Most Innovative 3D Printing Companies in India

In the age of Industry 4.0, no business can increase revenue, gain market share, and promote customer loyalty without fostering innovations. Companies and startups these days foster innovation in a variety of ways. But successful companies differentiate themselves from competitors by leveraging next-generation technologies like additive manufacturing or 3D printing.

3D printing technologies make businesses innovative by facilitating rapid prototyping, on-demand production, and low-volume manufacturing. Also, they have been transforming industries by reconfiguring existing business models and controlling operational costs.

3D printing companies in India help businesses in various sectors to become innovative by switching from subtractive manufacturing to additive manufacturing. Some of these companies make it easier for companies to create prototypes and produce parts by supplying different 3D printing machines and materials.

At the same time, many companies help businesses overcome skill and budget constraints by providing customized 3D printing services. Each of these companies contributes towards making 3D printing technologies accessible, affordable, and sustainable in the emerging economy. We are highlighting some of the most innovative 3D printing companies in India based on their offerings and contributions.

Identifying Some of the Most Innovative 3D Printing Companies in India

Aurum3D

Aurum3D is one of the hottest 3D printing companies in Bangalore. It has been providing 3D designing, 3D printing, and 3D scanning services to both individual and enterprise clients. The customized 3D printing services provided by Aurum3D make companies and startups innovative across industries - manufacturing, engineering, automotive, aerospace, defense, education, and medical.

The Bangalore-based company allows clients to customize 3D printing services by combining the appropriate 3D printing machines and materials. The experienced 3D printing professionals at the company ensure dimensional accuracy and improveprint quality. Also, Aurum3D improves customer satisfaction by reducing 3D printing time and cost at once.

3D Systems

3D Systems is one of the largest 3D printing companies in India. It helps businesses innovate by making it easier for them to buy and use 3D printers. At present, it supplies plastic, metal, and metal-casting 3D printers. Also, the company has developed specialized 3D printing machines for companies in the dental and jewelry industries.

In addition to supplying 3D printing machines and materials, 3D Systems provides consulting and maintenance services. Hence, businesses partner with 3D Systems to purchase the right 3D printer and use the machine without deploying an in-house support team. 3D System has already supplied 3D printers to customers from many industries.

Fractal Works

Fractal Works is one of the innovative 3D printing companies in India that supplies 3D printers as well as provides 3D designing and printing services. It allows customers to choose from several desktop, professional, and industrial 3D printing machines. The desktop 3D printer is powered by FFF 3D printing technology, while the industrial 3D printers are driven by SLA 3D printing technology.

At the same time, customers can get the 3D printing services provided by Fractal Works to produce parts and prototypes on demand. Fractal Works stands out from the crowd by supplying 3D printers to customers in the manufacturing, entertainment, education, automotive, dental, jewelry, and engineering industries.

Brahma3

The Bangalore-based startup surprised competitors by launching the first indigenously developed 3D printer in India – Brahma3 Anvil. The team of designers and engineers focuses extensively on making Brahma3 Anvil accessible to schools, colleges, small companies, and startups. The startup keeps the price of commercial 3D printers low by partnering with open-source communities.

Also, Brahma3 Anvil produces parts through an industrial 3D printing process – stereolithography (SL). The process is effective in producing parts with complex geometries. Hence, individuals and enterprises can use Brahma3 Anvil without a hefty upfront investment. The startup encourages enthusiasts, students, and hobbyists to design for 3D by running a designer-in-residence program.

Imaginarium

Imaginarium helps businesses innovate and experience by setting up an all-in-one store. Customers can visit the online store to choose from a wide range of 3D printing hardware and software. They have the option to buy desktop and professional 3D printing machines developed by leading manufacturers.

At the same time, the additive manufacturing services provided by Imaginarium help businesses produce prototypes, spare parts, production parts, and concept models on demand.

At present, Imaginarium provides both polymer and metal 3D printing services to customers. The customers also have the option to get specialized jewelry manufacturing and patient-specific healthcare solutions provided by Imaginarium.

Fabheads

The Chennai-based 3D printing company helps businesses promote innovation by supplying continuous fiber 3D printers. At present, Fabheads allows clients to choose from F Series Continuous Fiber 3D Printer and G Series Amazingly Intelligent and User-Friendly 3D Printer. At the same time, it produces customized 3D printers for clients according to their precise needs.

In addition to being user-friendly, the 3D printers developed by Fabheads come in various sizes and support different materials. They are further powered by cloud-based 3D printing software. Fabheads make it easier for clients to use its 3D printers by supplying customized continuous fiber materials and providing technical support.

Think3D

Think3D helps businesses transform processes by providing access to the largest digital manufacturing facility in India. Companies and startups from various sectors partner with this Hyderabad-based 3D printing company to leverage over 69 in-house machines. Also, the team of technically-qualified professionals at Think3D has already produced more than 4 million parts for 10000 customers across industries.

Think3D provides 3D designing, 3D printing, and 3D scanning services to clients in the manufacturing, automotive, architecture, and medical industries. It creates opportunities for businesses to innovate by allowing customers to choose from a wide range of 3D printing materials. Hence, it becomes easier for businesses to get customized 3D printing services at competitive prices.

Conclusion

Many companies and startups contribute towards making additive manufacturing technologies accessible, sustainable, and scalable in India. But some companies stand out from the crowd by producing industry-specific 3D printers or providing superior and customized 3D printing services. Many organizations highlight these innovative 3D printing companies in India by appreciating their contributions and achievements.

Best Automotive 3D Printing Companies in Bangalore

3D printing or additive manufacturing is one of the next-generation technologies transforming the global automotive industry.Companies and startups in the automotive industry use 3D printing machines and materials to simplify many time-consuming and cost-intensive processes.

In addition to switching from subtractive manufacturing to additive manufacturing, various 3D printing technologies enable automotive companies to modernize the designing, prototyping, testing, production, and maintenance of motor vehicles.

Most automotive companies these days save resources by 3D-printing end parts instead of producing parts and components. Likewise, many companies have already started selling 3D-printed cars and supercars in high-income countries.

In 2022, India emerged as the fourth-largest automotive market in the world. At present, Bangalore is home to many international automotive and automobile companies. The automotive companies in Bangalore leverage 3D printing technologies to become a part of Industry 4.0.

Some of these companies have built in-house 3D printing infrastructure, while others outsource 3D designing and 3D printing services. Many 3D printing companies have built a reputation by designing and printing parts for leading automotive companies.

Hence, every automotive company now has the option to choose from many automotive 3D printing companies in Bangalore. We are making it easier for you to get superior and customized automotive 3D printing solutions in Bangalore by comparing some of these reputable companies and startups.

Shortlisting 7 of the Best Automotive 3D Printing Companies in Bangalore

1. Aurum3D

Aurum3D is one of the local automotive 3D printing companies in Bangalore. But it has built a reputation by providing online 3D designing and 3D printing services to automotive companies across regions. The automotive 3D printing services provided by Aurum3D help manufacturers launch superior motor vehicles by accelerating prototyping, customization, and production.

Also, many automotive companies partner with Aurum3D to supply parts or components to customers on demand by getting FDM, SLS, or SLA 3D printing services. Aurum3D has been impressing automotive companies by reducing component weight, producing parts for vintage motor vehicles, and supplying spare parts on demand.

2. Rapidproto Labs

This 3D printing company's factory and office are located in Tamil Nadu. But Rapidproto Labs has been providing online 3D printing services to automotive companies in Bangalore. It has produced parts for automotive companies using FDM, SLS, and SLA 3D printing technologies.

Rapid3D delivers parts and conceptual models to clients in about 2 days. Hence, it becomes easier for automotive companies to validate and refine prototypes regularly. At the same time, the delivery time helps automotive companies to supply parts or components to customers on demand.

3. Think3D

The factory and corporate office of Think3D are located in Hyderabad. But Think3D has been providing 3D designing and 3D printing services to automotive companies in Bangalore through its website. Many automotive companies in Bangalore partner with Think3D to leverage its robust infrastructure consisting of 69 in-house machines.

Think3D meets the automotive 3D printing needs of clients using FDM, SLS, SLA, DMLS, and MJP 3D printing machines. In addition to deploying technically-qualified teams, Think3D focuses extensively on protecting customers’ designs and data. The company has produced fixtures, tooling, and spare parts for leading automotive companies in Bangalore.

4. 3Ding

This Bangalore-based 3D printing company meets the additive manufacturing needs of automotive companies in two district ways. 3Ding enables automotive companies in Bangalore to produce parts and components on their own by renting the right 3D printing machines.

Also, automotive companies in Bangalore have the option to avail themselves of the 3D designing and 3D printing services provided by 3Ding. Many automotive companies choose 3Ding to produce parts and prototypes in-house without escalating 3D printing costs.

5. Precious3D

This Chennai-based company has been providing online 3D printing services to companies from many sectors including automotive. Precious3D has produced parts for automotive companies using FDM, SLS, and SLA 3D printing technologies.

In addition to improving 3D printing quality consistently, Precious3D focuses on reducing 3D printing time and costs. Leading automotive companies in Bangalore partner with Precious3D to produce automobile parts for shop floors on demand.

6.Wipro3D

Its state-of-the-art manufacturing facilities differentiate Wipro3D from other automotive 3D printing companies in Bangalore. The Bangalore-based company has been providing 3D designing, printing, and post-processing services to many automotive companies. Also, it delivers superior parts and components through a comprehensive test and validation process.

Wipro3D aims to make metal 3D printing machines and materials affordable and accessible for companies in various sectors, including automotive and automobile. It makes it easier for automotive companies to create conceptual models and product prototypes by offering additive consultation services.

7. Makenica

This 3D printing company has offices in several locations in Bangalore. Makenica has been providing plastic and metal 3D printing companies to automotive companies through its website. Automotive companies have the option to choose from a wide range of 3D printing machines and materials – FDM, SLS, SLA, MJF, PolyJet, and metal.

Makenica ensures the dimensional accuracy of 3D-printed parts by keeping in place a five-step quality-checking process. It further focuses extensively on keeping customers’ designs and data safe. Automotive companies in Bangalore partner with Makenica to get parts produced using a network of over 2000 3D printing machines.

Conclusion

While outsourcing 3D designing or 3D printing activities, your company has the option to choose from many automotive 3D printing companies in Bangalore. Each company allows you to choose from a wide range of 3D printing technologies and manufacturers.

But you should remember that these companies provide online automotive 3D printing company. Hence, you can partner with one of the best automotive 3D printing companies in Bangalore regardless of the location of their 3D printing facilities.

Outsource Metal 3D Printing in Bangalore

The 3D printing technologies used by individuals and enterprises in Bangalore can be broadly divided into two categories – plastic/polymer and metal. Metal 3D printing technologies enable users to produce parts using high-performance metal alloys.

Many enterprises use metal 3D printing machines to produce strong, custom, and complex parts using aluminum, titanium, stainless steel, chrome, cobalt, or Inconel. But the metal 3D printing process is more complex and time-consuming than the plastic 3D printing process.

Also, Metal 3D printers are much more expensive than 3D printers driven by popular plastic 3D printing technologies like Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA).

Large enterprises in Bangalore facilitate metal 3D printing by investing in expensive metal 3D printers and deploying an in-house team of skilled technicians. But most enterprises outsource metal 3D printing in Bangalore to overcome constraints related to skill and resources.

Why Do Companies And Startups Outsource Metal 3d Printing In Bangalore?

Curtail Upfront and Ongoing Costs

The price of plastic 3D printing machines ranges from $600 to $4000. Enterprises can invest in different plastic 3D printing machines without escalating upfront investment. But the prices of metal 3D printing machines vary from $50000 to $1 million.

Also, enterprises have to incur recurring expenses to keep the metal 3D printer clean and boost their performance. Most companies and startups in Bangalore lack the funds to purchase expensive metal 3D printers. They outsource metal 3D printing to avoid upfront and ongoing expenses.

No Need to Build an In-House Team

As noted earlier, metal 3D printers are more complex than plastic 3D printers. Enterprises must deploy skilled technicians to operate metal 3D printing machines efficiently and safely. Also, they need dedicated staff to clean and maintain the printers after each 3D print job.

Outsourcing metal 3D printing helps businesses eliminate the need to hire and train staff. The leading metal 3D printing service providers in Bangalore deploy technicians with both experience and expertise. They use their expertise to improve part quality without increasing printing time and costs.

Mix and Match Metal 3D Printing Technologies

While printing a metal part, one has the option to choose from different metal 3D printing technologies, including Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM), Direct Energy Deposition (DED), and Binder Jetting. Each of these metal 3D printing technologies has its pros and cons.

Hence, an enterprise can produce high-quality parts only using the right metal 3D printing technology. It needs to invest in multiple metal 3D printers to leverage the desired technology on demand. But an enterprise can produce parts using the desired technology by outsourcing metal 3D printing in Bangalore.

Experiment with Different Materials

While planning a metal 3D printing project, one has the option to choose from a wide range of materials - aluminum, titanium, stainless steel, chrome, and cobalt. Some metal 3D printing machines support multiple materials while others support a specific material. For instance, DMLS systems support most of the metal 3D printing materials available in the market.

But DMSL systems are more expensive than other metal 3D printers. Also, one needs to deploy skilled technicians to monitor the printing process and perform post-processing activities. Enterprises can easily experiment with many metal 3D printing materials by outsourcing metal 3D printing in Bangalore.

Expand Build Size

The small build size is often cited as a major shortcoming of metal 3D printers. Most metal 3D printing systems available in the market are designed with small print chambers. Hence, they are effective in producing small parts. Engineers produce multiple parts using metal 3D printers and integrate them after the printing process to meet the requirements of large projects.

An enterprise can accelerate the production of large parts only by investing in multiple metal 3D printers and deploying additional technicians. But it can reduce the time and cost significantly by outsourcing metal 3D printing in Bangalore. There are many companies that have set up large facilities with multiple material 3D printing machines. Also, they speed up printing and post-processing by deploying in-house technicians.

Overcome Metal 3D Printing Problems

Cracking and warpage are some of the major issues related to metal 3D printing. Engineers can prevent warpage only by ensuring that the metal 3D printing process starts accurately. Likewise, they can prevent cracking from occurring by monitoring the process as the melted metal solidifies.

The leading metal 3D printing service providers in Bangalore monitor the metal 3D printing process by deploying dedicated technicians. Also, they fix various types of defects by implementing a slew of metal 3D printing best practices. Hence, enterprises receive parts without any defects.

Improve Part Quality

Post-processing is an integral part of the metal 3D printing process. The post-processing activities differ depending on the nature and size of the 3D-printed part. But engineers often perform a variety of post-processing activities – sanding, water jetting, chemical rising, and air/heat drying – to improve the metal part.

Once the part is printed, engineers need to remove the support structure using the right products. Also, they need to achieve the predefined surface finish by smothering the surface. Enterprises outsource metal 3D printing in Bangalore to get parts optimized by performing the required post-processing activities.

Conclusion

There are many companies and startups that offer metal 3D printing services in Bangalore at competitive rates. Some of these providers have set up metal 3D printing facilities in Bangalore, while others offer online metal 3D printing services to companies and startups in Bangalore.

These metal 3D printing service providers allow customers to customize the metal 3D printing process by choosing from a wide range of machines and materials. Also, they focus on reducing metal 3D printing time and cost without affecting the part quality.

Hence, both individuals and enterprises can produce complex and custom parts on demand by outsourcing metal 3D printing in Bangalore. But the metal 3D printing service providers differ from each other in several aspects, including industry expertise and infrastructure.

Hence, decision-makers must compare these providers using a variety of parameters. The comparison will help them partner with a reliable and reputable company while outsourcing metal 3D printing in Bangalore.

What is FDM 3D Printing?

The widely-used 3D printing technologies can be broadly divided into two categories – consumer and industrials. Consumer 3D printers are found in homes, offices, and educational institutions. At the same time, enterprises from various sectors use industrial-grade 3D printers to switch from subtractive or conventional manufacturing to additive manufacturing.

Fused Deposition Modeling (FDM) is a 3D printing technology that is used widely by individuals and enterprises. The usage statistics posted on Statista suggest that FDM is currently the most commonly used 3D printing technology.Also, FDM drives the steady and consistent growth of the global 3D printing market.

What is FDM 3D Printing?

Like other 3D printing technologies, FDM produces solid parts from digital files. Also, it creates the parts by depositing materials layer by layer. But FDM, unlike other 3D printing technologies, creates parts using the material extrusion method.

FDM 3D printers are designed with nozzles through which the thermoplastic filaments are extruded. The heated nozzle melts the filament and deposits the melted filament onto the build platform layer by layer. The material extrusion method makes FDM scores over other 3D printing technologies in several categories – ease of use and cost-efficiency.

How Do FDM 3D Printers Work?

While planning an FDM 3D printing project, engineers have the option to choose from a wide range of thermoplastic materials. They fed the thermoplastic filament into the 3D printing machines in the shape of plastic threads through a nozzle.

They melt the filament by heating the nozzle. The heated nozzle deposits the melted filament layer by layer over the build platform. The thermoplastic cools and solidifies gradually as the nozzle moves across the base. Also, they form a solid bond with the earlier layer.

Once a layer is printed, the build platform descents or ascents to facilitate the formation of the next layer. These steps are repeated till the printer created the part fully according to the digital 3D model.

Engineers always choose the FDM 3D printer according to the build size and layer height. Also, they customize the FDM 3D printing process by adjusting important parameters like build speed, nozzle temperature, cooling fan speed, and build platform temperature.

What are the Material Options for FDM 3D Printing?

FDM beats other 3D printing technologies in the category of material options. While planning the FDM 3D printing process, engineers have the option to choose from a wide range of feedstock materials or filaments. For instance, they can choose from widely-used polymers like PLA, PET, ABS, Nylon, TPU, and PC.

Also, they can improve the physical properties of the filament by opting for composite materials like Tough PLA which is produced by combining PLA and ABS. Likewise; they can make 3D-printed parts effective in resisting mechanical stress by opting for fiber-filled materials.

Leading manufacturers have been producing innovative FDM 3D printing filaments regularly. The affordability and availability of these polymer and composite filaments contribute hugely toward making FDM the most commonly used 3D printing technology.

What are the Common Applications of FDM 3D Printing?

Concept Modeling

Engineers use concept models to understand precise requirements or identify potential issues before starting production. FDM 3D printing machines and materials help them create concept models without putting in extra time and resources.

Rapid Prototyping

Engineers test a concept or evaluate a process by creating prototypes. They use FDM 3D printers to produce preliminary versions of a product in a short amount of time. Also, they leverage the printer to make several changes to the prototype during the testing process.

Low-Volume Manufacturing

FDM 3D printing helps manufacturers switch from subtractive manufacturing to additive manufacturing. A manufacturer can use industrial-grade FDM 3D printers to facilitate low-volume production of complex parts without using conventional tooling.

End Part Fabrication

Many companies these days prefer printing end parts to producing end parts. They leverage FDM 3D printing technology to reduce the time and costs required to fabricate end parts. Also, they can boost the part’s quality and durability using the appropriate FDM 3D printing material.

Manufacturing Tool Development

FDM 3D printing creates opportunities for engineers to produce next-generation manufacturing tools. Engineers can reduce the time and resources required to fabricate jigs, fixtures, and other manufacturing tools using industrial-grade FDM 3D printers.

Making Consumer Products

Access to FDM 3D printers creates opportunities for students and hobbyists to produce a variety of consumer products. Students showcase their creativity and skill by producing innovative toys, home decor, and gift items using FDM 3D printers. At the same time, hobbyists use FDM 3D printing technologies to create new use cases and meet emerging needs regularly.

What are the Pros and Cons of FDM 3D Printing Technology?

Pros

• Less complex than other 3D printing technologies
• Less expensive than other 3D printing technologies
• Availability of a wide range of FDM 3D printing materials
• Option to reuse FDM 3D printing materials
• Perform post-processing activities without investing in specialized tools and expensive liquids.
• FDM 3D printers are easy to store and move
• New-age FDM 3D printers support cloud server printing

Cons

• FDM printers need more time to produce a part as they print layer by layer.
• Engineers have to opt for multidirectional printing to unidirectional printing to make stronger parts.
• Often misalignment or weak adhesion of layers results in print failure.
• Engineers must clean and maintain the FDM 3D printer regularly to prevent nozzle clogging.
• Users can improve safety only by installing the FDM 3D printer in a well-ventilated environment.
  

Conclusion:

FDM is currently more popular than other 3D printing technologies. Enterprises invest in industrial-grade FDM 3D printers to produce product prototypes and functional parts. At the same time, desktop FDM 3D printers are used widely by students, engineers, and hobbyists. Also, many individuals and enterprises these days avail of FDM 3D printing services to produce physical objects by overcoming constraints related to time, resources, and skills.

FDM 3D Printing Applications

A 3D printer produces physical three-dimensional objects from three-dimensional digital models. But 3D printing machines are driven by several 3D printing technologies. The usage statistics posted on Statista suggest that Fused Deposition Modeling (FDM) currently has a much larger installation base than other 3D printing technologies.

Also, FDM is one of the additive manufacturing technologies that are used widely by individuals and enterprises. Students, innovators, and hobbyists opt for FDM as a beginner-friendly and cost-effective 3D printing technology. At the same time, industrial-grade FDM 3D printers help enterprises replace subtractive manufacturing with additive manufacturing.

Unlike other 3D printing technologies, FDM produces parts using the material extrusion technique. Users have the option to choose from a wide range of production-grade thermoplastics according to the nature and requirements of individual parts. Hence, they have can produce a variety of parts by combining the right FDM 3D printing machines and filaments.

Both individuals and enterprises create new FDM 3D printing applications regularly. Also, they use advanced FDM 3D printing machines and experiment with innovative FDM 3D printing materials. We can understand some of the major FDM 3D printing applications based on use cases created by individuals and enterprises across industries and regions.

Industrial Applications of FDM 3D Printing

Getting Ready for Industry 4.0

Enterprises have been switching from subtractive manufacturing to additive manufacturing to become a part of Industry 4.0. But they look for technologies effective in reducing production time and costs. FDM is a simple and cost-effective 3D printing technology.

Enterprises have the option to choose from a wide range of FDM 3D printing machines and materials. Also, they can reduce upfront investment by availing of professional FDM 3D printing services. Hence, manufacturers leverage FDM 3D printing to get ready for Industry 4.0.

Rapid Prototyping

Large companies invest in R&D to outperform competitors by coming up with unique ideas. Researchers evaluate the next best idea elaborately by making prototypes. In addition to reducing production time, prototypes help engineers identify and prevent potential problems. Researchers find it easier to create prototypes from digital files using FDM 3D printers. Also, they use the printer to create multiple versions of the prototype without increasing time and cost.

Testing Design Ideas

Automobile and aerospace companies these days boost user experience by producing innovative parts and customizing existing parts. They invest in FDM 3D printing machines and materials to test new design ideas without escalating project costs. Researchers can use an FDM 3D printer to evaluate new design ideas ad alter existing designs without delaying product launch.

Producing Replacement Parts

No automobile company can impress and attract customers without providing outstanding customer service. Also, it cannot deliver outstanding customer service without ensuring fast and reliable delivery of spare parts. Leading companies have already transformed spare part management using 3D printing technologies.

They invest in FDM 3D printing to reduce the time and resources required to produce replacement parts for individual customers. Hence, many companies these days print spare parts instead of maintaining an inventory of spare parts.

Low-Volume Manufacturing

Companies opt for low-volume manufacturing to reduce time to market and identify potential market risks. But no company can produce a lower number of parts using conventional manufacturing technologies. 3D printing technologies like FDM make it easier for companies to scale up or scale down the production of parts on demand.

Engineers use FDM 3D printers to drive low-volume production without investing in expensive tooling and additional materials. The printers create opportunities for them to experiment with different thermoplastic filaments while reducing material wastage. Also, engineers can change a part simply by altering the digital 3D model.

Creating Pre-Surgical Models

Pre-surgical models help surgeons reduce the risk of complications using the right instruments. Hence, surgeons develop patient-specific surgical models as part of pre-surgical planning. FDM 3D printers make it easier for surgeons to develop patient-specific surgical models that replicate specific organs of a patient exactly.

Producing Functional Prosthetics

The conventional manufacturing techniques make the production of functional prosthetics complicated and expensive. But medical practitioners find it easier to produce functional prosthetics for individual patients using FDM 3D printers. In addition to supporting personalization, FDM 3D printing makes prosthetic lambs affordable for a large number of people.

Non-Industrial Applications of FDM 3D Printing

Promoting Experimental Learning

Many schools, colleges, and universities these days invest in FDM 3D printers to promote experimental learning. Students use FDM 3D printers to visualize concepts and create models while mastering one of the important next-generation technologies. Recently, students surprised everyone by building, testing, and finetuning DIY drones using FDM 3D printing.

Personalizing and Customizing Gifts

FDM 3D printer helps enthusiasts and innovators unleash their creativity. Many people these days use FDM 3D printers to produce customized gifts for friends. They make the gift items like mobile covers, planters, key chains, and lamps look unique by designing their own digital 3D models or redesigning existing 3D models.

Replacing Household Items

Homeowners found it difficult to purchase and replace household items during the COVID-19 lockdowns and shutdowns. Many people use FDM 3D printers to produce household items during the pandemic. They use FDM printers to replace clips, buttons, hooks, showerheads, and other household items while working from home.

Changing Home Décor Styles

Many homeowners these days impress guests by changing home décor style as the season changes. FDM 3D printing machines help homeowners create unique and customized pieces on their own. Many homeowners these days use FDM 3D printers to produce beautiful home décor before the season changes.

Conclusion

In addition to being the most commonly used 3D printing technology, FDM has been evolving consistently. For instance, users nowadays have the option to choose from conventional and cloud-based FDM 3D printers. Likewise, they can experiment with many classic and innovative 3D printing materials.

Professional FDM 3D printing services create opportunities for individuals and enterprises to produce parts using the desired printing machine and filament. Hence, FDM 3D printing applications will continue to evolve in the future. The new use cases will keep the popularity of FDM intact while overcoming the major shortcomings of this 3D printing technology.

DMLS 3D Printing: A Quick Guide

3D printing technologies enable enterprises from various industries to produce production parts and functional prototypes without investing in extra resources. But engineers have to use specific materials according to their choice of 3D printing technologies. Direct Metal Laser Sintering enables manufacturers to produce spare parts and prototypes using a variety of metals and metal alloys.

What is DMLS 3D Printing?

According to ScienceDirect, “Direct Metal Laser Sintering (DMLS) is an AM technique for metal 3D printing. In this process, the metal powder (20 μm diameter), free of binder or fluxing agent, is completely melted by the scanning of a high-power laser beam. The resulting part has properties like the original material.”

DMLS is an industrial 3D printing technology. It belongs to the category of power bed fusion category of additive manufacturing technologies. It produces parts by melting metal powders or metal alloy powders completely using a high-power laser beam.

DMLS creates opportunities for engineers to print strong and durable functional parts using a wide range of metal powders and metal alloy powders.The metal powders differentiate DMLS from other 3D printing technologies.

What Metal Powders are used in DMLS 3D Printing Process?

While planning a DMLS 3D printing project, engineers have the option to choose from a variety of metal and metal alloy powders. They can choose from aluminum, stainless steel, titanium, cobalt chrome, or managing steel.

The metal material options make it engineers to produce parts using the appropriate metal. For instance, an engineer can create parts effective in resisting acid and corrosion by choosing stainless steel. At the same time, she can opt for aluminum to produce metal parts effective in resisting stress.

How Does DMLS 3D Printing Work?

Like other 3D printing technologies, DMLS printers create parts layer by layer based on digital 3D files. Engineers refine the digital 3D model using appropriate software to generate code that can be understood by the metal 3D printer. After preparing the digital 3D file, engineers fill the DMLS printer hopper with a specific metal or metal alloy powder.

The printer uses heaters to bring the metal powder up to the sintering range of the metal allow. It subsequently starts dispensing thin layers of the metal powder onto the build platform. The high-power laser form solid structures by sintering the metal powder selectively. The DMLS 3D printer continues dispensing and sintering the metal powder till the part is produced completely.

Once the physical printing process is over, engineers allow the part to cool fully. They remove the loose metal powder from the DMLS printer as well as remove the support before starting post-processing activities. They refine and treat the 3D-printed part by performing activities like surface finishing, machining, and heat treatment. DMLS 3D printing technology delivers metal parts in about 7 to 10 days.

What are the Common Applications/Use Cases of DMLS 3D Printing Technology?

Replacing Conventional Metalworking Technologies

Conventional metalworking technologies are not effective in producing parts with complex geometries. Many manufacturers invest in DMLS 3D printers to print complex parts directly using high-performance metals and metal alloys.

Producing Strong and Lightweight Parts

DMLS 3D printing machines produce single-component metals by melting metal powders completely. The single-component metal is effective in producing parts and prototypes that are strong, durable, and lightweight. Engineers can easily reduce the strength or weight of a spare part using the appropriate metal powder.

Improving Part’s Functional Performance

While using subtractive manufacturing methods, engineers have to focus extensively on manufactur ability. The focus on manufactur ability impacts the spare part’s functional performance negatively. DMLS 3D printing enables engineers to focus on improving a part’s functional performance instead of manufactur ability.

Reducing Part Count

At present, DMLS is used widely by companies in the aerospace and automotive industries. These companies leverage this 3D printing technologies for a variety of purposes, including weight reduction, complex part production, and mass customization. At the same time, DMLS creates opportunities for them to reduce the number of parts through integration and optimization.

Facilitating Customization and Personalization

Companies in the medicine and healthcare industries use DMLS 3D printing to produce bridges, crowns, and prosthetics. DMLS 3D printers create opportunities for medical practitioners to create custom prosthetics for individual patients. At the same time, they can use high-strength metals to produce prosthetics that patients can use over a longer period of time.

Providing Freedom of Design

DMLS, like other powder bed 3D printing technologies, provides freedom of design to engineers. As engineers are not required to use multiple tools and fixtures, they can produce new parts by experimenting with complex designs and innovative design rules. Also, they can customize existing designs and models to boost the functional performance of various parts.

What are the Pros and Cons of DMLS 3D Printing?

Pros

• Direct metal printing keeps the mechanical properties of the metal intact.
• Engineers can choose from a wide range of metals and metal alloys.
• Engineers can produce strong and durable metal parts without using additional tooling and fixture.
• Metal powders help engineers produce parts with dimensional accuracy and complex geometries.
• Options to produce parts with a smoother finish using finer metal powder.
• Manufacturers can control 3D printing costs by reusing metal powders.

Cons

• One of the complex industrial 3D printing technologies.
• Not popular with students and hobbyists due to the high cost of DMLS 3D printing machines and materials.
• Does not support large build volumes like other industrial 3D printing technologies.
• Engineers can produce parts and prototypes in weeks using this slow additive manufacturing technology.

Please read our blog “DMLS Advantages and Disadvantages” to know the pros and cons of this industrial 3D printing technology in detail.

Conclusion

Unlike other 3D printing technologies, DMLS facilitates the production of metal parts and prototypes. At present, DMLS 3D printing technology is used widely by enterprises from various industries. But the industrial 3D printing technology has its pros and cons. Leading 3D printing service providers overcome the limitation of DMLS 3D printing by monitoring the printing process and adopting several best practices.

References

https://www.sciencedirect.com/topics/materials-science/direct-metal-laser-sintering

https://www.protolabs.co.uk/services/3d-printing/direct-metal-laser-sintering/

https://all3dp.com/2/direct-metal-laser-sintering-dmls-simply-explained/

https://www.rapiddmls.com/what-is-dmls/

FDM 3D Printing Process

Additive manufacturing/3D printing is one of the fundamental technologies driving Industry 4.0. Enterprises leverage various 3D printing technologies to transit from Industry 3.0 to Industry 4.0. But some of these 3D printing technologies are used widely by both individuals and enterprises.

Fused Deposition Modeling (FDM) is one of the 3D printing technologies that are popular with companies, startups, engineers, students, and hobbyists. In addition to being easy-to-use and budget-friendly, FDM 3D printing technology allows you to choose many materials and reuse the filaments.

You can use an FDM 3D printer to convert computer-aided design (CAD) files into solid three-dimensional parts. The machine will create the part by depositing thermoplastic filament onto a print bed layer by layer. But you must remember that FDM 3D printing is a multistep process.

You can customize and streamline the 3D printing process only by choosing the right printer, model material, and support material. Also, you need to convert the CAD file into an STL file. After completing the preliminary tasks, you have to monitor the FDM 3D printing process and perform post-processing activities to produce a part that meets your precise project needs and preset quality standards.

How to Plan and Improve the FDM SLS 3D Printing Process?

Select the Right FDM 3D Printer

Based on your predefined project needs, you have the option to choose from several types of FDM 3D printers. The FDM 3D printing machines differ from each other primarily in two aspects –mechanical nature and operational coordinate system. Hence, you need to compare the FDM 3D printers manufactured by different companies.

Combine the Right Modeling and Support Material

While planning the FDM 3D printing process, you must focus on choosing the right modeling and support materials. The modeling material will form a solid three-dimensional object, while the support material will provide support to the part as it is 3D printed.

You have the option to choose from a variety of modeling materials – ABS, PLA, PET, Nylon, PC, and TPU (flexible). Some of these materials are pure polymer, while others are composites.

Hence, they differ from each other in many aspects – printability, layer adhesion, heat resistance, impact resistance, and stress resistance. In addition to choosing the right modeling material, you must complement it with the appropriate support material.

Convert the CAD File into STL File

FDM 3D printer will produce the part based on a digital 3D model. But you have to convey information to the printer in the form of an STL file. You have to convert the CAD file into an STL file to provide information to the printer in the standard data transmission format.

Set Print or Process Parameters

FDM 3D printers allow you to set various print parameters or process parameters – layer height, build speed, nozzle temperature, build platform temperature, and cooling fan speed. You must decide the build volume and layer height according to the size of the part to be 3D-printed.

The desktop 3D printers support smaller build volumes than industrial 3D printers. If you are using a desktop 3D printer, you have to divide the large parts into smaller parts according to the build volume supported by the machine.

You can create the large part by assembling the small parts after the 3D printing process. However, you can customize the FDM 3D printing process according to precise project needs by setting or adjusting these parameters.

Start the FDM Printing Process

You have to start the FDM 3D printing process by loading the thermoplastic material into the 3D printer. The FDM 3D printer will feed the filament as threads and extrude the melted filament through extrusion nozzles.

Most FDM 3D printers feature extrusion nozzles that deposit the melted filament in both horizontal and vertical ways. The FDM 3D printer will function according to the parameters set by you. Also, it will refer to the STL file to deposit the filament in the right physical dimensions.

The melted filament will cool and solidify gradually after being deposited onto the build platform. But you can reduce the cooling time using fans attached to the extrusion head.

Remove or Separate the Support Material

Once the FDM 3D printing process is over, you have to focus on improving the surface finish by removing or separating the support accurately. You have the option to choose from two distinct support removal methods – standard and dissolvable.

You can remove the support material quickly and effortlessly by opting for the standard method. The method requires you to remove support material by cleaning the surface. However, you have to use needle-nose pliers and dental picks to remove the support material from holes, hollows, and other hard-to-reach places.

You can opt for the dissolvable method when the support material is soluble. This method requires you to remove the support material using the appropriate solvent. You need to keep the 3D-printed part in a bath till the support material is dissolved and separated. However, you must remember that each of these support removal techniques has its pros and cons.

Perform Post-Processing Activities

After removing the support material, you need to improve the 3D-printed part’s look, feel, and finish by performing a variety of post-processing activities – polishing, sanding, priming and painting, gap filling, cold welding, dipping, metal plating, and epoxy coating.

But you must remember that the post-processing activities vary according to the nature and requirements of the 3D-printed part. Hence, you have to combine the post-processing activities according to the 3D-printed part. At the same time, you must perform every post-processing activity accurately and efficiently using the appropriate toolkit.

Conclusion

FDM 3D printing technologies create opportunities for you to produce a variety of parts without putting in extra time and effort. You must focus on customizing the FDM 3D printing process according to the precise needs of each project. At the same time, it is important to improve the dimensional accuracy and print quality by implementing a slew of FDM 3D printing best practices.

However, you can save both time and resources by availing of professional FDM 3D printing services. The leading 3D printing companies use advanced 3D printers and allow you to choose from a variety of filaments. Also, you can customize the FDM 3D printing process by sharing important information related to the part or product required for your upcoming project.

About Aurum3D

We are amongst the major 3D printing service providers in Bangalore, India. We have been providing custom SLA, SLS and FDM 3D printing services to many major industries. Please feel free to get in touch with us for your custom needs, our 3D printing solutions experts will get back to you within one business day.

References

https://all3dp.com/2/cartesian-3d-printer-delta-scara-belt-corexy-polar/

https://www.hubs.com/knowledge-base/fdm-3d-printing-materials-compared/

https://smc-fluidcontrol.com/cooling-systems-in-3d-printing/

https://www.hubs.com/knowledge-base/post-processing-fdm-printed-parts/#support