3D printer is a great potential for volumetric printing

3D Printers

Watching videos where 3D printers create familiar objects is truly captivating and leaves a lasting impression. It’s hard to believe that soon enough, anything can be created with the help of these systems.

This is now a reality. After decades of research and advancement, the potential of 3D printers has paved the way for their integration in various fields such as production, science, daily life, and entertainment. However, in order to accurately predict the future of 3D printing and understand how it works, we must delve into its origins.

The World of Printers

The mesmerizing sight of 3D printers crafting familiar objects in videos creates a lasting impact. It is intriguing to think that in the near future, almost anything can be created using such systems.

This is not just a fantasy. The potential of 3D printers, honed over decades, ensures their increasing integration into diverse domains of production, science, everyday life, and entertainment. To grasp where the future of 3D printing lies and comprehend its workings, it is essential to look back at its beginnings.

History of the emergence of the 3D printer

In 1980, Hideo Kodama, a doctoral student at the Nagoya Research Institute in Japan, conducted research on layer-by-layer volumetric printing of models (prototyping). During that year, he published a paper titled "Automatic Preparation of a Three-Dimensional Model for Three-Dimensional Data Display," detailing his experimental findings.

In a separate publication, Kodama introduced a method for producing 3D plastic parts automatically using photo-strengthening. This publication practically outlined the fundamental workings of a 3D printer: the use of photopolymers to create models, the utilization of laser radiation for curing, and the sequential layering process. Although Kodama applied for a patent for his invention, he was not granted one, ultimately relinquishing his claim to being the pioneer of 3D printing technology.

In 1984, a group of French researchers consisting of Alain Le Meayut, Olivier De Witte, and Jean Claude André filed a patent application for a system that utilized stereolithography to create 3D models through the layer-by-layer application of laser-cured polymers. Unfortunately, the application was ultimately rejected by major French companies due to a perceived lack of practical applications for the technology.

However, just two weeks after the French application was rejected, an American inventor named Chuck Hull submitted his own patent for a stereolithographic modeling system. Hull’s system involved the addition of layers through the use of UV laser curing of liquid photopolymers. In 1986, his patent was granted, and he went on to establish a company called 3D Systems to manufacture these pioneering 3D printers based on the SLA (laser stereolithography) method. One of Hull’s notable contributions was the implementation of G-code, which enabled the printing of complex objects with specific shapes.

In the late 1980s, two additional methods for quick prototyping were patented: the selective laser sintering (SLS) system by American Carl Deckard and fusion deposition modeling (FDM), developed by American Scott Crump. The SLS technique involves the layer-by-layer sintering of metal or plastic powder using laser radiation to form the desired part. In the FDM method, heated plastic – the material used by the 3D printer – is applied by the print head onto the previous layer.

These aforementioned techniques serve as the foundation for most volumetric printing technologies and will be further discussed later. Now, let’s briefly touch upon the twists and turns of technological progress.

It may surprise some to learn that volumetric printing has actually been in development for over 30 years. Many believe it to be a recent technical achievement of our century, rather than something from the past.

It is a well-known fact that the individuals who held the patents for fundamental prototyping technologies were Chuck Halley, Carl Deckard, and Scott Crump. In 2001, Carl Deckard sold his patent to Chuck Hulley. Unfortunately, companies focusing on the consumer market were unable (or unwilling) to establish negotiations with the patent holders. As a result, the production of 3D printers was largely limited to expensive industrial units for a significant period.

However, everything changed after 2010 when the patents expired, and the first mass-produced 3D printers hit the market. This sparked curiosity among people who began to inquire about the concept of 3D printing.

Once people caught a glimpse of what a 3D printer was capable of, they became eager to purchase such cutting-edge devices. The market swiftly responded to this demand, leading to a rapid saturation of the market and subsequent price reductions.

How it works

Let’s take a closer look at the operational principles of the 3D printer, the various technologies employed, and the pros and cons associated with each.

Technology of volumetric printing SLA

The technique entails utilizing liquid photopolymer as the material being used, which is solidified by means of ultraviolet laser radiation. The process of volumetric printing is carried out step by step, with each layer of polymer being cured by the laser in a single sweep. Following this, the movable base is submerged into the liquid polymer, allowing for the formation of an additional layer, and the procedure is repeated.

• The system ensures a high-quality surface for the final product, regardless of its shape, eliminating the need for additional processing.
• The final product exhibits excellent mechanical strength and can withstand temperatures up to 100°C.
• It is capable of producing complex and multi-level finished products.
• No waste is generated during the process.
• Only photopolymers are used as the working material.
• Volumetric color printing is not available.
• The printer operates at a relatively low speed of 2-3 cm per hour.
• The device and working materials are expensive, with a minimum cost of 300,000 rubles for widespread consumption.

SLS volumetric printing technology

The process of printing using SLS technology involves the utilization of different materials such as metal, glass, plastic, etc. These materials are in the form of powder, with a particle size of approximately 100 microns.

Prior to utilization, the powder is placed in a designated container and then heated to almost the point of melting. This heating process ensures a reduction in laser power. Furthermore, a roller is used to flatten the powder. The areas of the object that need to be sintered are then treated with laser pulses. After this step, the table is lowered to the desired layer thickness, and the process is repeated with a fresh layer of powder.

Although SLS 3D printing technology does not yield high-quality results, additional processing is required. It is common to use working materials that contain specific polymer additives, which need to be removed through the process of calcination in a specialized furnace to achieve the desired end product.

The technology of utilizing an electron beam with high-energy rather than laser radiation has been developed and implemented. This technique necessitates the use of a vacuum chamber, but it enables the creation of parts from tough metals, including titanium.

• Ability to produce a finished product with intricate shapes from various work materials;
• Greater work speed (compared to SLA);
• Suitable for small-scale production;
• Presence of high laser power, which can pose safety risks during operation;
• The finished product’s surface requires additional processing;
• Lengthy pre and post-processing stages (powder heating and product annealing in a furnace required);
• High cost (starting from approximately 1 million rubles).

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MJM volumetric printing technology (multi-jet modeling method)

In this method of volumetric printing, the printing device incorporates a head with several dozens to several hundred small diameter nozzles.

The working material utilized in this method includes various plastics, photopolymers, special waxes, or a combination of these substances. Support structures are necessary to achieve objects with intricate shapes due to the softness of the working material.

A UV lamp is integrated into the photopolymer 3D printer to cure the printed objects.

This method also enables printing in color, which is determined by the materials used or their combination.

• This system allows for a minimum layer thickness, resulting in a smooth surface for the final product that does not necessitate additional processing.
• Volumetric printing using a variety of colors and substances;
• Excellent portability;
• Complex-shaped prototypes require the use of supporting structures;
• There is a limited range of materials available for use.

LOM volumetric printing technology (layer-by-layer film bonding method)

This method of volume printing utilizes sheets of paper or plastic (some systems utilize foil) as a substrate. The sheets are pulled across a platform covered in adhesive, with the aid of rollers. A heated roller then rolls and bonds the sheet to the previous layer.

Next, a laser trims away any excess material according to a programmed pattern, after which the platform lowers to the thickness of the sheet used, and the whole process is repeated.

This technology enables fast operation and cost-effective consumables. However, it is not widely adopted.

• The final product can be printed in color.
• Availability of printing material.
• Capability to create complex, large objects.
• No need for using supporting frames.
• The finished product has low durability;
• There is a possibility of defects on the object’s surface after its additional processing;
• There is a significant amount of waste.

CJP volumetric printing technology

• The device operating on this technology of volumetric printing uses gypsum composite material.
• The layers in the device are connected by gluing them with a special substance.
• First, composite powder is spread evenly over the platform surface.
• A special device is used to level the composite powder.
• The printer’s printheads apply liquid binder along a predetermined contour.
• Then the platform is lowered and the process is repeated.
• The finished product requires additional processing, including heating to dry the adhesive and removing excess powder mechanically.
• CJP technology supports color volumetric printing by introducing dyes or combinations of dyes into the adhesive composition.
• This allows for a wide range of colors to be achieved in the final product.
• The option to produce intricate, multi-colored items of diverse forms sans any supporting elements.
• A constrained selection of work materials;
• Additional post-production processing is required for the final product
• The final product possesses a lower level of strength.

FDM volumetric printing technology

Thermal printers, also called FDM printers, have gained popularity due to their affordable price. These devices can be purchased for as low as $500. But what is the mechanism behind a thermal printer?

In a thermal printer, the material used for printing is easily meltable plastics. However, there are also options for volumetric printing that utilize low-melting point metals.

The process of printing occurs step by step. Each new layer is formed by heating the working material in the print head of the device and applying it to the model layer through a nozzle with one or more holes. Following a predetermined path, the head covers the entire outline of the part. Then, the table is lowered (or the head is raised in some systems) and this process is repeated until the final result is achieved.

• High durability of the final product;
• Capability to produce large sizes and intricate shapes;
• Diversity of available materials to work with;
• Cost-effectiveness.
• Slow speed of operation;
• Visible surface irregularities on the finished product;
• Complex-shaped objects require support structures;
• Heat-induced shrinkage (dimension reduction after cooling) of the final product.
• Further processing of the completed item is necessary.

Controlling the 3D printing process

The physical manifestation of a computer model created by specialized software is the end result of the 3D printing process. The management of this process is broken down into multiple stages.

Creating a digital model and entering data into the printing device

To digitally process the object, specialized software like "3D Studio Max" or "AutoCAD" is necessary. If you lack the skills in using these programs, it is advisable to seek help from a professional. The modeling process is time-consuming and may take several days.

Alternatively, you can utilize a dedicated 3D scanner, but the resulting virtual model may have reduced quality.

If the object you want to create is a standard item, you can search for information on the internet or specialized websites. The digital model is typically saved in STL format. Afterwards, a specialized program-slicer generates G-code, which is a series of commands that control the movement of printed components of the device. The user interface of these programs is simple and user-friendly, allowing for easy operation.

Preparation for work

The stage of the printing process is determined by the specific type of printing device in use. For instance, when preparing to use an FDM system, the work table of the device is covered with a special film and a spool of plastic filament is inserted. The selection of the type and color of the plastic filament depends on the desired characteristics of the final product. It is also important to ensure that the filament is free from any dirt or damage, as this can greatly impact the quality of the printed object.

Printing stage

Produced autonomously. It is imperative to ensure even application of the layers onto the object, avoiding any instances of the polymer thread solidifying or becoming too malleable. Device settings are adjusted as needed.

Additional processing of the object

If required, further processing is conducted: the final product undergoes skinning and polishing. In the case where support structures were employed during the printing of a complex-shaped object (to prevent damage to the model), it becomes necessary to eliminate them and smoothen the seams.

Where you can use a 3D printer

The application of additive technologies in various aspects of human life has already been made possible due to their immense potential.

Industry

3D printing systems are now widely used in manufacturing processes. They are used to produce models and prototypes of finished products, which allows for the evaluation of their actual characteristics. Additionally, these systems are used to manufacture complex molds for non-standard parts and to produce spare parts for quick repairs of units and mechanisms. They also enable small-scale production of unique products such as parts for rocket engines.

Medicine

The process of acquiring intricate molds is centered around generating replicas of absent sections of the human skeleton, such as shattered bones or missing skull fragments. These molds prove essential in the production of implants that are subsequently inserted into the human body. Furthermore, extensive research is being conducted on printing human organs, such as kidneys or thyroid glands, which are later successfully transplanted and assimilated within the human body. Lastly, the creation of prosthetic limbs stands as another crucial facet of this field.

Architecture and construction

Manufacturing of architectural project presentations through the creation of 3D models of buildings. The advent of prototyping technology for residential structures has revolutionized the industry. Utilizing this innovative process, it is now possible to print a house within a matter of hours, a task that would typically require several days using traditional construction methods.

Education

Acquiring educational tools that facilitate reaching a new milestone in learning. Crafting intricate objects with diverse contours, such as graphical representations of algebraic equations. Enhances students’ spatial cognition.

Space

An initiative has been put forward that suggests implementing 3D printing technology in space: the idea is to utilize this technology for constructing a base on the moon, utilizing lunar regolith as the primary material.

Small business

Working with 3D printers provides an opportunity to design one-of-a-kind objects, craft miniature figurines featuring printed dolls that bear a striking resemblance to clients, and manufacture custom clothing accessories… The potential is limitless. Additive technologies empower creative entrepreneurs to confidently carve out their own niche in the business world.

To take or not to take – that is the question

After providing a detailed explanation of how a 3D printer operates, we can now address the question of whether it is necessary to acquire such systems.

For individuals with machine-building production, investing in 3D printing devices would prove to be a fruitful decision. Although the price of industrial models can reach tens of thousands of dollars, incorporating them into the production process would result in a rapid return on the initial investment. Of course, it is important to note that they cannot entirely replace traditional manufacturing methods.

Nevertheless, the integration of these devices would enable a prompt response to market demands, making them a worthwhile purchase.

If an entrepreneur is engaged in the production of one-of-a-kind interior elements, aircraft and ship modeling, or the creation of reduced replicas of architectural designs, they may find it advantageous to invest in a 3D printer. This would cater to people’s desire for unique items and could be a wise purchase. However, if their business is not connected to these areas, buying a 3D printer would not be profitable.

In conclusion, it is important to consider the necessity of purchasing a 3D printer for personal use. The cost of an FDN system is around $500. However, it may not be a worthwhile investment as this device is more of a showcase for capabilities rather than a tool for producing practical home items. Additionally, the quality of the finished products is often subpar.

Toys produced through the use of a 3D printing machine generally come with a higher price tag than those bought in a traditional store. Consequently, at this time, acquiring a 3D printer for household use should not be seen as a top priority. However, for an imaginative individual in search of new avenues of self-expression in all aspects of life, obtaining a printer could serve as a catalyst for unlocking their unique potential.