There are a variety of important aspects to take into consideration when looking at additive manufacturing. These five essential elements are crucial to ensure that your item is created in a balanced manner. The balance between size, resolution as well as thickness, orientation, and choice of material will help ensure the function and aesthetics of your work.

Size

One feature to consider when designing your product is its size. Each technology has its own ideal format. Some are smaller than others. FDM machines can reach 16"x14''x16". If your piece is bigger than that, it may be sectioned before fabrication and then glued together in a professional way. Fabrication time will be affected by the dimensions of your components. Large parts take more time to construct and will need more material, which results in higher prices.

The resolution

In additive manufacturing, the resolution refers to the thickness of the material that is applied. Depending on the technology used the thinner layer will reduce imperfections or ridges that may appear on the surface of the part. High-resolution 3d printing warping will give you a smoother surface and better quality prior to any post-processing. The manufacturing time is longer when the layers are thinner.

For an object with very high resolution, choose SLA (Stereolitography) technology that has layers with thicknesses that can reach 25 microns (0.025mm). SLS technology has a very high resolution, i.e. 100 microns (0.1mm). The standard FDM layer thickness is 250 microns (0.25mm) and we also provide high-resolution (0.175mm). Printing can be done at the lower resolution (330 microns or 0.330mm). This is an excellent alternative for large and less attractive objects that are produced efficiently and with lower cost.

Wall thickness

The most important characteristics of your design are the thickness of the component's walls. This will ensure stability, precision, and tolerance in additive manufacturing components. Smaller thickness shortens build time, but too thin can result in a brittle component with less precise properties.

The thin parts made with SLS are more likely to warp due to the manufacturing process. SLS components are exposed to high temperatures and also the mass of the powder is a factor during the manufacturing process. SLS material may shrink when it cools down or solidifies. With a thickness between 1mm to 3mm, geometric stability of these properties is more easily achieved. You can still achieve an acceptable thickness of less than 0.4mm. This is however riskier. Learn more about fusion 360 vs inventor by going to our website.

FDM is an example of a material where the minimum thickness recommended is 1.6mm

The orientation

The orientation of a component in 3D printing is determined by its placement on the printer's platform. It can be oriented in an angle, laid flat, or placed vertically. The correct orientation of the components to fabricate is an essential element that influences the final quality, especially when it comes to the geometric dimension and tolerance to errors. The amount of energy utilized and the extent of support structures are directly affected. All these elements add to the total cost of the component.

Based on the method of printing, orientation may vary. FDM prints are characterized by a strong elastic force in the X-Y directions, but a weaker Z direction due to the method in which the layers were printed. This can lead to visible lines between layers which can affect the aesthetics of your components. For this reason, certain orientations are preferred for curves. Sometimes, orientations that are too high off the surface won't be as effective and require more support.

We will take care of positioning your parts so that they are in the optimal ratio between parts' strength and surface quality (unless stated otherwise).

Material selection

The technique you choose, there are different types of materials that you can choose for your 3D printer. The limitations of the component will determine the type of material you select. It is essential to pick the correct material for your part. If your part will be subject to extreme temperatures or chemical solvents, think about ULTEM (in FDM tech). If it needs to be resistant to impact, polycarbonate will be the best option.

SLA technology has a wide range of intriguing resins that can be utilized in various ways. If you are looking for a material that is that are similar to rubber, you can try using a flexible resin. If you're looking to create an lost wax casting and want to make a lost wax casting, we have "castable wax" resin. ABS (FDM) as well as nylon (SLS) and acrylic resin (SLA) All three are suitable for your needs.

Design balance

The resolution, size as well as the thickness, orientation and the material you choose to use are the most important aspects of a creation dedicated to 3D printing.When these factors are all thought of and balanced, you are sure to get a functional part that meets your needs.