3D Printing: What to know?

1. Choosing the Right 3D Printer

The first choice is whether we want a resin printer for highly detailed objects (e.g. miniature characters) or an FDM printer, more suited for industrial designs. Resin printers are more expensive to operate and the material produces toxic fumes, requiring some ventilation. FDM printers are considered less toxic but it's always subject to the printing material. There is a lack of scientific data and studies, but it's best not to stay for prolonged hours in the room while you are printing without proper ventilation.

Enclosed Printers:

• Enclosed printers have a protective case around them, which helps maintain a consistent temperature during printing.
• Ideal for printing materials sensitive to temperature variations or that require high temperatures (ASA, ABS).
• Safer for households with children or pets, as the enclosure keeps moving parts and hot components out of reach.

Open Printers:

• They lack an enclosure, making them more affordable and accessible.
• Suitable for materials that don’t require strict temperature control (PLA, PETG, TPU).
• Easier to modify or repair.

Popular Manufacturers and Their Philosophies

• Creality: Known for affordable, user-friendly printers like the Ender series. Focuses on accessibility for hobbyists.
• Prusa Research: Prusa’s printers, like the Prusa i3 MK4, are highly reliable with strong open-source development support.
• Bambu Lab: Advanced, feature-rich printers focusing on speed, automation, and multi-color printing.
• Anycubic and Elegoo: Known for resin printers and FDM models for small, detailed prints like miniatures.

These are the most sold printers. Nevertheless, Uniformation or Flashforge are less popular companies offering great printers.

2. Understanding Key Components

AMS (Automatic Material System)

An AMS enables a printer to automatically switch between filaments, allowing for multi-color or multi-material prints. For example, PETG can be used as a support material while PLA is used for the main object. This system makes post-processing easier and less time-consuming.

Build Plates

The build plate is the flat surface where the printer lays down material to form your print. It plays a key role in both adhesion and the final appearance of your print. There are several types:

• Smooth Plates: Provide a glossy finish but may struggle with adhesion for certain materials.
• Textured or Surface Plates: Offer better adhesion and a matte or textured finish.
• Cryo Plates: Enhance durability and resist extreme temperatures.

Replace worn-out or damaged build plates based on the manufacturer's recommendations for cleaning and maintenance.

Hotends

The hot end is the part of a 3D printer that melts and extrudes filament. It consists of a nozzle, a heater block, and a heat break. Nozzles typically come in different diameters, from 0.2mm (slower prints, higher detail) to 0.8mm (faster prints, thick layers). Most printers come with a brass nozzle which works perfectly fine for most projects but wears out quickly when printing abrasive materials (glitter, glow filaments,...). Hardened steel nozzles last much longer but conduct heat less efficiently, requiring higher temperatures and recalibrating the printing temperatures when first using.

3. Typical Challenges in 3D Printing

Automated Calibrations: Critical for First-Time Use

Proper calibration is essential when setting up your printer. Skipping calibration steps can cause serious damage. Always ensure bed leveling, filament loading, and successful extrusion tests before beginning your print.

A Benchy: Your First Print Test

A benchy is a small test print that helps evaluate your printer’s performance. It identifies common issues like overhangs, layer adhesion, stringing, and overall print quality.

Common Issues and Troubleshooting Tips

• Bed Adhesion Problems: Ensure the bed is clean and leveled. Avoid adhesives like glue sticks that can degrade the build plate.
• Stringing: Store filament properly in airtight containers to avoid moisture. You can dry filament in an oven at 50ºC (122ºF).
• Warping: Ensure the print is not placed near air conditioning units or heaters, as this can cause uneven cooling and warping. Adjust fan settings if necessary.

4. Going Professional

Professional 3D printing targets high-quality production with advanced equipment. Filament dryers, post-processing tools, and monitoring systems ensure consistent, high-quality results for large-volume production.

Filament Dryers

Moisture can ruin prints, so filament dryers are essential for keeping materials in optimal condition. Proper storage, such as in dry boxes or cabinets, is also crucial for preserving filament quality.

Post-Processing

Professional prints often require finishing touches, including sanding, painting, or other modifications to improve the appearance and durability.

Monitoring Systems

Many professional printers include cameras for monitoring prints. For better quality, consider using external cameras like Blink or Wyze connected via USB.

5. Estimating Costs for Jobs

• Design File: Include any costs associated with purchasing or licensing design files.
• Material Costs: Calculate the cost of filament used for the print.
• Machine Time: Estimate an hourly rate for machine use based on depreciation and energy consumption.
• Your Time: Factor in the time spent printing, monitoring, and post-processing.