainable for mechanical parts
Common Applications ▪ DIY Projects
▪ Concept Models
▪ Toys and art decoration

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3D printing processes and technologies

Process Vat Polymerization

Description Vat polymerization cures a liquid photopolymer resin with ultraviolet (UV) light layer by
layer. The photopolymer resin is placed on a vat supported by a platform which moves
downwards after each layer is cured on top of the previous one.
The exposure to the UV light cures and solidifies the resin and joins it to the layer below.
There is no structural support during the build phase. Therefore, support structures are
often required.
After the object is produced, the resin is drained from the vat, leaving the printed object.

Technologies There are two main technologies for Vat polymerization: SLA and DLP. The main
difference is the type of light source:
▪ SLA (Stereolithography) uses ultraviolet laser.
▪ DLP (Digital Light Processing) utilizes traditional light-sources like arc lamps

Features / Pros ▪ High accuracy and good finish

▪ Smooth surface finish and fine feature details
▪ Relatively quick process
▪ Good for large build areas
Cons ▪ Relatively expensive
▪ Post processing time and resin removal
▪ Often requires support structures and post curing
▪ Not suitable for mechanical parts
Common Applications ▪ Injection mold-like polymer prototypes
▪ Jewelry
▪ Dental applications
▪ Hearing aids

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3D printing processes and technologies

Process Powder Bed Fusion (Polymers)

Description A high-power laser induces the fusion of very small plastic powder particles, layer by
layer over the surface of a "powder bed". Each layer is bonded to the previous one, and
the process is repeated until the object is produced. The power bed is lowered by the
thickness of one layer, after each layer is produced. The powder material is spread over
previous layers using a roller or blade.
This is the typical powder bed fusion process:
▪ One layer of powder material is spread over the build platform
▪ Laser fuses the layer
▪ A new layer of powder material is spread over the previous layer through a roller
▪ Subsequent layers are fused and added until the object is produced
▪ Unfused material that remains in place during the production is removed during
post-processing

Technologies SLS (Selective Laser Sintering) is the most common 3D printing technology for Powder
Bed Fusion process

Features / Pros ▪ Suitable for models and prototypes

▪ Powder works as support structure
▪ Large range of material options
▪ Functional parts
▪ Good mechanical properties
▪ Complex geometries
Cons ▪ Longer lead times
▪ Lack of structural properties
▪ Size limitations
▪ High power consumption
▪ Finish is dependent on powder grain size
Common Applications ▪ Aerospace parts
▪ Medical and healthcare
▪ Electronics: packaging and connectors
▪ Functional proof of concept prototypes
▪ Design evaluation models

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3D printing processes and technologies

Process Material Jetting

Description The material is selectively deposited (jetted) in hundreds of droplets through a small
diameter nozzle which moves horizontally across a build surface (platform) where it
solidifies as the model is built layer by layer. Once deposited, the material is hardened by
UV light.
Material Jetting process allows for different materials to be printed in the same object.
This allows creating support structures from a different material to the model being
produced.
Step by step process:
▪ The print head is positioned over the build platform.
▪ Droplets of material are deposited from the print head onto surface
▪ The droplets solidify each layer which is bonded to the previous one.
▪ Post processing (removal of support material).

Technologies MJ (Material Jetting)

DOD (Drop on Demand)

Features / Pros ▪ High accuracy of deposition of droplets

▪ Low waste of production material
▪ Multiple material parts and colors under one process
▪ Best surface finish
▪ Full mix of color
Cons ▪ Support material is usually required
▪ Materials are limited to polymers and waxes
▪ Brittle, not suitable for mechanical parts
▪ Higher cost than SLA/DLP for visual purposes
Common Applications ▪ Ideal for creating realistic visual and haptic prototypes with very smooth
surfaces that resemble injection molded parts

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3D printing processes and technologies

Process Binder Jetting

Description The binder jetting process requires two materials: powder base material and a liquid
binder. Powder is spread in the build chamber in layers and binder is applied through jet
nozzles that “glue” the powder particles, creating the layer by layer shape of the object.
The finishing consists of leaving the object in the unused powder to cure and
strengthen. The object is removed from the platform and any unbound powder is
removed with compressed air.

Technologies Sand Binder Jetting

Metal Binder Jetting

Features / Pros ▪ Objects can have different colors

▪ Range of materials including metal, polymers and ceramics
▪ Faster process
▪ Large build volumes
▪ Functional metal parts
Cons ▪ Not always suitable for structural parts
▪ Post processing can require significant time
Common Applications ▪ Sand molds for castings
▪ Complex ceramic parts
▪ Functional metal parts
▪ Orthopedics
▪ Custom tools
▪ Tools for avionics

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3D printing processes and technologies

Process Powder Bed Fusion (Metals)

Description Metal Powder Bed Fusion produces objects, using a thermal source to fuse metal
powder particles layer after layer.
Powder Bed Fusion technologies employ mechanisms for adding powder as the object is
being produced, resulting in the final component being encased in the metal powder.
The main variations come from the use of different energy sources; lasers or electron
beams.

Technologies DMLS (Direct Metal Laser Sintering)

SLM (Selective Laser Melting)
EBM (Electron Beam Melting)
MJF (Multi Jet Fusion)

Features / Pros ▪ Strong, functional parts

▪ Complex geometries
Cons ▪ High price
Common Applications ▪ Aerospace
▪ Oil & gas
▪ Marine
▪ Automobile

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