The Process: How to Get Something 3D Printed

Getting an item 3D printed is a journey that transforms a mere concept into a physical reality. This process, while intricate, can be broken down into a series of well-defined steps:

• 1. Conceptualization and Design: Every 3D printed object starts with an idea. This concept is then translated into a digital design using Computer-Aided Design (CAD) software. CAD allows designers to create precise, detailed models of their ideas. This stage is crucial for defining the dimensions, shape, and functionality of the object. For those without CAD expertise, many 3D printing companies offer design services to help bring ideas to life.
• 2. Selecting the Right Technology and Material: Once the design is ready, the next step is to choose the appropriate 3D printing technology and material. This decision depends on the intended use of the object, its required properties (such as strength, flexibility, or temperature resistance), and the level of detail needed. Common choices include FDM for robust, less detailed parts, SLA for high-detail prototypes, and MJF or SLS for functional, durable components. Material selection ranges from various plastics and resins to metals, each offering different benefits. If you are using a desktop machine you will typically have way more technology and material limitations than if you are working with a service bureau (covered below in step 4.) Desktop machines are typically limited to small scale filament and resin machines with few exceptions.
• 3. Optimizing the Design for 3D Printing: Before printing, it’s important to optimize the CAD model for the chosen printing technology. This step involves ensuring the design is structurally sound and making adjustments to avoid printing issues. Factors like wall thickness, support structures, and print orientation need to be considered. Optimization helps in reducing material usage, minimizing printing errors, and ensuring the final product’s quality. Design optimization is 100% based on the technology selected. Different processes have different design rules and it is best to consult design guides or experts.
• 4. 3D Printing the Object: The actual printing of the object marks a pivotal moment in the process, where digital designs materialize into physical form. At this stage, one crucial decision is whether to use a desktop 3D printer or engage a professional service bureau.
  • Using a Desktop 3D Printer: For individuals or small businesses with access to desktop 3D printers, this option allows for in-house printing. Desktop printers are ideal for smaller projects, prototypes, or personal use. While they offer convenience and immediate control over the printing process, their capabilities are often limited in terms of size, precision, and material options compared to professional-grade machines. Users need to have a good understanding of their printer’s settings and capabilities, and be prepared to handle any maintenance or troubleshooting. This is an enormous investment in time and money to get consistent quality and is usually only worth it for repeat users or hobbyists.
  • Choosing a Professional Service Bureau: For larger, more complex, or high-quality prints, a professional 3D printing service bureau is often the preferred choice. These bureaus house advanced 3D printing technologies, like SLA, SLS, and MJF, which may not be feasible for individual users to own. They offer a wider range of material choices, professional-grade precision, and the expertise of experienced technicians. Additionally, service bureaus can provide valuable insights into optimizing designs for better results. While this option may come with a higher cost and longer turnaround time, it ensures a higher quality and consistency, especially for commercial-grade projects or specialized applications.

• 5. Post-Processing: After the object is printed, it often requires post-processing to achieve the desired finish and functionality. The extent and nature of post-processing can vary significantly depending on whether the printing is done using a desktop 3D printer or through a professional service bureau.
  • Post-Processing with Desktop 3D Printing: When using a desktop 3D printer, post-processing is typically a hands-on, DIY task. It may involve removing support structures, which are extra pieces of material added during printing to support overhanging features. Sanding or filing may be needed to smooth out rough edges or surfaces. Users might also engage in painting or sealing the object to enhance its appearance or durability. While these steps can be rewarding and offer a high degree of customization, they require time, effort, and a certain level of skill from the user.
  • Post-Processing through a Service Bureau: Professional service bureaus offer a more comprehensive range of post-processing options with greater precision. These may include advanced techniques like chemical smoothing, color dyeing, or UV curing, which are not typically available for home users. The bureau’s expertise ensures that the finished product has a higher level of quality and professionalism. Additionally, for materials like metals, which require specialized post-processing (like heat treatment to relieve stresses or CNC machining for precision features), a service bureau is equipped to handle these complex procedures.

• 6. Quality Check and Delivery: The final phase in the 3D printing process involves ensuring the printed object meets the desired quality standards and is delivered to the end user. This stage varies notably between desktop printing and using a professional service bureau.

• Quality Check and Delivery with Desktop 3D Printing: In a desktop printing setting, the quality check is typically conducted by the individual who performed the printing. This involves inspecting the object for accuracy in dimensions, structural integrity, and surface finish. Any discrepancies or defects might require reprinting or additional post-processing. The advantage here is the immediate feedback and control over the quality process. However, the limitation lies in the subjective nature of the assessment and the potential lack of specialized measuring tools. Obviously parts are made in-house so a major advantage here is no need for shipping.
• Quality Check and Delivery through a Service Bureau: Professional service bureaus employ a more rigorous and standardized quality control process. They utilize advanced measuring and inspection equipment to ensure that each part meets precise specifications and quality standards. This may include dimensional accuracy checks, material quality assessments, and functional tests, depending on the nature of the object. Once an item passes these stringent checks, the service bureau arranges for its secure packaging and delivery to the client. The benefit of using a service bureau lies in their expertise and access to advanced quality control methods, ensuring a high-quality, reliable product. Additionally, their experience in logistics allows for safe and efficient delivery, particularly important for larger, more complex, or sensitive items.

Throughout this process, the role of CAD models and design optimization cannot be overstated.  They are the foundation upon which successful 3D printing projects are built, ensuring that the final product not only looks good but also performs as intended. Junk in, junk out!