Workflow, Materials, Usual 3D Printed Uses, Top Benefits of 3D Printing, Top Problems with 3D Printing, What to print What to not print

1. The standard
Workflow
From design to real object
3D Model (the IP)What:
CAD Software (free/paid)How:
Digital File (.obj, .stl, .dwg…)Specs:
A File that can be preserved and
iterated upon. It's “perfect” until it
becomes “physical”
Detail:
3D Sliced File
Slicer Software (free)
Digital File (.gcode)
It's the exact set of instructions for
a specific printer. The coordinates
the printer has to move to.
Physical Object
3D Printer
Material choice
The final object is created. Its
resolution (detail) and material is
proportional to the time it takes.
Printer + 3D Model
Printer + .gcode
Depends of printer
An extruder moves in the x,y and z
direction using the code. Quality
and material depend on printer.
Use o test
Not good?
Iterate
Insights
Redesign

2. Biggest direct cost:
Materials
20€/Kilo for most simple materials, more specific, more expensive
Material accounts for 70 - 90% of the total direct costs.
So 1.3 x weight of the product is a good estimation.
Wood PLA Marble PLA multi colored PLA There is PLA in every color imaginable
ABS Nylon TPU (elastomero) Composites Metal

3. A lower barrier to create a physical object
● Prototyping
● Tooling (directly or indirectly) (Eg: PLA to Silicon to Final)
● Low volume manufacturing
● Customization / personalization at scale
● Art/design (complex shapes)
● Education
● Medical (very adapted)
● Replacement parts (Retrocompatibility)
● Model making
● Research
Usual 3D Printed Uses

4. A lower barrier to create a physical object
1. Get products into the customers or teams hands quicker
2. Save money and time on tooling
3. Ability to iterate and incorporate new feedback quicker
4. Limited risk if design is not appropriate
5. Complexity and design freedom
(New shapes and structures compared to traditional methods)
6. Ease of access to a printer
7. Reduced overhead cost in general
8. No logistics cost if sent online and printed on site wanted
9. Much less waste than subtractive manufacturing
Top Benefits of 3D Printing

5. 1. Limited materials
2. Unreliability of machines
3. Challenges large scaling up (volume)
4. Speed
5. Environmental Concerns
6. Surface finish
7. Resolution
8. Mechanical properties
9. Post processing
10. Still only making shapes
Printers are getting better and support more materials.
I've only used ABS and PLA (cheapest, around 15€/kilo)
Can print with most polymers and even metal now.
But cost goes up.
I currently print in PLA (food safe), made from corn starch
and “Environmentally friendly”.
Have plans to reuse inhouse waste plastic for 3D printing.
You also cut pollution as you cut logistics overall.
Can also be painted one, and most post processing
techniques can be applied.
Can print transparent, and even with specific mechanical
properties now. (Composites, carbon fibre…)
Most issues and how we are solving them
Top Problems with 3D Printing

6. 1. Limited materials
2. Unreliability of machines
3. Challenges large scaling up (volume)
4. Speed
5. Environmental Concerns
6. Surface finish
7. Resolution
8. Mechanical properties
9. Post processing
10. Still only making shapes
You can run as many machines simultaneously as
required. That reduces unreliability.
If 2 designs print and one fails, the probability of the other
failing is 1%, if we have 3, its 0.1% Failure rate, great.
If it's the same object thousands of times, you should
reconsider another manufacturing method
Depends on the 3D printer
If a printer is 500€ - 5000€ it's always cheaper than
tooling and also can print any other thing in the future.
That's the essence of the method, other have to be
chosen then.
Most issues and how we are solving them
Top Problems with 3D Printing

7. Other interesting overlaps
Photogrammetry
Using images/video as the blueprint to create a 3D Model
Use cases:
- Reverse engineering: Photo - 3D Model - Print - Reverse engineer
- Keeping a digital copy of a real object.
You could print repair parts if you own the whole digital model.
- CGI (Working with the digital model not the real thing)
- Just making the modelling much quicker if you have a reference

8. I always say:
Reality is the sum of all perspectives

9. Other interesting overlaps
Food
Using low melting point materials to 3D print
Although it does not have the scale or its viable at the
moment, it's nice to look at what's happening in food.
For expensive shared products like cakes, it could make
sense, charging a big premium on personalisation

10. 1. Protects against physical wear (being digital)
2. Provides retrocompatibility and simple replicability
3. Can perform simulations on the digital model at lower
cost and faster speed than physical.
4. Can connect as a IoT device to make data transmission
seamless, from location to sensors.
5. Easier product redesign/development
6. Virtual Start Up
7. Analytics and collaboration
Other interesting overlaps
Digital Twin
Having an exact digital copy of a physical object.

11. Objects that have ideal characteristics to print
1. The smaller volume the better.
If it fits on a plate, it's done quickly and extremely cheaply.
2. Very specific, complex shapes, in low quantities.
“Geometric and design freedom”
3. Branded objects or with slight variations on an original
4. When shape is more important than material
5. Has a working temperature of less than 180 Degrees
(Other materials support 250 to 500)
6.
What to not printWhat to print
More suited to other manufacturing processes
1. The biggest disassembled piece has a big volume
If it's bigger than a microwave, cost and time goes up, but
can be printed. Just resolution goes down.
2. Generic, easily tooled shapes for large quantities.
3. If it needs very complex or specific materials
4. If it has to support extreme temperatures or require specific
mechanical properties unachievable via geometric
engineering.
5.

12. Objects that have being designed and share freely with the community
1. https://www.thingiverse.com/
2. https://www.myminifactory.com/
3. https://cults3d.com/en
4. https://pinshape.com/3d-marketplace
5. https://grabcad.com/library
6. https://3dwarehouse.sketchup.com/
Top Free STL Sources