To Print or Not To Print? 3D Printing for Prototyping
3D Printing has quickly become a go-to tool throughout the product development design process. The fast turnaround and efficient material use is perfectly suited for early-stage rapid prototyping, achieving additional confidence in concepts before moving on to traditional manufacturing methods.
As a relatively recent manufacturing technology, it has rapidly taken over the world. Hobbyists and professionals have turned to 3D printing to support their iterative process. That being said it still has its limitations. Every technology has its own pros and cons that people need to consider.
In this post, we break down some of the different reasons to print, or not to print a part during the development process.
When to 3D Print
Fast Turnaround Development: Compared to conventional manufacturing methods (milling, injection molding prints require significantly less lead time. Not having to deal with any fixtures or material prep allows a design to be produced in just a handful of hours. This means testing and iterating between concepts has become faster than ever.
Lower Material Cost: Due to 3D printers' additive process very little of the material is wasted. This coupled with an already low-cost material such as PLA, ABS, PETG allows for a relatively unbeatable part cost.
Low Labor Cost: While more expensive materials do exist for 3D printers, Labor cost is consistently low. Assuming the part has been designed properly, minimal supervision is needed. One operator can easily run multiple printers simultaneously. Additionally, with the use of soluble supports, complex geometries do not need additional labor to be fully processed.
Complex Geometry in Fewer Steps: With well-placed support structures, complex 3D geometries are possible with minimal steps. Complex forms previously impossible without significant fixturing, specialized equipment, or post-processing are now consistently and easily reproduced. This has not only allowed for mechanical advancements but also opened a world of design opportunities as well.
When NOT to 3D Print
Durability: Some parts require durability requirements that the standard 3D Printing materials simply can not meet. While some printers do accommodate certain thermoplastics, ceramics, and metals they come with varying cost implications.
Build Size: Prints need to fit within the print bed/chamber with common sizes typically around 10”x10”x12”. Users often split larger models into multiple pieces and assemble them after printing is complete. This adds significant post-processing to the final model, however. Using a specialized larger format printer is also possible in some cases.
Dimensional Tolerance: For most 3D prints, parts are produced in layers of defined height increments. In the case of FDM prints, nozzle size, and print shrinkage need to be considered as well. This means parts that require very small tolerances for them to perform properly are not well suited. The typical tolerances range from 0.1mm [0.004”] to 0.5mm [0.2”] depending on the printer type and material choice.
Finish: 3D-printed parts are easily recognizable by their layered appearance. while advancements have improved how smooth a print can be, it is still impossible to achieve a perfect finish straight off the print bed. Depending on the type of material & 3D printing process, additional post-processing may be required to fully cure, waterproof the prints, or achieve a polished finish.
Newer capabilities and techniques have lowered printing costs while improving quality and capabilities. As a result, 3D Printers can be used to create early prototypes, physical ID mockups, and even production parts in some cases. Acorn has printing capabilities on site and has been using them for years to reduce our client's time to market. If you have a product you want made, Acorn has everything you need to engineer, design, and test concepts.