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Choosing the correct 3D printing method involves considering numerous factors, such as the intended function, dimensions, and material of the part. At i-make3D, we specialize in guiding you through this selection process to determine the most suitable 3D printing technology for your project.

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Our 3D Printing Services Include

1. Fused Deposition Modeling (FDM)

Fused Deposition Modeling (FDM), also referred to as Fused Filament Fabrication (FFF), stands as the predominant additive manufacturing method utilized in desktop 3D printers. This process entails the extrusion of molten plastic from a computer-controlled nozzle, meticulously constructing a part layer by layer.

In FDM 3D printing, a spool of filament serves as the primary raw material. This filament is guided into the print head, where it undergoes melting before being precisely deposited onto the evolving part. Guided by computer directives, the print head maneuvers along three axes to ensure accurate material placement.
As the freshly deposited material cools, subsequent layers are added atop existing ones, facilitating the formation of intricate 3D shapes.

Advantages:

Most cost-effective 3D printing process for plastic components

Diverse material options available

Widely accessible technology

Disadvantages:

Relatively lower resolution compared to other methods
Visible layer lines may be present

Typical accuracy:
± 0.5% (desktop)
± 0.15% (industrial)

Typical layer height:
Ranges from 50 to 400 microns

FDM Materials:

  • PLA (Polylactic Acid): Widely favored for its affordability, rigidity, and color variety.
  • ABS (Acrylonitrile Butadiene Styrene): Recognized for its high-temperature resistance and durability.
  • PETG (Polyethylene terephthalate): Boasting high impact resistance and favorable thermal properties, also deemed food-safe.
  • Nylon: Known for its toughness, flexibility, and resistance to wear and chemicals.
  • TPE/TPU: These thermoplastic filaments yield highly flexible parts owing to their plastic-rubber blend.
  • PC (Polycarbonate): Renowned for producing exceptionally robust parts resistant to both heat and impact.

2. Stereolithography (SLA)

Stereolithography (SLA) stands out as a distinctive additive manufacturing process that operates differently from FDM. In SLA 3D printing, a laser is utilized to shape a 3D object by selectively hardening areas of photosensitive liquid resin.
During the SLA process, a moving platform submerged in a reservoir of liquid resin facilitates the creation of each layer. Unlike FDM, where the platform remains stationary, in SLA, it adjusts its position vertically after each layer is fully cured. The precise focusing of the SLA laser is achieved through a system of mirrors.
SLA is compatible exclusively with photosensitive polymers, offering exceptional accuracy and intricate detailing. Remarkably, it predates other additive manufacturing techniques, having originated in the 1980s.

Advantages:

High-resolution output

Smooth finish devoid of visible layer lines

Availability of clear material options

Disadvantages:

Higher printer costs compared to FDM

Susceptibility of parts to degradation under sunlight exposure

Requirement for extensive post-processing

Typical accuracy:

± 0.5% (desktop)

± 0.15% (industrial)

Typical layer height:

Ranges from 25 to 100 microns

Stereolithography Materials:

  • Resin 8119: A commonly used SLA material featuring a temperature resistance of up to 65°C.
  • Resin 8118H: Nylon-like resin renowned for its exceptionally high tenacity.
  • Resin 8228: ABS-like resin recognized for its impact resistance and tolerance to temperatures up to 70°C.
  • Resin 8338: Our most temperature-resistant resin capable of withstanding temperatures up to 120°C.
  • Grey Resin - suitable for A-side visual models with limited functionality; Smooth surface, much smoother in fact than almost all other 3D printing materials. Easy to paint
  • Mammoth Resin - Suitable for (large) visual models with limited functionality. Smooth surface
  • Transparent Resin - Suitable for (large) models needing a good, smooth, quality surface with a transparent look. Ideal for demo models, accurate models, and models with limited functionality

3. Selective laser sintering (SLS)

Selective Laser Sintering (SLS) represents a powder bed additive manufacturing technique utilized for fabricating parts from thermoplastic polymer powders, often favored for their functional applications due to the commendable mechanical properties exhibited by SLS printed components.
In SLS 3D printing, a laser is employed to sinter specific areas of powdered material. The process commences with the uniform distribution of a thin layer of powder across the build platform, followed by the laser selectively sintering targeted regions within the 2D layer. Subsequently, the platform descends, additional powder is introduced, and the laser proceeds to sinter the subsequent layer.
Upon completion of all layers, the part undergoes a cooling period. Any unused powder is reclaimed for future use, while excess material is removed during the cleaning process.

Advantages:

Consistent mechanical properties across parts

Elimination of support structures

Disadvantages:

Potential for porosity in printed parts

Surface finish may be rough

Typical accuracy:

± 0.3%

Typical layer height:

Ranges from 100 to 120 microns

SLS Materials:

  • Nylon PA12: Renowned for its mechanical strength, thermal and chemical resistance, and long-term stability.
  • Polyamide: suitable for complex models, prototypes, small series of components, end products, and functional models.
  • Alumide: A blend of aluminum-filled nylon offering high stiffness and a distinctive metallic appearance.
  • TPU: Highly elastic material boasting exceptional tear and abrasion resistance, along with satisfactory thermal resistance.

4. Selective laser melting (SLM)

Selective Laser Melting (SLM) stands as a metal additive manufacturing process renowned for crafting functional, end-use products. Employing a laser, SLM printers melt metal powder particles, fusing them together to produce intricate 3D objects.
In SLM 3D printing, a gas-filled chamber containing metal powder serves as the foundation. The laser traverses over designated sections of the powder, inducing melting and bonding of particles. Upon completion of a layer, the build platform descends to enable the laser’s progression to the subsequent layer.
The SLM process empowers engineers with unparalleled design freedom, enabling the creation of robust metal parts with highly intricate geometries.

Advantages:

Production of robust and durable parts

Facilitation of complex shapes

Disadvantages:

Constraints on build size

Elevated costs associated with the process

Typical accuracy:

± 0.1mm

Typical layer height:

Ranges from 20 to 50 microns

SLM Materials:

  • Titanium: Renowned for its high-temperature resistance, exceptional strength-to-weight ratio, and corrosion resistance. Capable of superior strength through heat treatment.
  • Aluminum: Aluminum alloys offer strength, hardness, and compatibility with intricate shapes or thin-walled parts.
  • Stainless Steel: Resistant to wear, corrosion, and abrasion.
  • Cobalt: Cobalt-chrome alloys boast high strength, hardness, and resilience to high temperatures.
  • Nickel: Nickel alloys exhibit resistance to heat, corrosion, and oxidation, producing parts with strength in high-temperature environments.
  • Precious Metals: Ductile metals like gold, silver, and platinum lend a desirable appearance to parts.

DMLS

With DMLS, you can create 3D metal parts directly from a CAD model. The primary requirement to produce such a part is metal powder in a metal 3D printer. An ultra-fine layer of this metal powder is spread across the building platform.
A powerful laser in the 3D printer then melts the powder precisely at the points specified by the CAD model. This process is repeated layer by layer until the part is fully formed. DMLS technology, standing for Direct Metal Laser Melting, is a type of Laser Powder Bed Fusion (LPBF) technology. It is recognized as one of the most advanced and reliable technologies in metal additive manufacturing worldwide.
This industrial-grade 3D printing technology is used for the serial production of metal parts across various industries, including aerospace, automotive, medical, tool making, and turbomachinery. EOS is a leading global provider of industrial metal 3D printers, materials, and services and has been utilizing DMLS technology for more than three decades.

Advantages:

Unlimited design possibilities – Direct Metal Laser Sintering (DMLS) is the ideal solution when traditional manufacturing methods fall short of requirements.
Boosted production speed: With DMLS technology, you can produce prototypes during the initial stages of development, significantly accelerating the time to market.
Personalized solutions tailored to your needs: DMLS enables the creation of adaptable and customized solutions tailored to specific needs.

Vacuum Casting

What is Vacuum Casting?

Vacuum casting is a manufacturing technology that uses a vacuum to draw liquid casting material into a mold. It differs significantly from injection molding, which pushes liquid material into a mold using a screw.
The process of vacuum casting offers significant advantages, and is particularly useful for parts that have undercuts or fine details.
The process starts with a master model, which 3ERP creates using one of its CNC machining centers — though 3D printing can also be used. This master model is then immersed in liquid silicone, which is cured and becomes the mold.
Once it has been cut and the master model removed, the silicone mold can be put to use. This stage involves pouring casting resin into the mold, as the vacuum removes bubbles and air pockets to ensure a smooth finish.
The resin part is then cured in an oven and removed from the silicone mold after cool down, which can be reused around 20 times.
Each cast part is an exact copy of the original master model. It’s a perfect solution for rapid prototyping and making small batches of quality parts.

Vacuum Casting Process:

Step 1: Master building

Masters are 3D solids of your CAD designs. They are usually made by CNC machining or with 3D Printing. After finishing and inspecting the masters, we will move to the silicone mold making.

Step 2: Mold making

Casting molds are made from liquid silicone. The casting box is half-filled With liquid silicone, heated until the silicone is fully cured and then allowed to cure in an oven for 16 hours. The casting box is filled with extra silicone liquid which is also heated & cured. Once dried, the mold is cut open and the master sample is removed.

Step 3: Make the parts

Casting resins are poured into the empty cavity to create a highly accurate copy of the original. It’s even possible to “overmold” with two or more materials. Silicone molds are typically good for 20 or so copies of the master pattern.

Vacuum Casting Technical Specifications:

  • Typical lead time Up to 20 parts in 15 days or less, depending on the part specification and volumes.
  • Accurate ± 0.3% (with lower limit on ± 0.3 mm on dimensions smaller than 100 mm)
  • Minimum wall thickness To ensure that the mold is filled properly, a wall thickness of at least 0.75 mm is necessary. For best results, we recommend a wall thickness of at least 1.5 mm
  • Maximum part dimensions The size of the mold is limited by the dimensions of the vacuum chamber (1900 x 900 x 750 mm) and by the volume of the product (maximum volume: 10 liters)
  • Typical quantities Up to 25 copies per mold (depending on the mold’s complexity and the casting materials)
  • Color & Finishing Pigment is added to the liquid polyurethane prior to casting, custom painting and texture.

Vacuum Casting FAQ and Answers

Why would I choose vacuum casting over injection molding?
Vacuum casting is a more affordable alternative to IM, especially in low volumes. It also offers unique advantages like an excellent surface finish.
Vacuum casting is best for making visually impressive prototypes, but it can also be used for non-mechanical end-use parts like cases and covers.

The silicone molds used in vacuum casting have a short lifespan, typically around 20 moldings, so we dispose of them after use.

If you wish to keep the 3D printed or CNC machined master model, talk to us directly.

Common Vacuum Casting Applications

  • Visual prototypes
  • Concept proofs
  • Cases and covers
  • Low-volume production
  • Market testing
  • Investor pitches
  • Trade shows
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