Venturing into the realm of industrial 3D printers can be daunting, especially when it comes to understanding the advantages and complexities of operating and maintaining advanced equipment during the initial planning stages. With a plethora of 3D printer designs and technologies available, determining where to begin can be overwhelming.
In this blog post, we will break down the essential information you need to get started with industrial 3D printing, offering guidance on navigating the diverse options and setting up your printing processes effectively.
Exploring the Top 3 3D Printing Technologies
As you embark on your journey into 3D printing (or additive manufacturing), understanding the various printing technologies and their benefits is crucial. Printing systems are generally categorized by the type of raw material they use. The three main categories are:
- Filament-Based Systems: Such as the Markforged Fused Filament Fabrication (FFF), which uses thermoplastic filaments.
- Resin-Based Systems: Like the Formlabs Stereolithography (SLA), which employs liquid resins hardened by light.
- Powder-Based Systems: Including HP Multi Jet Fusion (MJF) and Formlabs Selective Laser Sintering (SLS), which use powdered materials fused by lasers or other methods.
Each technology has its own set of advantages and is suited to different applications. In this guide, we will delve into each technology and provide real-life examples of 3D printers we offer at Hawk Ridge Systems to illustrate their capabilities and applications.
Working with Filament 3D Printers: Markforged FFF Technology
Filament-based 3D printers, such as those from Markforged, exemplify the strength and versatility of Fused Filament Fabrication (FFF) technology. Markforged is renowned for its industrial-grade FFF printers designed for robust factory use. These printers not only use standard filaments but also incorporate continuous fiber reinforcement (CFR) to enhance the strength and durability of printed parts.
CFR technology allows Markforged printers to create parts that are both lightweight and exceptionally strong, often replacing traditional aluminum components in machinery. This capability sets Markforged apart from other technologies, as their printers are known for their strength, user-friendly design, and advanced software tools, including simulation and inspection features. For those interested in the best 3D printer designs, Markforged offers a variety of models, such as the Metal X 3D printer, which is well-suited for industrial applications, as well as composite printers for diverse business needs.
Common Applications for Filament-Based Printers
Filament 3D printers are versatile and can be used for a range of applications, including jigs, fixtures, assembly aids, soft jaws, and structural components. Markforged stands out by offering materials with flame-retardant properties, suitable for aerospace and defense applications, and features machines capable of operating offline for secure environments. The strength of CFR parts has also made Markforged a popular choice in robotics competitions.
Designing Parts for Markforged FFF & CFR
When designing parts for Markforged FFF printers, it’s important to consider support structure removal and part strength. Simplifying support structures through design adjustments, such as adding chamfers and angled surfaces, can enhance both part aesthetics and efficiency. To maximize strength, focus on increasing the X-Y cross-section and prioritizing critical areas for continuous fibers, as FFF parts tend to be weaker in the Z-direction. Markforged’s simulation tools can help optimize 3D printer design for FFF printing, ensuring the best possible outcomes.
Markforged printers provide a powerful entry point into additive manufacturing, offering advanced capabilities and a wide range of applications for industrial and creative needs.
Overview of Filament 3D Printing Applications
Filament-based 3D printers, particularly those from Markforged, are widely used in industrial settings for creating jigs, fixtures, assembly aids, soft jaws, and structural components. Markforged stands out in the industry with its range of materials that meet NCAMP certifications, making them suitable for aerospace and defense applications. Their printers also offer offline operation for high-security environments.
Markforged’s continuous fiber reinforcement (CFR) technology has gained recognition in robotics competitions, such as battle bots, for producing parts that are significantly stronger than those made by other 3D printing systems. The versatility of Markforged printers makes them ideal for various common 3D printing needs, including prototyping, enclosures, and cosmetic parts, making them a great entry point into additive manufacturing.
Design Considerations for Markforged FFF & CFR Printers
When designing parts for Markforged printers, it’s essential to consider support structure removal and part strength. You can often eliminate the need for support structures by incorporating chamfers and angled surfaces in your CAD designs, which also improves the part’s surface finish. To maximize part strength, focus on expanding the X-Y cross-section to accommodate continuous fibers, as FFF parts are generally weaker in the Z-direction. Utilizing Markforged’s simulation tools can help optimize designs for FFF printing.
Installation and Facility Considerations for Markforged Printers
Installing Markforged printers is straightforward, with most models, except the FX20, requiring only a standard wall outlet. Industrial models like the FX20 need 3-phase 240V power, whereas the more compact Metal X printer can operate on a 110V outlet, making it office-friendly.
The installation process is simple, involving powering the machine, loading materials, and leveling the print bed. Additionally, Markforged printers are easy to relocate due to their minimal space requirements.
For network connectivity, Markforged printers require either Wi-Fi or a hardwired connection unless the Offline Eiger software is used. The Metal X printer may need additional facility considerations, such as an exhaust system for the wash station and sinter oven, which can be managed with a BOFA extraction unit. Moreover, the sinter oven requires specific gases, and the wash station uses an Opteon solvent.
Finally, Markforged printers operate quietly and without odors, making them suitable for both office and factory environments. The Metal X equipment, in particular, is quiet with minimal personal protective equipment (PPE) requirements, especially compared to other metal 3D printing technologies.
Operating Markforged 3D Printers: A Comprehensive Guide
Overview of Operating Markforged Printers
Understanding the operation of Markforged 3D printers involves mastering the Eiger software, managing the printing process, and handling post-print tasks. This guide delves into each step, providing insights into the software tools, the printing workflow, and the procedures for post-printing.
1. Eiger Software – Preparing and Launching a Print
Operating a Markforged printer begins with Eiger, a top-tier 3D printing management software. Available in both cloud-based and offline versions, Eiger offers a user-friendly platform built on a file-folder structure with role-based access control (RBAC) and enterprise software APIs for seamless scalability and integration.
The cloud-based version of Eiger, which is free to use, stands out as a collaborative tool, enabling teams across the globe to work together on printing projects. Eiger also features a simulation add-on that allows users to conduct strength analysis on parts by applying loads, anchors, and safety factors. This feature optimizes internal slice parameters to meet design criteria, eliminating the guesswork in selecting print settings. Prints can be sent to the printer remotely via the cloud, securely over a local network, or directly using a USB connection. For those interested in online 3D printing services, Eiger’s cloud capabilities offer excellent remote management options.
2. The Printing Process
Before initiating a print, it’s recommended to apply a thin layer of adhesive to the print bed to ensure proper filament adhesion. If the bed is clear, printing can start immediately once the job is submitted from the Eiger software.
Markforged printers operate autonomously after job submission, with the system updating print progress through Eiger. Many models include a camera for remote print monitoring. Typically, Markforged printers use two nozzles: one for plastic and another for continuous fiber. The printer will alternate between laying down filaments, fibers, and support structures until the part is complete.
3. Post-Print – Removing Support Structures
Once printing is complete, the user can detach the print bed and remove the parts. Support structures can be easily removed by hand or with needle-nose pliers. In most cases, support structures are made from the same material as the printed part and are automatically generated in an easy-to-remove, accordion-like shape by the Eiger software.
A key advantage of Markforged printers is the simplicity of the post-print process—no additional equipment, chemicals, or tools are required to finish parts. This makes Markforged printers among the cleanest and most efficient additive manufacturing systems available.
Maintaining Markforged 3D Printers: A Guide to Efficient Upkeep
Maintaining a Markforged 3D printer is straightforward, with regular tasks including bed leveling every two weeks and timely replacement of consumable parts according to a maintenance schedule that the printer continuously monitors. This schedule is easily accessible through the Eiger software.
Key maintenance tasks typically involve changing nozzles, replacing the Bowden tube, and ensuring proper belt tension. Markforged offers a suite of support packages under the Digital Forge program, designed to minimize downtime and keep your printer running smoothly.
Swapping materials on a Markforged printer is a quick process, usually taking around 10 minutes. It involves removing the old filament spool from the dry box, loading a new spool, and feeding the filament through the Bowden tube until it reaches the extruder motor, which will then purge a small amount of material before completing the process.
Training and Support Resources
Markforged provides extensive training and support through its online platform, Markforged University. This platform offers self-paced courses and modules to help users quickly become proficient with the printing systems. Access to Markforged University is typically included with the Digital Forge support package.
For larger systems like the FX20 and Metal X, both onsite and online training options are available with the purchase of the equipment. Additionally, Hawk Ridge Systems offers specialized training and dedicated support teams to assist with troubleshooting, part replacement (covered under support plans), and resolving technical issues.
Working with Resin 3D Printers: An Overview of Formlabs SLA Systems
Formlabs is a leader in the additive manufacturing industry, known for its high-quality SLA (Stereolithography) 3D printing systems. SLA technology offers several advantages, including:
- Exceptionally smooth surface finishes
- A wide range of material options, including transparent and biocompatible resins
- High-resolution printing for intricate, detailed features
Formlabs provides over 30 different resin materials, catering to various applications from tough engineering materials to flexible elastomers, ceramics, medical-grade resins, and quick-draft materials. The product lineup includes models such as the Form 3+/3B+, Form 3L/3BL, and the latest Form 4/4B.
Common Applications for Resin 3D Printing
Formlabs SLA printers are highly versatile, making them suitable for a broad range of applications, including rapid prototyping, tooling, manufacturing aids, end-use parts, and detailed models or props. The wide array of materials available allows these printers to meet the needs of many industries, particularly in medical fields where biocompatibility is crucial. The ability to produce both soft silicone components and rigid technical ceramics, along with everything in between, makes Formlabs printers ideal for even the most demanding use cases.
Designing for Formlabs SLA Printers
Designing parts for SLA printers like those from Formlabs requires careful consideration of support structures and the prevention of resin entrapment within hollow sections of the part. Fine design details are possible with Formlabs technology, but it’s essential to include small drain holes in hollow areas to avoid resin encapsulation during the printing process.
Installation and Facility Requirements for Formlabs SLA Printers
1. Setting Up Your Formlabs SLA Printer
After receiving your Formlabs SLA printer, the setup process is straightforward. It involves leveling the printer, establishing a network connection (and updating the printer if necessary), and loading the consumables (resin cartridge, resin tanks, and build platform). Once these steps are completed, your printer is ready to begin printing.
2. Power and Space Requirements
Formlabs SLA printers are designed for ease of installation, requiring only a standard 110V power outlet and a stable network connection. In addition to the printer itself, the SLA printing process also requires a wash station and a curing oven. These tools, essential for the post-printing process, also run on 110V power. To ensure a pleasant working environment, it is recommended to place the wash station in a well-ventilated area or near an open window to manage any solvent odors, typically from IPA used in the cleaning process.
Preform & Dashboard Software – Preparing, Submitting, and Monitoring Prints
Preform Software Overview
Preform is a free, user-friendly software designed to prepare and submit prints to all Formlabs 3D printing systems. Specifically for SLA printers, Preform offers tools for automatic orientation and support structure generation, with additional options for customization. The software includes built-in settings for materials and layer heights, allowing you to easily configure print specifications, such as material usage and estimated print time.
Dashboard Platform Overview
Dashboard is an online platform that provides real-time monitoring of your prints and printer utilization. It also tracks consumable usage and offers advanced statistics and data analysis to help optimize the performance of your equipment.
1. The Printing Process
Formlabs SLA printers use light-reactive resins that solidify when exposed to a UV laser, which fuses layers together to create the final part. The printer builds parts upside down on a build plate, repeatedly dipping the part in and out of the resin until the print is complete. The machine operates autonomously, requiring no manual supervision during the printing process.
2. Post-Print Process: Washing, Curing, and Support Removal
After printing, parts need to be rinsed in isopropyl alcohol (IPA) to remove any uncured resin. Once the parts have dried, many require post-curing, which enhances their strength and mechanical properties. The final steps involve removing support structures and sanding down any residual support points for a smooth finish.
Maintaining Formlabs SLA Printers
To ensure optimal performance of Formlabs SLA printers, daily maintenance should include checking the build platform for any liquid or cured resin. If resin is found, clean the area using isopropyl alcohol (IPA), paper towels, and a paint scraper before starting the next print. Monthly maintenance involves cleaning the optical window on the laser processing unit. Additionally, tasks such as replacing resin cartridges may be required periodically. For a comprehensive list of maintenance tasks, refer to the Form 3 maintenance schedule.
Training & Support Resources
Formlabs offers a comprehensive range of training and support resources to help users quickly get up to speed with their systems. These include quick start guides, industry-specific learning pathways, training sessions, seminars, and personalized one-on-one training. Formlabs also provides a robust support network, featuring various service plan options and a detailed support documentation database. The Formlabs Pro Support Plan offers email and chat support, phone assistance, live customized training, and hot swap part replacement to ensure minimal downtime.
Working with Powder-Based 3D Printers: Formlabs SLS Systems
Formlabs made a significant impact in the SLS (Selective Laser Sintering) 3D printing market with the launch of the Fuse 1 in 2021, quickly becoming a dominant player. Today, more than half of the SLS systems sold worldwide are Formlabs Fuse SLS 3D printers, a testament to their high-quality, user-friendly workflow, diverse material options, and excellent printed-part quality—all offered at a competitive price point compared to other SLS systems.
SLS technology, a powder bed fusion process, is known for its speed and the production of durable, end-use parts. A key advantage of SLS printing is that it eliminates the need for support structures, allowing for more complex and innovative designs. The latest advancement in Formlabs’ SLS lineup is the Fuse+ 30W, which continues to push the boundaries of what’s possible in 3D printing.
Common Applications of Powder Bed Fusion Printing
Powder bed fusion, particularly with Formlabs SLS printers like the Fuse 1+ 30W, produces parts that are notably robust compared to other 3D printing technologies. One of the key advantages of SLS printing is the absence of support structures, allowing for greater design flexibility. While prototyping and manufacturing aids remain popular uses, SLS technology truly excels in producing end-use parts due to its faster printing speeds and the ability to automate post-processing.
SLS printing is especially well-suited for parts with complex geometries, including curved surfaces and internal cavities, which can be easily achieved without compromising the integrity of the design. The technology also delivers impressive surface textures, making it ideal for a wide range of applications.
Designing Parts for Formlabs SLS Printers
Designing for SLS printing is straightforward compared to other 3D printing methods. Since the powder bed supports the models during printing, there’s no need for additional support structures. The primary design consideration is to avoid geometries that could trap powder. Otherwise, SLS printing excels with intricate internal features, lattices, curved surfaces, and detailed textures, making it a versatile option for various applications.
Installation and Facility Requirements
The Fuse system is designed for straightforward installation, with both the printer and sift requiring 110V power through a dedicated NEMA 5-20R socket. While many users handle the setup themselves, professional installation services are also available.
Given that the Fuse system operates on powder bed technology, post-processing demands specific attention to maintain a clean workspace. The system typically includes a sift unit that simplifies the unpacking of prints and powder recycling, minimizing mess and labor. Proper ventilation is essential to ensure fresh air circulation and maintain optimal operating temperatures. Additionally, a Class II, Division 2-rated vacuum is necessary for dust collection and system cleanup.
The final step in processing powder bed prints is bead blasting, which can be performed manually using a bead blast cabinet or through the automated Fuse Blast system. The bead blast cabinet requires a compressed air supply, so it’s important to factor this into your workspace setup. Environmental conditions should also be maintained, with room temperatures between 64-84ºF (17.8-28.9ºC) and relative humidity at 50% or lower.
Operating Formlabs SLS 3D Printers
Operating the Formlabs SLS 3D printers involves using specific software, managing the printing process, and handling post-print tasks. Here’s a streamlined guide on how to effectively operate these printers.
1. Preform & Dashboard Software: Preparing, Submitting, and Monitoring Prints
Preform, a free software tool from Formlabs, excels in preparing prints, nesting parts, and sending print jobs to the machine. Its automated nesting feature efficiently arranges parts of various shapes and sizes for optimal packing. Dashboard is another essential tool, providing real-time monitoring, job planning, and detailed analytics on material usage and printer performance.
2. Printing Process
The Formlabs Fuse 1+ 30W utilizes Selective Laser Sintering (SLS) technology, which sinters powdered material layer by layer. To begin, load the build chamber and powder into the printer. The machine then sinters the part geometry within the build chamber. After sintering, the printer enters a cooling phase. The build can continue to cool outside the printer once the chamber temperature drops below 212ºF (100ºC).
3. Post-Print
Once the print is complete and cooled, use the Fuse Sift station for unpacking and powder recovery. The sift station features a docking port for the build chamber, allowing for easy removal of printed parts and efficient powder collection. Finally, bead blasting is required to remove any residual powder. The Fuse Blast system, an automated depowdering solution, integrates seamlessly with the Fuse ecosystem to prepare parts for end-use applications.
Maintaining Formlabs SLS Printers
To ensure optimal performance of the Fuse system, regular maintenance includes cleaning sensor lenses and windows and vacuuming any residual powder from the printer. For a comprehensive list of maintenance tasks for Fuse 1 generation printers, refer to the detailed maintenance guidelines.
Training & Support
After installing the system, users can access both onsite and online training options. Formlabs offers a range of resources, including training webinars and documentation, to help users become proficient with their new printer. The Fuse support plan provides email and phone support, as well as onsite repairs in collaboration with the Hawk Ridge Systems support team.
Working with HP Multi Jet Fusion (MJF) Printers
HP Multi Jet Fusion (MJF) has established itself as a leader in powder bed fusion technology thanks to its impressive speed, cost-efficiency, and effective print workflow.
1. Printing Technology
Unlike Selective Laser Sintering (SLS), MJF uses a different approach: it employs two distinct agents that interact with concentrated heat to fuse layers of powder, rather than using a laser. This method allows MJF to print an entire layer in a single pass, regardless of the complexity of the geometry, resulting in significantly faster print times.
2. Build Volume and Reliability
HP’s MJF printers, such as the 5600 model, feature a substantial build volume of 15 in. x 11.2 in. x 15 in. These systems are engineered for production environments and offer high reliability, enabling continuous, unattended operation.
3. Industry Adoption and Automation
Additive manufacturing service providers favor HP MJF technology for its rapid production capabilities, low part costs, high accuracy, and design flexibility. Additionally, MJF supports automation solutions, like the HP Automation Accessory and Automatic Unpacking Station, which enhance productivity by reducing manual labor.
4. HP MJF Printer Models
HP’s MJF printer lineup includes the 5000, 5200, 5420W, and 5600 systems, each designed to meet various production needs with advanced powder bed printing technology.
Applications Across Industries
HP Multi Jet Fusion (MJF) technology is versatile, finding applications in various sectors such as consumer electronics, aerospace, healthcare, and industrial manufacturing. MJF printers are commonly used to produce both high volumes of prototype parts and end-use products. This technology is particularly useful for large-scale manufacturing and can even replace traditional methods in some cases. Industries focusing on mass customization, like medical fields for orthotics and prosthetics, benefit significantly from HP MJF’s capabilities. The technology allows for tailored, high-quality production that meets specific needs efficiently.
Designing for MJF
MJF’s powder bed process is relatively flexible, with minimal design constraints. Key design considerations include reducing material volume to lower costs and ensuring parts are designed to facilitate effective bead blasting, which prevents residual powder from being trapped inside. The technology excels at producing intricate details, including fine features as small as 0.5 mm and complex textures. Designers can leverage MJF’s ability to create sophisticated internal structures and detailed surface textures for high-quality outcomes.
Installation and Facility Planning for HP Multi Jet Fusion Systems
1. Facility Preparation
Installing an HP Multi Jet Fusion (MJF) system involves careful planning for space, power, network, compressed air, and ventilation. For detailed guidance, refer to the site preparation guide provided. Planning and preparation typically take a few weeks, with assistance available from the Hawk Ridge Systems team. This includes help with installation and training once your site is ready.
2. Space Requirements
Proper environmental conditions are crucial for operating MJF systems, including maintaining room temperature, air exchange, and humidity levels. An MJF setup generally includes a printer, processing station, and bead blasting equipment. Both the processing station and bead blasting unit require compressed air and have specific power needs.
3. Additional Considerations
Each component of the MJF system requires a dedicated network connection and has specific clearance requirements for maintenance. Our team offers support in planning facility layouts and ensuring that all equipment is properly accommodated.
Operating HP Multi Jet Fusion Printers
1. Software for Print Preparation and Monitoring
To operate HP Multi Jet Fusion (MJF) printers effectively, use the Smart Stream Build Manager and Command Center software. Smart Stream is designed for job preparation and nesting, although companies with complex needs may prefer third-party solutions like Materialise Magics for advanced nesting capabilities. The Command Center software provides a centralized interface to monitor printer status, track current jobs, and manage consumables.
2. Printing Process
Start the print process by sending a job from the Smart Stream software to the printer. The printer will then load a mobile build unit filled with powder. The system disperses agents to fuse the powder layer by layer according to the part geometry. After printing, the job needs to cool. This can be done outside the printer, or more rapidly in the processing station using a vacuum hose to enhance airflow and reduce cooling time to about one-third of the natural cooling duration.
3. Post-Print Procedures
Once cooling is complete, unpack the build using the HP processing station. This station facilitates easy removal of parts and powder recovery in a clean, controlled environment. It features active airflow to contain powder and a closed-loop system for powder recycling and build unit loading. Finally, depowder the parts using bead blasting. This can be done manually or with an automated blasting cabinet, depending on your preference and needs.
Maintaining HP MJF Printers
To keep HP Multi Jet Fusion (MJF) printers operating optimally, regular job-to-job maintenance is essential. This includes cleaning the thermal camera lens, heating lamp glass, and fusing lamp glasses between jobs. Additionally, any loose powder in the printer should be vacuumed, and the spittoon component needs cleaning before starting the next print. Periodic maintenance involves replacing filters and other consumables, with the printer providing notifications when these items need attention.
Training and Support
HP offers a comprehensive training program for MJF systems, which includes:
- Online Self-Paced Training: Allows users to learn at their own pace.
- Onsite Training: Conducted by a field service engineer for hands-on experience.
- Remote One-on-One Training: Provided by an application engineer for personalized instruction.
Upon completing the training, operators receive certification, ensuring they are fully prepared to use the technology effectively.
Conclusion
With a clearer understanding of what it takes to begin with industrial 3D printers from Markforged, Formlabs, and HP, you’re well-positioned to embark on your additive manufacturing journey. This is an exciting time to dive into 3D printing, as advancements in technology offer incredible opportunities for innovation and efficiency. For those looking to seeking 3D printing service near me, considering these post-processing steps is crucial for achieving high-quality results.
Contact us at Dezpad for more information on how to begin your journey with industrial 3D printers. Our team is here to provide expert advice, comprehensive service, and support for all your additive manufacturing needs. Whether you’re interested in Markforged, Formlabs, or HP technologies, we can help you find the right solutions and guide you through every step of the process. Reach out today to explore how Dezpad can assist you in achieving your 3D printing goals.