3D PRINTING

A PRACTICAL GUIDE TO

OVERVIEW OF TECHNOLOGIES
AND THEIR APPLICATIONS
IN THE INDUSTRY
PROFESSORSHIP FOR POLYMER ENGINEERING

The Professorship for Polymer Engineering supports

higher education in plastics. This is achieved by
conducting research, teaching and setting up projects.

This book is the result of the 3D printing project and

serves the goal of giving small and medium enterprises
insight into the possibilities 3D printing might offer
them. It also provides the basic knowledge and tools to

A practical guide to 3D printing

get started with 3D printing. For this project 10 cases
have been worked out with companies.

Other projects by the professorship are Recycling

Rubber, Recycling Composites, Plastics in Machinery,
Plastics in Medical Applications and New Materials for
3D printing.

Windesheim University of Applied Sciences

Rik Wesselink
P.O. Box 10090 Paul Dijkstra
8000 GB Zwolle Tommie Stobbe
Netherlands Marc Beusenberg
Colophon
Title This book is a result of a research project
A practical guide to 3D printing - on 3D printing, conducted as a collaboration
Overview of technologies and their applica- between Windesheim University of Applied
tions in the industry Sciences, Stenden University of Applied
Sciences, and the companies mentioned
Publication number throughout this book.
LKT-3DPR-105071-1601 1
This study was financially supported by Green
Authors Polymer Application Centre (GreenPAC).
Rik Wesselink
Paul Dijkstra
Tommie Stobbe
Marc Beusenberg

Design
Rik Wesselink

Illustrations
Paul Dijkstra
Rik Wesselink
Perry Lok

ISBN: 978-90-77901-86-1

This is a Windesheim publication.

P.O. Box 10090, 8000 GB Zwolle,
Netherlands

Reproduction and/or publication of any part of

this publication without prior written permission
from the publisher is prohibited.

April 2017
 3
Preface
In 2014 “Printen in de derde dimensie” - a
booklet on 3D printing and its applications
within small and medium enterprises - was
published as the result of research conducted
by the Professorship for Polymer Engineering.
It showed the rapidly growing possibilities
resulting from the accelerating technological
developments in the area of 3D printing.

Its success and the ongoing developments

made us decide to continue on this path and to
create an updated, accessible and easy-to-use
catalogue. Because of the rapid and ongoing
developments in the area of 3D printing, we
decided not only to create this booklet, but to
also create a website - 3DprintWiki.org - that
contains a range of information on the subject.
Whereas this booklet focusses on basic infor-
mation and example cases of use, the website
functions as a live platform and provides more
detailed information, including videos, printing
methods, materials, decision models and
examples.

We will regularly refer to the website using

QR codes that can be scanned with any QR
scanner App on your smartphone.
 5
3DprintWiki.org
The goal of the the 3DprintWiki is to create an
accessible source of information on 3D print-
ing. It’s primarily targeted at SMEs, but can be
used by anyone who wants to get involved in
3D printing.

other printing methods 3DprintWiki is a starting point to get to know

the area of 3D printing. You can browse
through the different methods, materials, ap-
plications, printers and scanners, and build up
your knowledge on the subject. This website
will help you with the first steps, point you in
the right direction and show you what is pos-
sible with 3D printing. Content can easily be
updated to keep track of new developments.

Scan the QR-codes with any QR-code

explanatory video’s
scanner App on your smartphone to get more
information on the subject of that page.

decision-making models
 7
Contents
Colophon1 Which Print Method to Use? 65

Preface3 Ownership versus Outsourcing 65

Selecting a 3D Print Method 65
3DprintWiki.org5
Future Advancement in AM 69
Contents7
More Functionality 69
Introduction to 3D Printing 9 Higher Productivity 70
Additive Manufacturing 9 Increased Convenience 70
AM in Industrial Settings 10
Cooperating Companies 72
The Process of 3D Printing 12
Characteristics of 3D Printing 14 Glossary74

Areas of Application 16

3D Printing Methods 19
Overview of 3D printing methods 19
SLA22
DLP26
CLIP30
POLYJET32
LOM34
SDL36
INKJET44
SLS48
SHS54
FDM58
METAL62
SUBTRACTIVE
MANUFACTURING
9
Introduction to 3D Printing
Additive Manufacturing are the bended metal tubes for streetlights
Manufacturing technologies can be divided and injection moulded plastic parts in many
into three categories: subtractive, formative consumer products.
and additive.
Additive manufacturing (AM) is the newest
In subtractive manufacturing the desired category and is also referred to as 3D printing.
shape is created by removing material from a The desired product shape is created by

FORMATIVE
base material. This can be done, for example, adding material layer by layer. This can be
by drilling, turning or milling and is used a lot in done using a wide variation of technologies.
The most popular ones are based on plastics,
MANUFACTURING woodworking and in the metal industry.
but there is currently a rapid development
In formative manufacturing the base material in new technologies to use AM for metals or
can be formed by bending, forging or casting. composites.
Examples of products manufactured this way

ADDITIVE
MANUFACTURING
 11

AM in Industrial Settings replace all other production techniques (e.g. need for assembly, which can result in a cost manual labour and post-processing. Possi-
With just some basic knowledge, consum- milling, turning, injection moulding, etc.)? reduction. Example: GE’s new line of airplane bilities to embed multiple 3D-printers into an
er-level 3D-printing is easily accessible For now, the answer is no. Especially when engines (LEAP-series) that use 3D-printed fuel automated production facility for example,
nowadays. You can simply buy a 3D-printer dealing with higher production volumes, use of nozzles (19 per engine), by which 18 compo- include automated material supply, cleaning
and some material, download the required conventional production techniques will gener- nents per nozzle are reduced to just one. stations, build job preparation and unpacking.
software (free of charge in most cases), ally result in a higher output at lower cost.
design or download a digital 3D-model and Spare Parts Management Bigger, Better, Faster
start printing. “Impossible” Products Production facilities that manufacture (com- 3D-printer manufacturers are constantly
3D-printing becomes interesting when a part plex) machines usually require a stockroom improving their product line-up. Build volumes
However, additive manufacturing can also or product requires features that cannot (or for spare parts and/or production tools (e.g. are getting bigger, enabling their customers to
be highly effective in industrial settings. can only with great difficulty) be made with injection moulds) to facilitate after-sales ser- produce larger parts or to print more separate
Currently, additive manufacturing is primarily conventional techniques. This involves, for vice. By implementing 3D-printing techniques, parts at once. Since larger print jobs take
being implemented in high-end applications example, strong and lightweight lattice struc- it is possible to digitally maintain the spare more time to complete, manufacturers are
(aerospace, automotive industries), but is tures, curved and/or non-circular channels parts portfolio. This reduces, or potentially constantly looking for possibilities to speed up
also attracting interest from more and more through a solid or products with features in even eliminates, the need for stockrooms as the process without neglecting the print quality.
producers. locations where conventional tools cannot the spare parts can easily be produced on Apart from the chosen printing method and the
reach. demand. product, manufacturing speed and quality are
Replacement for Conventional Produc- highly dependent on the material used. Nu-
tion Techniques? The fact that AM makes it possible to produce Automated AM Facilities merous new materials, blends and alloys are
Using additive manufacturing techniques, such complex parts also means that different Recent developments (especially in metal AM) developed each year, stretching the possibili-
virtually any shape can be made from a wide parts can be combined and produced as one show a trend towards further automation of the ties of additive manufacturing to new levels.
range of materials. But does this mean it can piece. This reduces or even eliminates the fabrication process, reducing the amount of
 SLS
?
FDM
DLP

idea digital select produce / print post product 13

3D model production process ready
method

The Process of 3D Printing Steps Preparing Printing

3D printing is a process of creating products 1. 3D printing begins with an idea. The user The process starts with the digital 3D file. This There is a variety of printing methods, but one
based on a digital 3D-file. In this process has an idea for a specific three-dimen- file is created in a CAD (computer aided de- thing they all have in common is: the printing is
the product is built up layer by layer. This sional object. The required specifications sign) program or by scanning a product. The done layer by layer. When one layer is printed,
allows you to print almost every product you of the model (such as stiffness, transpar- 3D CAD file is commonly saved as an STL the next one will be laid on top. This process
can design on your computer. It even allows ency, heat resistance, colour, etc.) are file*, which every 3D printer can read. will be repeated until the complete model is
printing a product assembly with moving parts defined. created.
at once: a ball inside a larger ball or a network 2. The next step is to digitize this idea. It The printer’s software will now slice the STL
of organic shapes. has to be converted into a digital 3D file into tiny layers which will be printed one by Post Processing
model, most commonly an STL-file has to one. The height of these layers determine the If any support material is used, it needs to be
There are different types of printers and there be generated. Digitizing can be achieved accuracy of the printed model. If required, the removed after printing. How this is done varies
is a great variety of materials that can be in different ways: the model is created slicing software will add support material for per print method, but it can often be broken
used, each of them having its pros and cons. using 3D-modelling software or the model overhang elements. away or dissolved .
Plastics are most often used, but printing with is scanned using special 3D-scanning
devices. * STL is the most common file format for 3D Most of the time the model will be post pro-
other materials, such as ceramics and metal,
printing, but other file types, such as OBJ, 3MF,
is becoming more and more popular. 3. After the digital model has been created, VRML, could also be used depending on the cessed using sanding and painting for better
the user chooses the required 3D-printing 3D printer software. optical performance. It can also be post
The overall process from idea to final product process (see “3D Printing Methods”). * pro- cessed to enhance strength or to make it
is very much like other industrial production 4. The three-dimensional product is created. airtight.
methods. 5. Subsequently the model is post-pro-
cessed. The amount of post processing required to
6. Now the user can enjoy a real life 3D- achieve end-user product quality is one of
representation of his/her idea! the bottlenecks for upscaling 3D printing for
production quantities.
* The digital model will often have to be updat-
ed to suit the requirements for the selected
production/print method.
 15
Characteristics of 3D Printing
To make the best use of additive manufactur- of designs that normally cannot be produced Accuracy Cost Breakdown
ing, there are some fundamental characteris- as a single component. It also enables Perpendicular to the layers, accuracy is limited Production time and costs are coupled to how
tics to take into consideration. optimization facilitating the use of material to the thickness of a single layer. The layered much material is printed. This means model
only where it is required (topology optimized structure may be visible and, thus, affect size and wall thickness make a significant con-
Adaptivity structures). aesthetics. These aspects may be improved tribution to overall costs. Post-processing is
3D printers do not require moulds or additional by post-processing the model. often also expensive, so avoiding it can save
tools to create a geometry. This makes it rela- Support Material a lot of money. The cost of product design
tively easy and cheap to produce small series During production, some elements of a Material Properties and data preparation becomes increasingly
or even ‘one-off’ products and it results in a product may create an overhang or floating The strength between layers (Z-direction) is important in the overall costs as production
short lead time for production. structure that cannot support its own weight usually lower than the strength of the material quantities of a model decrease.
until the model has been fully printed. This within a layer (X & Y directions). This must be
Design Freedom problem is solved by either making a design kept in mind when the part is subject to loads
Building layer-by-layer makes it easier to pro- that fully supports itself or adding a support and stresses.
duce complex shapes and enables production structure that is removed afterwards.

source: bender am / eos

 17

Areas of Application
Applications of 3D printing are very diverse
and constantly expanding. In a design pro-
cess, printed models can be used to test and
discuss product functions with a client. It can
also be used to personalize products or to pro-
duce small production batches, not requiring
any expensive production tooling like moulds.

Some areas where 3D printing is used are:

consumer products, industrial applications,
small series production, jewellery, medical,
fashion, automotive, architecture, dentistry,
aerospace and education.

source: bender am / eos

source: enablingthefuture.org
 3D PRINTING
PROCESS

APPLICTAION MEDIUM

METHOD

BASE MATERIAL
SLA

19
DLP 3D Printing Methods
The world of 3D printing is rapidly growing used for thermoset materials.
UV light Liquid
(resin) and so is the diversity of printers. Prices are + Wide variety of material properties may be
CLIP dropping, making higher quality printers more achieved.
affordable for SMEs or even consumers. At the - Safety and health precautions must be taken
moment, plastics are the most popular mate- to process reactive materials.
Chemical

POLY rial for 3D printing. For the high-end industrial

JET
applications metal printers are being used Thermal
more and more often. The costs for metal The material is heated up into a pliable molten
printing are still quite high, but in a couple of mass, shaped and cooled down. This method
LOM
years we expect them to be a serious option is only used for thermoplastics.
Sheet for a larger part of the manufacturing industry. + Uses thermoplastics, which are widely used

Binder SDL and its properties well known.

In this booklet we will focus on the 3D printing - Not all thermoplastics have suitable proper-
methods most used by SMEs, which are all in ties for 3D printing.
INK the area of plastics.
JET
Application medium
Overview of 3D printing methods UV-light
There is a wide variety of 3D printing methods, A polymerization process is initiated by expo-
Laser SLS Powder bed but they all use some fundamental principles. sure to UV-light. This method is used only with
Below is a brief description of these principles resins.
Thermal

and their general advantages and drawbacks. + High detail is possible.

Thermal SHS - Material properties are highly dependent on
printhead
Process type the curing process.
Chemical
Extrusion FDM Wire The material converts into a plastic or bonds Binder
(filament)
material together with a chemical reaction. A base material is bonded together.
This method is mostly – but not exclusively – + Some materials may be printed that cannot
 21

be processed otherwise (such as plaster or + Many machines are available, from hobby to layer is cut out. material on the product.
paper). production grade. + The method is suitable for specialty pur- - Powder stays behind in areas of a product
- Mechanical properties are usually inferior. + Widespread use has made the technology poses, such as film hinges (of a single layer that are hard to reach with sandblasting, pres-
accessible and affordable. thickness) and full-colour models (paper). surized air, brushes and other tools.
Laser - Strength in the Z-direction (between layers) - An entire sheet of material is used regardless
A deposited layer of thermoplastic powder is is low. of the cross-section of the printed product. Wire (Filament)
melted by the addition of heat by a laser. The - Layers are very visible. Thermoplastic wire is wound on a roll. This is
material is usually pre-heated for favourable Powder bed the common form of material used for printing
processing conditions. Base material A layer of powder is deposited each time and with extrusion.
+ High detail is possible. Liquid (Resin) a portion of that layer is bonded or melted + Handling and storage of the material is
+ Strength in the Z-direction (between layers) Base materials that undergo curing by UV-light together to form the cross-section of the prod- generally easy.
is favourable. are in liquid form before processing. uct. The unprinted powder serves as support - The rolls must be prevented from unwinding
- Machines are relatively complex and expen- + Layers (Z-direction) are less visible. material. themselves (which can cause problems in
sive. - The material degrades by prolonged expo- + There are, almost, no limitations to the processing).
sure to UV-light, limiting service life. shapes that can be printed.
Extrusion + A support structure does not need to be
Material (thermoplastic) is extruded through a Sheet printed, because unused powder functions
heated nozzle into the desired shape. The base material is a sheet, from which a as support. There are no marks of support
 Print Method: SLA
Principle: UV-sensitive resin, UV-laser
Materials: Wide variation of UV-sensitive resins comparable to
ABS, PP, PE, PC and more.
Support material: Yes
Minimal layer thickness: 0.025 mm
Advantages: Good surface quality, accurate
Disadvantages: Not UV-stable

SLA 23
Stereolithography
SLA (Stereo Lithography Apparatus) is a printing Advantages Available materials can be comparable to
technique based on photopolymers. These liquid • Very accurate, allowing models with a real plastics (ABS, PP), flexible, transpar-
UV-sensitive resins, which contain the building high level of detail in the design. ent, high-temperature resistant, etc.
blocks of the final material, are solidified with the • Good surface-finish reduces the necessi-
Disadvantages
LIQUID

aid of a UV-laser. The printer consists of a bath ty for post-processing.

containing a UV-sensitive resin, a photo-polymer, • Can easily be painted. • Materials are not UV-stable. Can discol-
which is cured by the laser beam. The laser beam, • Limited waste material, only the used our and become brittle over time.
controlled by means of a movable mirror, follows supports are wasted. • Removing support can be quite some
work.
UV-LIGHT -

the contour of the model which is then cured • Variety of resins available and many more
forming a complete layer. Then, the table moves are being currently developed
down one layer in thickness, so that a thin layer of
resin comes to lie on top of the model. The next
layer of the model is then cured and this process is
repeated until the complete model has been built.
CHEMICAL -

Some printers work the other way around: the

model moves up and is lifted out of the resin
layer by layer. In this case, the laser is positioned
underneath the resin.

When printing with SLA, thin pillars have to

be constructed that serve as support for the
over-hanging portions. These pillars are easily
removed from the printed object, but will leave
marks.

Post-curing is required to obtain optimal mechani-

cal properties.
CASE 25
Mobile Lighting
Background accurate model was created. Polishing
Spanninga Metaal BV is a well-known was required to make these lenses com-
name in the area of bicycle lights and pletely smooth.
accessories. The R&D department is
constantly developing new lighting con- Result
cepts. A sound user experience is crucial This case required the use of two different
for these products. To test these lighting printing techniques and resulted in a
concepts in a realistic setting, all functions completely functional prototype with
need to be incorporated into a prototype. properties comparable to a final produced
version. With the electrical components
Important requirements: 1. Material embedded in the prototype, a realistic and
properties in line with production version; fully functioning model was created. The
2. Functional prototype (e.g. snap joints implementation of the functional lenses
and lenses). resulted in a product that can be used
not only as a visual model, but also as a
Research functional model for testing.
Most of Spanninga’s products are made
Company: Spanninga
from injection moulded nylon. For the
components that will be exposed to me- * Due to confidentiality, the actual product
could not be shown here. The image
chanical loads, nylon products are printed
shown provides an indication.
using an SLS printer. The mechanical
properties of these prints are quite close
to the injection moulded parts.

For the optical parts of the model, trans-

parent material is required. Using an SLA
printer and fully transparent material an
 Print Method: DLP
Principle: UV-sensitive resin, beamer
Materials: Wide variation of UV-sensitive resins comparable to
ABS, PP, PE, PC and more.
Support material: Yes
Minimal layer thickness: 0.0125 mm
Advantages: High resolution, fast
Disadvantages: Smells, difference in preciseness, expensive resin

DLP 27
Digital Light Processing
Digital Light Processing (DLP) is a technique Advantages Disadvantages
using a light sensitive resin and a beamer to • DLP works fast, because a complete • The centre of the model is more exact
cure the resin. There are two common imple- layer of the model can be printed at once. than the edges, because of the scattered
mentations of this method: Bottom-Top and The size of the layers don’t influence to light from the beamer.
LIQUID

Top-Down. The technique is similar to SLA, the processing speed, because the whole • Materials are not UV-stable. Can discol-
but uses a different light source. layer is being lit at once. our and become brittle over time.
• DLP has a high resolution, layer thick- • Removing support can be quite some
Bottom-Top uses a light sensitive resin and nesses vary in eight steps from 0.0125 to work.
UV-LIGHT -

a beamer. The bed on which the model is 0.1mm.

created is immersed in a bath of resin. A
UV-beamer lights the resin from underneath
through a translucent bottom, curing the resin.
When a layer has cured, the bed holding the
model moves upwards by one layer of thick-
ness. The surrounding resin, in which the bed
CHEMICAL -

is immersed, flows underneath the model and

is then lit, curing the new layer. This process
repeats itself until the model is finished.
Top-Down is a method very similar to the one
described above. Although here the model is
not pulled out of the resin moving upwards,
but is pulled down lowering the object into
the resin and placing it back at exactly one
layer in thickness underneath the surface and
subsequently being cured by a UV-source
from above. Post-curing is required to obtain
optimal mechanical properties.
CASE 29
Impression Tray
Background Results
In dentistry, individual impression trays are The 3D printed impression tray is made
used to create accurate impressions of from a suitable non-toxic material and
the patient’s teeth. An accurate impres- is accurate enough for its purpose. The
sion is required for a good fitting, but the design software (for modelling in 3D) is a
process of creating individual impression hurdle for commercial success, and
trays takes about 30 minutes. Using 3D would have to be developed further. Suit-
modelling and printing drastically reduces able 3D printers are still quite expensive.
processing time as well as the amount of For this reason Level by Level is now
waste. developing a more affordable printer.

3D printing could offer a solution if the fol-

lowing requirements can be met: 1. High Company: Level by Level

accuracy; 2. Retain shape; 3. Suitable for

in-mouth application (non-toxic).

Research
Several impression trays have been
printed using a DLP printer and suitable
non-toxic materials. The models have
been tested for accuracy. Clinical trials
have not yet taken place.
 Print Method: CLIP
Principle: UV-sensitive resin, LED, continuous vertical movement
Materials: UV-sensitive resins
Support material: Yes
Minimal layer thickness: None
Advantages: High quality, material properties comparable to Injec-
tion Moulded product
Disadvantages: No hard evidence of quality as yet

CLIP 31
Continuous Liquid Interface Production
CLIP is a 3D printing method that is based on Disadvantages
the DLP technology. A light-sensitive resin is • Very new method, only a few printers
cured using LED lights. The model is hanging available at this moment.
on the platform and lifted up in a continuous • No hard evidence of the claimed quality
LIQUID

movement. has been produced.

• Post-curing could be a bottleneck for
CLIP does not cure layer by layer, but instead productivity.
pulls up the component with a constant speed
UV-LIGHT -

whilst continuously curing the cross-section

of the object. An oxygen permeable window
prevents the resin from curing and sticking to
the window. The absence of a layered struc-
ture is reported to give the Z-direction strength
comparable to the other directions, similar to
moulded components.
CHEMICAL -

Advantages
• Layerless printing results in a better
structural integrity and the material
properties are claimed to be the same in
each direction.
• Very quick method, making it more suita-
ble for production.
• High surface quality .
 Print Method: Polyjet
Principle: UV-sensitive resin, UV-light
Materials: UV-sensitive resins with properties similar to ABS, PP
and rubber
Support material: Yes
Minimal layer thickness: 0.016 mm
Advantages: Multi-material, no post-processing
Disadvantages: Poor heat resistance

POLYJET 33
Polyjet
Polyjet is a printing technique using a Advantages Disadvantages
UV-sensitive resin and a UV-light. The print- • High resolution. • The materials used are not very heat
head consists of several small nozzles and • Full colour printing. resistant. The “heat deflection temper-
is also equipped with a roller and a UV light. • Multi-Material: Polyjet is a unique tech- ature”, the temperature at which the
LIQUID

The nozzles spray small droplets of resin onto nology that can jet multiple materials in a material can be deformed, is at 55ºC for
the printing bed according to the contours of single print run. This means that you can most materials.
the model. The droplets are spherical at first selectively position multiple materials and • Expensive resins.
and are rolled flat using the roller, then they colours in one print. • Expensive machines.
UV-LIGHT -

are cured using the UV-light. When a layer • Minimal post-processing: very high
has been printed the bed moves down by one resolution, full colour and multi-material
layer, so a next layer can be printed. advantages also result in a minimal of
post-processing.
This process repeats until the complete model
has been built. This technique allows for
printing with multiple materials. It allows for full
CHEMICAL -

colour printing and adjusting material stiffness.

This feature is often used for models with hard
and soft features, like a toothbrush having a
hard base and soft grips. The support material
for this technique is a gel that can be easily
washed off after the model has been printed.
 Print Method: LOM
Principle: Foil, knife or laser
Materials: PVC-foil, paper
Support material: No
Minimal layer thickness: 0.1 mm (80gr paper), 0.165 mm (PVC)
Advantages: Flexible materials, film hinge possible
Disadvantages: A lot of waste material, removing this is a lot of work.

LOM 35
Laminated Object Manufacturing
LOM (Laminated Object Manufacturing) is a
3D print method that uses a knife or laser to
cut layers of adhesive coated foil. An anti-stick
layer is applied on areas that are not part
SHEET

of the printed object. These areas can be

removed afterwards.

Advantages
-

• A major advantage of LOM is that it uses

flexible materials such as paper and PVC,
BINDER

while other 3D printing methods mostly

use hard and brittle materials. This allows
for working film hinges.
• No support structure printed: the product
is supported by the foil.
-
CHEMICAL

Disadvantages
• The full width of the foil is always used.
This results in a lot of waste material.
• Removing surplus material on the inside
can be a lot of work, if not impossible.
 Print Method: SDL
Principle: Printed paper, cutting knife
Materials: Paper
Support material: Yes
Minimal layer thickness: 0.1-0.19 mm
Advantages: Full colour, low material cost, stable
Disadvantages: Breaking away excess material is a tricky job

SDL 37
Selective Deposition Lamination
Selective Deposition Lamination is a printing Disadvantages
technique related to LOM, by which sheets of • Breaking away the support/waste material
full colour printed paper are layered to create a can be a tricky job.
3D model. These sheets are bonded together • Edges cannot be bonded by the printer.
SHEET

by applying tiny drops of glue only where This causes delamination if the model is
necessary. not coated.
• Not moisture resistant (unless is it
Every layer of the model has a full colour print coated).
-

around the edges of the model and is cut at • Thin, long and/or sharp details may
the contours. Areas that function as support for not stay intact when removing support
BINDER

the model, are cut and bonded in small blocks material.

to aid removal after printing

Advantages
• Full colour models: Each layer of the
-

model can be printed in high resolution

CHEMICAL

resulting in precisely coloured objects.

• Very suitable for printing realistic textures.
• Strong and stiff objects can be created,
especially after coating is applied.
• Post-processing: The material can easily
be coated with traditional paper coatings
(high gloss, water resistant, hardness,
etc.).
CASE 39
Luxury Perfume Sample
Background perfume. The selected SDL printer uses
A well-known British luxury fashion house paper for 3D printing combined with
- that designs and sells a wide range of water-based glue that does not add any
products like clothing, bags, wallets, belts, odour when printing, which is exactly what
umbrella’s, sunglasses, watches, jewellery is currently being used, making it the most
and perfume - was looking for a unique logical first test.
and more luxurious perfume sample. Cur-
rent perfume testers are sprayed onto a Results
strip of paper which absorbs the perfume Myeasy3D created a 3D model of their
quite well, but the customer experience of latest perfume bottle, printed miniature
this piece of paper is not in line with their versions using the 3D SDL printer and
vision and brand identity. For the introduc- tested them. The 3D printed perfume bot-
tion of their latest perfume they would like tle is used as-is and absorbs the perfume
to have a miniature perfume bottle that is very well. A substantial amount of these
identical to the new perfume bottle as a bottles were printed.
sample giveaway.

Company: MyEasy3D
Research
In this case there are three important crite-
ria: 1. Price per sample should not be too
high; 2. The 3D printed material must ab-
sorb the perfume; 3. The 3D print process
and material must not add any odours that
could mix with the perfume.

Most 3D printing methods use plastics as

3D print material which does not absorb
®

myeasy3d
3D Print Concepts & Services
CASE 41
Shop Display Fruit
Background Results
A new product was sought for displaying The matted surface and textures on the
artificial fruit in the display window of a outside and inside of the fruit made it
patisserie. Current artificial fruit is too fake look quite realistic. In addition, a standard
and shiny, and the choice is limited. Real well-tested UV coating for the paper 3D
fruit is also not an option, as it would have printed fruit was used to protect colours
to be replaced too often. from fading.

The requirements for the 3D print for this Other 3D printing methods would have
case are: 1. Realistic 3D prints in full required at least a decent paint job by
colour; 2. Affordable and durable prints; 3. hand, to create realistic looking fruit, while
UV protection. the selected SDL 3D printer enables the
fruit to be directly painted with vivid and
Research realistic colours at an affordable price.
To create realistic 3D models of the fruit,
real fruit was scanned using a 3D scanner.
Using an SDL printer, an affordable
full-colour 3D model could be printed out Company: MyEasy3D
of paper. A UV protective coating was
applied to prevent discolouring by expo-
sure to sunlight. UV coating can be easily
applied to 3D paper printed products and
it also protects the object from humid envi-
ronments. Full colour 3D printed products
from materials such as sandstone will fade
in colour over time, are easily stained by
water drops and are quite fragile.
®

myeasy3d
3D Print Concepts & Services
CASE 43
Chocolates From 3D Scanned Faces
Background Results
There is a growing demand for personal- Turnaround time for the process from
ized food gifts, and a birthday cake with scanning to the final chocolate product
your name on it may no longer suffice. To takes less than 48 hours. The chocolate
offer a completely unique food experience product is a very unique and personal
this patisserie wanted to create chocolate gift already created for a diversity of
in the shape of people’s faces and full clients.
body figurines.

The requirement for such a product and Company: MyEasy3D

system are: 1. Mobile scanning solution

to enable to scan faces and/or a complete
body (figurine); 2. A low cost 3D print
suitable for creating the mould.

Research
An iPad equipped with a 3D scanner
driven by specifically developed software
for this purpose was used as a mobile
solution for scanning people. Then a full
3D or 2 ½ D print was made using an
SDL printer. The printed object was then
used to create a mould suitable for casting
chocolate.

myeasy3d
3D Print Concepts & Services
 Print Method: Inkjet
Principle: Gypsum, binder
Materials: Gypsum
Support material: No
Minimal layer thickness: 0.089 mm
Advantages: Multi-coloured models, heat resistance
Disadvantages: Brittle, low surface quality

INKJET 45
Inkjet
Inkjet printing is a technique using plaster and Advantages Disadvantages
a binder. This technique has similarities to con- • Full colour: The biggest advantage to this • The biggest disadvantage of this
ventional Inkjet printers. Alongside the tricolour technique is that it can produce full colour technique is that the models are brittle,
cartridges allowing models to be fully coloured, models. especially without any post-processing,
CHEMICAL - BINDER - POWDER BED

a cartridge with a binder is used to stick the • No support: Inkjet does not need any making post-processing necessary. Often
coloured gypsum together. The print-head with printed support, the unused gypsum the model is impregnated with epoxy,
the binder moves over the right-hand container serves as a support. glue or wax, making the model stronger,
to print the binder in accordance with the con- • The excess material is easily removed but it will always remain brittle.
tours of the model. When the digital 3D-model using a spatula, brush or compressed air. • Removing excess gypsum can be labour
is textured with one or several colours, this • Heat resistant. intensive with more complex shapes,
colour is added to the outer layer of the model. because places can be difficult to reach
When a layer has been completely printed, and the model is brittle.
new gypsum from the left-hand tray is moved
over to the right-hand bin. This process is
repeated until the complete model is built. On
completion, the model should be at least one
hour in the printer in order to cure the binder.
Subsequently, the excess plaster can be re-
moved with a spatula, brush or by compressed
air. Finally the model needs to be reinforced by
impregnating it with epoxy, glue or wax.

Techniques similar to Inkjet are SLS and SHS,

but whereas they use a thermal process, Inkjet
uses a binder.
CASE 47
Heat Resistant Component
Background The two most important questions were:
Kumagaya has developed a new rotation 1. Is the FDM model heat resistant
moulding process that only heats the enough for this application?
mould instead of using an oven. The 2. Is the Inkjet model strong enough for
machine required a new type of electronic this application? (Inkjet models can be
contact to be designed (carbon brushes). quite brittle)
To increase working speed and reduce
costs, the possibilities of 3D printing the Results
casing for these carbon brushes was The FDM models are very usable, but
researched. only if the product is not placed directly
onto the mould: it needs to be placed at
The requirements for this case are: an offset for heat isolation. This is a good
1. Heat resistance; 2. Strength. solution. The inkjet model could be placed
closer onto the mould, but appeared to be
Research too fragile for this application and could,
When the design of the casing was therefore, not be used.
finished it was first tested using an FDM
printer and PETG filament. To improve
Company: Kumagaya Kunststoffen
manufacturability of this product, the
design was split up into several smaller
parts.

In addition to the FDM model, a more

heat resistant model was printed using an
Inkjet printer.
 Print Method: SLS
Principle: Thermoplastic powder, preheating, laser.
Materials: Many, e.g. (glass-filled) PA, PS, Glass, PS, PP, PEEK, TPU
Support material: No
Minimal layer thickness: 0.06- 0.10 mm
Advantages: Good mechanical properties, many parts in one print-
job, suitable for final products
Disadvantages: Post-processing may be desirable

SLS 49
Selective Laser Sintering
SLS is a printing technique that works using a ther- • The creation of realistic prototypes or Disadvantages
moplastic powder as its base material. The powder a small series of complex products is • The material becomes soft and can
is fused together by a laser spot, which is posi- possible. swell on coming into contact with water
tioned using a moveable mirror. In order to prevent • The material is strong and fairly flexible (impregnating will solve this issue).
THERMAL - LASER - POWDER BED

oxidation and shrinkage, the process takes place (when printed in thin walls). • The surface of SLS models is fairly
in a closed chamber heated to +/- 170ºC filled • Mechanical properties are so good that precise, but grained and post-processing
with an inert gas. When a complete layer of the it is possible to produce working snap may be desirable.
model is melted together, a new layer of powder is hooks and even spring systems, making • Sanding the material is a hard job, so
added. The right-hand bin moves down while the this technique outstanding for creating tumbling is often used instead.
left-hand bin moves up, so that from the left-hand mechanical prototypes. • Material waste.
side a small layer of powder is being rolled over • Design freedom, thanks to the method of • Expensive machine.
to the right. A new layer can now be sintered. This support during printing.
process is repeated until the complete model is • The models can easily be painted.
built. This technique does not require the printing • Print many parts in one print-job.
of support material. The powder that has not been
melted together acts as the supporting material,
which also means objects can be stacked on
top of and inside each other. Although unused
powder can partially be re-used in other models,
a significant amount of powder will still be waste.
The finishing of the model consists of the removal
of the loose powder using glass bead blasting.

Advantages
• It is possible to reach densities that are sim-
ilar to densities of conventional techniques,
meaning that the model can obtain good
mechanical properties.
CASE 51
Modular Proof of Concept
Background New tests were conducted using an SLS
Vuurs is a start-up company founded with model for its accuracy and ability to print
the plan of creating a new generation multiple parts at once, therefore reducing
of wood-burning stoves. The technical printing time and costs.
principles were tested and proven, so it
was time to design and develop a product. Results
A modular design was made using CAD A highly detailed model was printed clearly
software. In order to check whether the demonstrating the modular capabilities
product would assembled as on the pc, a of the product. The model gave a clear
physical scale model was made and test- insight into fittings, product assembly and
ed. As an added benefit the model could stability.
also be used as a demonstrator during
pitches for potential investors. The model has been, and is still being
used for product pitches and demon-
For this case the most important require- stra- tions. All the insights gained from
ments are: 1. Accuracy; 2. Finishing; 3. the 3D-printed model were used in the
Low cost creation of the first prototype, which is
currently fully operational.
Research
The first test samples were created with
Company: Vuurs / Tjelp
FDM printers. Several models were
created using different printers and thread
thicknesses. Unfortunately, the accuracy
was insufficient (design details got lost)
and some slight sagging appeared.
CASE 53
Machine Part
Background Results
Moba is a manufacturer of egg grading, A product has been 3D-printed using an
packing and processing machines. For SLS printer and the material PA2200. It
many old machine parts, the mould is has been successfully tested in the ma-
no longer available or is worn out. Spare chine and the costs have been compared
parts for these machines will still need to Injection Moulding: over a period of
to be produced on demand and in small three years the 3D-printed product would
numbers. To still be able to provide spare be 44% less expensive.
parts for these machines, the possibili-
ties of 3D printing these parts has been
researched. Company: MOBA

For this case the most important require-

ments are: 1. Strength; 2. Chemical
resistance; 3. Hygiene.

Research
Based on the product’s technical specifi-
cations, several 3D-printing technologies
and materials have been researched and
a cost calculation has been made to com-
pare the costs for 3D printing and Injection
Moulding. A selection model developed by
MOBA and the Professorship for Polymer
Engineering at Windesheim has been
used for this. The product has been rede-
signed based on the requirements and the
3D printing design guidelines.
 Print Method: SHS
Principle: Thermoplastic Powder/ Thermal print-head
Materials: Thermoplastic Powder (PA12)
Support material: No
Minimal layer thickness: 0.10 mm
Advantages: No support needed, more than one products in one
container
Disadvantages: Rough surface finish, no variation in materials

SHS 55
Selective Heat Sintering
SHS is a technique that works on a very Disadvantages
THERMAL - THERMAL PRINTHEAD - POWDER BED

similar principle as SLS, but uses a thermal • Rough surface finish. This is because
print-head instead of a laser to melt the around the sintered edges unsintered
thermo-plastic powder. powder sticks to the model.
• More brittle than - and not as strong as -
The machine has two containers of powder on prints from an SLS printer.
each side of the build chamber. A thin layer of • Post-processing like sanding and
powder is applied on top of the bed, while an varnishing the models may be required.
infra-red light moves over it to melt the powder • No variation in materials available.
where needed.

Advantages
• SHS offers the possibility to print several
different products at the same time.
• No need for additional support materials,
as models are supported by the powder
in the build chamber.
• Products are fairly flexible. Excess pow-
der is reusable.
• SHS was developed as a low-investment
alternative for SLS printed PA12.
• No waste material: in contrast to SLS, the
unfused powder has better re-usability
thanks to processing at lower tempera-
tures.
• Design freedom, thanks to the method of
support during printing.
CASE 57
Muscle Sensor
Background
Arexx designs and manufactures a wide
range of technical products. During the
design process of a new product – a
wearable muscle sensor – they want to
be able to regularly check the design for
compatibility with the electronic compo-
nents. The 3D-printed models should be
as close as possible to the product that
will be produced.

For this case the most important require-

ments are: 1. Allow for thin walls (1mm); 2.
Accurate and high quality; 3. Affordable.

Research
First tests with an FDM printer proved
that this technique is not a viable option Results
to produce this prototype. Lots of support A variation of designs was printed and
material was required and due to the small evaluated. The latest (SHS) models were
wall thickness, the FDM technique was used to make the final design decisions.
unable to build a sufficiently strong part. At this point a final design will be made
An SHS printer was selected because it is and printed again, as a final check before
relatively affordable, accurate, allows for starting production.
a wall-thickness of 1mm and no support
material is required. These models were
used to determine the design details for Company: Arexx
the electronics.
 Print Method: FDM
Principle: Filament, nozzle
Materials: Many: e.g. ABS, PLA, PC, ABS-PC, Heat-conductive, etc.
Support material: Yes
Minimal layer thickness: 0.1 mm (depends on printer design)
Advantages: Cheap, real plastics, soluble support material possible,
easy to post process, easy to use.
Disadvantages: Surface quality, layer strength.

FDM 59
Fused Deposition Modelling
FDM, also known as FFF (fused filament fabri- Disadvantages Filaments
cation), is a 3D print method that uses a plastic • Without post-processing/finishing, the There are many types of filaments and many
thread – a filament – to build the 3D model layer FDM model has a low surface quality. more will be available in the near future. Each
by layer. The filament melts when passing through • The layers are clearly visible. filament has its unique material properties. Fil-
WIRE

a heated nozzle, which moves in the horizontal • The model is porous. aments can, for example, be heat-conductive,
plane to build each layer of the model. When one • Filament is available in many different fibre reinforced, flexible, fluorescent or contain
layer is completed, the model moves down (or the colours, but with just one nozzle it is wood, cork, bamboo or many types of metal.
nozzle moves up, depending on the printer design) commonly not possible to print multiple
-

one layer of thickness and the next layer is printed colours at once (this is possible with
EXTRUSION

on top. This process is repeated until the model is multiple nozzles).

finished.

Advantages
• The most affordable 3D printing method.
• Wide range of materials and suppliers
-

available. Varying from very cheap to more

THERMAL

expensive engineering materials.

• Uses ‘real’ plastics. Allows for production of
final products.
• When the FDM printer has two nozzles, it is
possible to use a soluble support material.
• FDM models can easily be post-processed by
sanding and spray painting. Other post-pro-
cessing methods can, for example, make the
model watertight and airtight with a high-gloss
finish (using a solvent).
CASE 61
Heat-Conductive Filament
Background
FDM printing is an outstanding technique A 3D model with regular filament has been
to create complex geometries, such as printed to test the product design.
one would need to create heat sinks.
However, most plastics that are now used Results
in FDM printing do not have good thermal The design and computer simulations
conductivity. This, of course, limits FDM in show the added value of 3D printing with
its use for functional prototyping in certain conductive materials. The next steps will
applications in which heat is generated, be printing the model with actual con-
such as in clusters of cameras for shoot- ductive material, conducting
ing 360 degree film footage. measurements and
using these results
The challenge of Bond BV and Green- to perform
PAC/Windesheim was to consider what more realistic
an improved camera cluster design would simulations.
look like and how it would behave in the
event that thermal conductive material is
Company: Bond B.V.
available.

Research
CAD designs of an individual camera
bracket are made and supported by
computer simulations of the thermo-
dynamic behaviour. Bond BV is contin-
uously improving its technology to use
conductive materials as well as other
advanced materials for FDM.
 Print Methods: DMLS, SLM, EBM, LMDW
Principles: Melting metal powder, welding
Materials: Many alloys have been or are being developed for this.
Some examples are: stainless steels, aluminium, titani-
um, nickel, cobal and copper-based alloys
Support material: Yes
Minimal layer thickness: 0.03 - 0.12 mm (varying per method and material)
Advantages: Strength, temperature resistance, conductive, durability
Disadvantages: Expensive, post-processing, surface quality

METAL 63
Metal Printers
There are several technologies for printing
metal products. Although the materials and
printers are still quite costly, additive man-
ufacturing using metal already brings clear
advantages:

1. Weight reduction thanks to the design

freedom 3D printing offers.
2. Creating complex products out of one
part.

If you can reduce the weight of an armrest for

all chairs in a plane, you can reduce the fuel
costs. Even if the armrest itself is more expen-
sive, you can still have a return on investment
based on the reduced fuel costs.
Creating one complex product instead of ten
parts that need to be assembled can also
result in a considerable cost reduction and a
higher level of efficiency.

Popular methods for 3D printing metal are:

• DMLS: Direct Laser Melting
• SLM: Selective Laser Melting
• EBM: Electron Beam Melting
• LMDW: Laser Metal Deposition Welding

images of 3d prints by eos

 65
Which Print Method to Use?
Ownership versus Outsourcing Selecting a 3D Print Method
If you want to 3D print a model you have two There are many different 3D printing methods
options: you can do it yourself or you can let and even more materials that can be used with
your model be printed elsewhere. Each option it. If you are not an expert on this matter, how
has its own benefits and disadvantages to do you know which method is most suitable for
consider. your situation?

3D printing yourself may be cheaper if you In our previous booklet on 3D printing a goal-
print regularly. It leaves you in control of when based selection model was created. For more
and with what quality a product is printed. information on this selection model, follow the
It also, however, requires investment in link on the left page (top image). Based on that
machinery, maintenance and, in many cases, model and new information we have created
knowledge about the production process. a new overview that can be used to select a
method. This overview focusses on contextual
Outsourcing 3D printing to companies (e.g. and functional requirements (see next page).
Shapeways, Materialise and 3D Hubs) is inter- Please note that this overview guides you
esting if you want freedom of choice for every in the right direction, but it does not tell you
print or only occasionally need 3D printed which method and material to use. There are
parts. These companies may also offer con- simply too many variables to take into account
sultancy for the most suitable printing methods and, in many cases, there are multiple options
and offer post-processing of your print. The to choose from.
downside is the dependence on delivery times
and higher costs per product. You can use this model in two directions:
1. Start from your requirements and see
which methods are suitable;
2. Start from the 3D print method and exam-
ine the advantages (and disadvantages).
 3D Print Methods and their Qualities 67

CONTEXTUAL FUNCTIONAL
NO SUPPORT FAST CHEAP STRONG TRANSPARENT HEAT RES. FLEXIBLE MULTI-MATERIAL FILM HINGE SURFACE Q. FULL COLOUR ACCURACY

FDM SHS SLS INK LOM SDL POLY DLP CLIP SLA
JET JET
eos shared modules

69
Future Advancement in AM
So far this publication has emphasized the cur-
rent possibilities, technologies and applications
of Additive Manufacturing of polymers. The AM
industry is expanding rapidly and the following
advancements are expected in the future.

More Functionality
AM offers design and production capabilities
that other methods cannot offer. In 2016, HP
introduced Multi Jet Fusion technology, combining
printing of thermoplastics in full colour with me-
chanical properties approximating those of SLS
printed parts. Another recent development is the
introduction of machines that combine subtractive
and additive manufacturing in one process. This
enables precision of subtractive manufacturing
in areas in which post-processing cannot take
place traditionally. Such advancements increase
the functionality of AM, and it is expected that the
advantages of AM over traditional manufacturing
methods will continue to increase.

source: bender am / eos

 71

Higher Productivity Increased Convenience

The unique capabilities of AM have created a In addition to productivity and functionality,
demand to make AM viable on a large scale. there is a growing demand to make AM
AM processes are becoming increasingly convenient. Software and machine interfaces
consistent, productive and automated. An are becoming more intuitive and user-friendly.
example is the ‘Figure 4’ technology recently Production by AM is also becoming more
introduced by 3DSystems, by which a printing streamlined and embedded with design source: up3d.com
method similar to CLIP is used in conjunction software. Such developments lower the bar to
with automated build-tray removal, cleaning use AM within production facilities and design
and post-curing. AM has already replaced firms, but could also lower the bar to use
traditional manufacturing methods for some AM in environments such as healthcare and
products (e.g. for the aviation industry). Fur- education.
ther advancements in productivity will increase
the application of AM for the production of a
wider variation of products.

source: bender am / eos

 73
Cooperating Companies
Level by Level (LBL) responds to the developing Bond BV is a Dutch company in high performance
opportunities for 3D-printing on the medical market, 3D-printing, bringing advanced FDM printing technol-
focussing on dental applications. ogy and materials together to new industrial applica-
www.levelbylevel.nl tions.

Inspired by our values, Spanninga’s vision focuses on VUURS will renew fire. With the newest materials,
a strong link between technology and design to ensure technologies and an innovative design we will give fire
security of bicycle users. Our motivation being people, the strength to bring us further once again.
innovation and efficiency. www.vuurs.nl
www.spanninga.com

Myeasy3D fully embraces 3D printing. Making it AREXX Engineering and its Far East Partners design,
accessible and affordable by designing and develop- manufacture and distribute a wide range of electronic
ing turnkey solutions for the entire process. From the products for hobby, professional and educational use.
®

myeasy3d designer to the consumer. www.arexx.nl

3D Print Concepts & Services

www.myeasy3d.com

Kumagaya is an expert in rotation and vacuum The Moba Group is the world leading manufacturer of
moulding. Our expertise and in-house development of egg grading, packing and processing machines. Moba
new methods allow us to create specialized and very offers global solutions and is close to its customers at
accurate products. the same time.
www.kumagaya.nl www.moba.net
 75
Glossary
Additive Manufacturing (AM) leaves the printer, such as removing support, printable layers. All actual print settings can
A manufacturing process by which products sanding the product and painting it. be set here (layer thickness, print speed, infill
are created by adding material layer by layer. type, etc.).
It is often referred to as 3D printing. Post-curing
A curing-treatment conducted after 3D printing SME
Binder a photopolymer to enhance material strength Small and Medium Enterprises
A material that binds/glues powdery base and stability, often using a UV-chamber and an
material together. increased temperature. Thermoplastic
A plastic that becomes pliable above a certain
CAD Support termperature and solidifies when cooled.
Computer Aided Modelling. Used to create A structure that is printed to support
digital 3D models. overhanging elements in the 3D printed prod- Thermoset
uct. Has to be removed in post-processing. A plastic which is irreversibly solidified by
Filament curing.
Wire used as base material for 3D printing STL-file
using FDM/FFF. STL is the most common file format for 3D
printing.
Overhang
The part of the product that hangs free. Sintering
The process of heating material up to just be-
Photopolymer low the melting point. Contact points between
Liquid UV-sensitive resins which are solidified the powder will partly merge together, creating
with the aid of a UV-light. a solid product.

Post-processing Slicing Software

The work that has to be done after the 3D print Software used to ‘slice’ the 3D CAD file into