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/