3D Printing 101
Welcome to the fascinating world of 3D printing! This guide will introduce you to the basics of 3D printing and help you get started with this amazing hobby.
What is 3D Printing?
3D printing, also known as additive manufacturing, is a process of creating three-dimensional objects from a digital file. Instead of removing material, 3D printing adds material layer by layer to build an object.
FDM works by using thermoplastic filament, which is basically a cord of plastic that can be melted, selectively deposited, and cooled. This is repeated, layer by layer, until an entire model is formed.
This technology was created by people who wanted to rapidly prototype parts. Even today, rapid prototype production is one of the biggest benefits of FDM and 3D printing in general. Not surprisingly, 3D printing has also become a potent manufacturing solution.
Before we proceed with the details of how FDM works, there’s one more thing worth mentioning. In case you’ve already done some research on 3D printing, you may have noticed that some sources use the term “FFF”, which stands for “fused filament fabrication”, instead of “FDM”. That’s because the term FDM was originally trademarked by Stratasys, and the other abbreviation is a more general term. Remember, it’s the same technology, only the names are different. Today, most people use “FDM”.
Types of 3D Printing
There are several types of 3D printing methods, but the most popular ones are:
- FDM (Fused Deposition Modeling): Uses a spool of filament which is heated and extruded layer by layer.
- SLA (Stereolithography): Uses a resin and a light source (often UV) to solidify layers of the object.
- SLS (Selective Laser Sintering): Uses powder and a laser to create objects.
Types of 3D Printers
- Cartesian: also known as
i3
or bed-slingers, these were the most prolific for a while, but other technologies are staring to take over. Here, the print head moves along thex
andz
axis, and the bed moves along they
axis. These have proven to be reliable but slow. - CoreXY: These machines are known for speed and can be seen on higher-end
machines such as the Bambu Labs machines and the new Prusa XL. With these
machines, the
z
axis (bed) moves up and down and the print head (also known as tool head), moves along thex
andy
axis via belts driven by motors typically in the back of the gantry. This has the added benefit of a lighter print head and allowing for faster print speeds at the cost of complexity. - And others: See 3D Printer Hardware for more.
Getting Started
1. Choosing a Printer
Depending on your budget and requirements, there are several great printers available for beginners, such as:
- Creality Ender 3 - the heavy-weight for many years, currently on v3
- Prusa i3 MK3S+/MK4 - high-end bed-slingers known for legendary reliability and quality... and price tag.
- Bambu Labs X1/P1P/P1S - Known as the disruptors of the space, these coreXY machines have challenged the status quo with their speedy prints without sacrificing on quality at a reasonable price. They achieve this by using technology not typically seen on other printers such as LIDAR and dual bed leveling.
2. Selecting Filament/Resin
- PLA: Most common filament, "biodegradable", and easy to print with.
- While they are biodegradable, it will take many many years to decompose
- ABS: Durable but requires a heated bed. Emits toxic fumes and is sensitive to temperature changes and drafts, so you must use an enclosure and either have filtration or be in a well-ventilated area.
- TPU: Flexible filament. Can be tricky to print. Typically used on direct drive systems, where the extruder sits on the tool head
- Resin: For SLA printers. Toxic, but most machines on the market now have built-in filtration systems. Requires extensive post-processing consisting of:
- Breaking away supports
- Washing/bath in alcohol
- Curing
- But models show no layer lines, and details are typically much sharper
3. Design and Slicing
- Design your model using software like Tinkercad, Fusion 360, OnShape, or Blender.
- Or download models from sites such as Thingiverse, Thangs.com, Printables.com, and others.
- Slice the model using slicers like Cura, PrusaSlicer, or OrcaSlicer to convert it into G-code. G-code is the "language" that printers understand. Note that some vendors include their own slicers, but are usually forks (clones) of the slicers mentioned above.
- Export it to the printer. This can be done either through the network, cloud, or an SD card inserted into the printer.
4. Printing and Post-processing
- Print your object!
- Clean up the model by removing supports and sanding if needed.
Common Issues and Solutions
- Warping: Caused by uneven cooling. Use a heated bed or enclose the printer.
- Clogging: Regularly clean the nozzle.
- Poor Adhesion: Clean the bed, use adhesive agents, or adjust bed leveling.
Safety Tips
- Ensure good ventilation when printing, especially with ABS.
- Never leave a printer unattended.
- Keep printers away from flammable materials.
Resources
- All3DP has an amazing 3D printing 101 article here
- Forums: Websites like Reddit's r/3Dprinting and the RepRap community.
- Tutorials: YouTube channels like Maker's Muse Teaching Tech, and Thomas Sanladerer.
Happy Printing!