Advanced processes in 3D printing, such as inserts, core modeling and multiple materials, can expand the capabilities of a 3D printer. Incorporating non-printed elements, such as fasteners, electronics, switches, sensors, or even metal sub-structures, into a printed part expands the spectrum of usability—resulting in fully functional models and prototypes. The ability to add inserts is a key advantage to FFF, Fused Filament Fabrication, type of 3D printing—where hardware is inserted mid-print and completely encompassed by the 3D print process.

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Expanded 3D Printing
Capabilities
Going Beyond Prototyping

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Before We Start

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Leslie Langnau
Design World
Moderator
Melissa Cavanagh
Marketing Communication
Manager
3D Platform
Joseph Binka
Additive Manufacturing
Engineer
3D Platform
Expanded 3D Printing Capabilities – Going Beyond Prototyping
Meet your presenters

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Topics
• Going beyond prototypingà why?
• Advanced processes in 3D printing, such as:
• Inserts
• Fasteners
• Living Hinges
• Linear Bearings
• Sensors
• Core Modeling
• What is it?
• Why use it?
• Using Multiple Materials
• Choosing the best material for the job
• Easy-to-use alternatives to tricky materials

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Going Beyond Prototyping
• Production and Manufacturing Support Applications
• Job Requirements
• Require additional strength
• Require rigidity and flexibility (Living Hinge)
• Multi-piece… must be assembled
• What’s the solution?
• Advanced 3D printing processes
• Inserts
• Core modeling
• Multiple materials

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Going Beyond Prototyping
• Production and Manufacturing
Support Applications
Jigs
Brackets
Vacuum Fixtures
Shadow Boards

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3DP Insert Capability
• Insert metal, wire, connectors,
sensors, and more into a print
• Video Link …
www.youtube.com/watch?v=keZuEaNcIbc

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About Inserts
• Enables design to incorporate
non printed elements such as:
• Fasteners
• Electronics
• Metal sub-structure
• Implementation is to insert a
M600 Pause instruction in the G
Code at the layer height and
location that you wish for the
print to pause
• This is a key advantage for FDM
Printing as inserts are not
practical with SLA, SLS, and
Polyjet.

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Insert Examples
Nut
Bolt Piano Hinge
Bearing
Switch

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Insert Example

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Wire Insert in NinjaFlex

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Insert Example - Electronics & Wiring

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Core Modeling
• Open market software allows us to run
independent processes in the same print
• Multiple zones (cores) within the same print
object can have different process settings
such as:
• Material choice
• Infill percentage
• # Top & Bottom Layers
• Wall Thickness
• Print speeds
• Customer benefit is the ability to optimize the
design for:
• Strength
• Print speed
• Aesthetics
• Functionality

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Property of 3DP Unlimited#DWwebinar
Core Modeling
• Shadow Board Application

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Core Modeling
1. Less infill allows the part to print quickly
2. More infill in select areas provides added strength
3. Embedded inserts provide the ability to add and/or remove a protective
cover

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Multiple Materials
• ABS - 1950’s injection molding material
• Tendency to warp, twist, curl, shrink
• Problems with layer-to-layer adhesion
• Unpleasant odor
• Open Platform Advantage
• Wide range of modern materials
• http://colorfabb.com/xt-copolyester
• http://gizmodorks.com/petg-3d-printer-filament/
• Many More … http://nicklievendag.com/filament-guide/
• 3DP Blog … “Top 10 New 3D Printing Materials You Should Try”
• Part 1 … http://3dpunlimited.com/top-10-new-3d-printing-materials-you-should-try-part-i/
• Part II … http://3dpunlimited.com/top-10-new-3d-printing-materials-you-should-try-part-ii/

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Property of 3DP Unlimited#DWwebinar
Going Beyond Prototyping
• Other areas using advanced 3D printing processes,
beyond Production and Manufacturing Support
Applications
• Creative Applications
• Personalization

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Going Beyond Prototyping
• Creative Applications
• Sales Models
• Set Design
• Exhibits
• Architecture
• Art

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Going Beyond Prototyping
• Personalization
• Prosthetics

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Going Beyond Prototyping
• Personalization
• Full Body Printing
• Scan and Print Me!

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Joseph Binka
Additive Manufacturing Engineer
3D Platform
Joe.binka@3dpunlimited.com
Expanded 3D Printing Capabilities – Going Beyond Prototyping
Melissa Cavanagh
Marketing Communications Manager
3D Platform
Melissa.cavanagh@3dpunlimited.com
Questions?
Leslie Langnau
Managing Editor
Design World
llangnau@wtwhmedia.com
@DW_3DPrinting

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Thank You
q This webinar will be available at
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