What is 3D Printing and How Does it Work?

What is 3D Printing and How Does it Work?

If you’ve been wondering, “What is 3D printing and how does it work?” then you’ve come to the right place. 3D printing is a manufacturing process whereby a 3D model is broken down into many layers. Slicing software is used to do this. Then, these sliced files can be fed to a 3D printer via USB, SD, or Wi-Fi. Once the model is ready, the printer prints layer by layer. While this technology was originally only used for prototyping, it’s now rapidly becoming a production technology.

3D printing is a point-of-care medical device

In addition to the creation of custom prostheses, 3D printing also opens up new options for clinicians. On-site 3D printing hubs allow for the creation of surgical models and anatomical models. These physical models are a helpful tool during surgical procedures and can be simulated before surgery. A virtual environment allows for surgeons to see exactly how a surgical procedure will look before they perform it.

During recent years, 3D-printed patient-specific anatomical models have gained considerable momentum. Recently, a deal between Formlabs and Vizient, the largest member-driven healthcare group-buying organization in the United States, was announced. The companies will collaborate to use CT/MRI images as patient-specific anatomical models for implant sizing and surgical planning. This new technology provides a rapid, nimble solution to a long-standing problem in healthcare.

It is an additive manufacturing process

In the world of additive manufacturing, parts are built by building up layers of material instead of subtracting them. Traditional manufacturing processes start with larger blocks of material, which are then machined to produce the parts. However, the process of subtracting material results in waste. This is where additive manufacturing comes in. It builds up layers of material to create the part. There are two primary types: FDM and SLA. This article will explore each of these types and how they can benefit the production of your products.

A 3D printer can print several kinds of materials. The first one is 3D-printed plastics. These plastics are able to withstand high temperatures, making them highly durable. They are also easy to clean, allowing them to be disposed of and reused. 3D printing is also known as ‘additive manufacturing’. This is not the same as 2D printing, but the basic principles are the same.

It is cheaper than traditional manufacturing

One of the most obvious benefits of 3D printing is its ability to cut costs. It is significantly less expensive than traditional manufacturing methods such as casting and molding, which require large capital investments. Additionally, the process is flexible, requiring smaller production runs than traditional manufacturing methods. And because of its rapid turnaround time, 3D printing is a much better option for small to medium-sized businesses. As a result, many companies are choosing to manufacture their own parts to cut costs and improve quality control.

In addition to reducing material costs, 3D printing also reduces waste. Traditional manufacturing processes involve high setup and make-ready costs, as well as long lead-times. These costs are also reflected in delayed revenue. Furthermore, the cost of tooling is amortized over high volumes of identical parts. Because of this, the upfront cost of conventional manufacturing methods is significantly less than the overall cost of each piece. This advantage means that the cost of 3D printing is much cheaper than the cost of third-world labour.

It is transforming into a production technology

Companies have been able to cut their production costs by using 3D printing as part of the manufacturing process. For example, Nissan was able to decrease the prototype manufacturing time from a week to one day and cut their production costs by about 20 percent by using 3D printing. With a shorter production time and reduced costs, 3D printing is the most effective method of production today, especially in a weak economy. By lowering the cost of an element, 3D printing can help companies increase their profit margins and boost their return on investment.

As the number of products being created with 3D printing grows, so do the possibilities for customizing products. Manufacturers can now perform low-volume production, test out different parts, and satisfy consumer needs by creating custom products. Because 3D printing is still a relatively new process, future technological advancements are likely to bring it to the mainstream of manufacturing. The benefits of 3D printing are numerous. Here are some of the most compelling reasons why manufacturers should consider using it as part of their manufacturing processes.

It is becoming more accessible

Currently, 3D printing is mostly restricted to specialized labs and technical universities. The technology needs to be brought to the hands of local changemakers. United Nations agencies are working to bring 3D printing into the hands of the average consumer.

What is Rapid Prototyping in 3D Printing?

What is Rapid Prototyping in 3D Printing?

If you have not yet heard of 3d printing or rapid prototyping, you might be wondering what it is and how it works. There are several advantages and disadvantages to rapid prototyping, including cost, process, and techniques. Keep reading to learn more about this amazing technology! Listed below are some of the most popular methods of rapid prototyping. These methods are great for creating metal or plastic prototypes, and can be used for both metal and plastic parts.

Rapid prototyping

A 3-D printer can be the answer to rapid prototyping needs. Using computer controlled ultra violet light, photosensitive liquid is solidified layer by layer. The final product is often used to test the efficacy and usability of the idea. It can be a low-cost way to develop a product that demonstrates its value to potential customers. Unlike traditional methods, 3D printers can create scale models, allowing rapid changes and iterations.

A common application for rapid prototyping involves the manufacturing of complex metal parts. SLS uses a high-power laser to fuse powdered thermoplastics onto a build plate. Each layer forms a part. Unlike traditional manufacturing processes, parts are created layer by layer. A support structure is surrounded by a layer of powder media. SLS is used to manufacture both plastic and metal prototypes. The process can produce intricate geometries and internal lattice structures.


There are several different types of rapid prototyping techniques in 3D printing. Several of these technologies use photogrammetry to create parts. For example, SLS uses a high-power laser to fuse powdered thermoplastic materials on a build plate. Layers of material are then fused one at a time. SLS works with both metal and plastic prototyping and can produce parts with complex geometries, such as internal lattice structures.

Printed circuit boards and electronics are two popular examples of how 3D printing can be used for prototyping. PHYTEC, a leading supplier of solutions for the industrial embedded market, used Rapid Prototyping to develop a PCB. The DragonFly 2020 3D printer can produce a PCB in as little as twelve to eighteen hours, making it ten to fifteen times faster than traditional methods. This makes it possible to develop working prototypes faster and reduce the development cycle while improving the quality of final products.


Before you launch a product, you must have at least one prototype. Often, customers go through 2-4 prototypes before they launch the final product. However, for simple products, you can expect to build tens or even hundreds of prototypes before you launch the final product. In other words, the cost of rapid prototyping in 3d printing is minimal compared to the cost of large-scale equipment or automated machines.

A functional prototype is a design that works exactly as planned. This prototype is usually made of materials similar to the final product. Later on, the engineers pay attention to the details and performance of the product. This step is crucial for the product’s manufacturing process, as the end result must pass strict quality assurance measures. For these reasons, 3d printing is an excellent choice for many products. Despite the high cost, the process is well worth the price.


Rapid prototyping in 3D printing can speed up the time-to-market process for new products. By creating multiple models of a product in different shapes and sizes, a company can test different design concepts at once. This can help them find the ideal design in less time. Prototypes produced by 3D printing are often much easier to examine than those created with 3D software tools. In addition to being easier to understand, real-life prototypes are also easier to explain to upper management and customers.

The process of rapid prototyping is essentially divided into three phases. First, you create the CAD data for your product. Next, you choose the material to print it out. Once the design is finalized, the next phase is to develop the prototype. The final step involves making adjustments, adding materials, and machining it. With rapid prototyping, the entire process takes only a day, while traditional prototyping methods can take weeks or even months to complete.

How Aluminum Extrusion is Made?

How Aluminum Extrusion is Made?

When making an aluminum extrusion, you’ll want to know how the aluminum billets are formed. The aluminum billet is divided into two sections – the butt and the core. The butt contains oxides from the billet skin, so it’s not used in the extrusion process. This is then sheared off and discarded. Once the butt is removed, the process continues with the next billet loaded. Then, the aluminum alloy is cut with a shear or profile saw. The metal is then transferred via belt systems or walking beam systems to a stretcher. This step performs work hardening and straightening the aluminum alloy.

Problems with wall thickness in aluminum extrusion

Having the right wall thickness is critical in obtaining quality aluminum profiles. Incorrect wall thickness causes distortion of the metal during the extrusion process. When choosing the thickness for your profiles, consider the following factors:

Unbalanced shapes have less strength. In addition, shapes with large variations in wall thickness will deform unevenly and are difficult to hold together. Aim for a wall thickness of at least 50% of the largest wall thickness. Inexperienced designers often specify wall thicknesses that are too thin or too thick. If the thickness changes abruptly, it will cause distortion and can be difficult to control dimensionally.

Die design

The design of the die is one of the most critical components of the aluminum extrusion process. The design of the product determines several production parameters, including the alloy to be used and the finish desired. For example, the diameter and circumscribed circle of the profile will depend on its function and will be determined using a cross-sectional drawing. The complexity of the profile also influences the type of aluminum extrusion machine to be used.

The die’s features are divided into five nodes. They are the mandrel, die plate, bearing, and bridges. The die plate defines the outer contour of the hollow section, while the mandrel provides the interior contour. The portholes on the die are designed to permit aluminium flow into the bearing zone. The steel zones between the portholes are known as bridges. These dies have several advantages, so a thorough understanding of their design is important.

Platen pressure ring

A platen is a cylindrical canister that includes one or more apertures. The inert material that enters the die ring is usually nitrogen, although it may be near or entirely absent of oxygen. It may be partially or completely closed, and the inerting gas is pumped in by a fluid supply tube into the platen’s bore. During aluminum extrusion, the inerting gas is usually kept at a desired range.

The pressure ring supports the die stack and acts as a guide for the die. The pressure applied by the main cylinder forces the ring to flex and wear, but it is essential to ensure that the dies are stable. In direct and indirect aluminum extrusion, the die assembly moves against the billet, creating a constant pressure and stress on it. The resulting aluminum is called “tempered,” a combination of strength and hardness.

Canister guide

An aluminum extrusion canister is used to guide the extrusion from the die. The canister has the same number of holes as the die, and has tie rods to connect the back and front press platens. The main cylinder, which is the driving force of the press, is responsible for exerting pressure on the die stack, causing stress and wear. This wear is remedied by a canister guide, which prevents the aluminum from falling out of the die.

Extrusion is a process that shapes aluminum by forcing heated alloy material through a die. The metal is then pushed out of the canister as a long piece with the same profile as the opening of the die. It can be hollow, solid, or semi-hollow, and can be simple or complex. Once extruded, the metal can be finished or fabricated according to specifications. Aluminum extrusion is commonly used in aerospace, automotive, and appliance manufacturing.

Aluminum alloys used in extrusion

When forming components, the best metal to use is aluminum. Because of its high strength and corrosion resistance, it is used in a variety of end applications. Extrusion companies typically provide a wide range of alloys. In addition to construction and automotive applications, aluminum is also widely used in appliances, electronics, and infrastructure. Here, we’ll examine the most common aluminum alloys and the ways they can benefit the end user.

Listed below are some common alloys that are used in aluminum extrusion. Alloys offer different strengths. Some aluminum alloys are stronger than others, while others are harder or more flexible. Each of these alloys has its own advantages and disadvantages. For example, some alloys have a higher strength than others, while others are softer and can be fabricated into different shapes. If you need a particular aluminum alloy for a specific application, try a 6061 alloy.

How to Fix Under Extrusion

How to Fix Under Extrusion

Many printer users have faced the problem of under extrusion and are wondering how to fix it. The print job may start out smoothly, with adequate adhesion to the print bed and layering as planned. However, when you return to it, you discover that the print job has gone wrong and that there are gaps, holes, and missing print layers. Under extrusion is a problem that can cause these problems, and if you’re having trouble, you should read this article to learn how to fix under extrusion and solve other issues.

High temperatures

If your printer is having trouble with under-extrusion at high temperatures, you will need to know what the root cause of the problem is. If you’re printing PLA at 240 degrees Celsius and 20mm/s for 60 micron layers, the problem will probably be in the temperature. But if the temperature is too low, the filament may not be able to reach the nozzle properly. In this case, the feeder will skip back and the pressure in the head will increase.

One of the most common causes of under-extrusion is improper hot-end adjustment. When you change filament, you must ensure that the parts fit well together. If they don’t, there’s extra friction and the new thread will not be able to move through the nozzle and the extruder head. If you have this problem, you can try adjusting the feeder motor to prevent the problem.

Blockage in the extruder head

A blockage in the nozzle of an extruder head under the process of printing may result in inconsistent material flow. The filament is not allowed to fully extrude, and this will lead to the printer being inoperable. To fix this, you can use a fine wire or guitar string to poke the filament through the clogged nozzle. Make sure to clean the nozzle inside and out, and repeat if necessary.

Another potential cause of a blockage in the extruder head is uncleaned filament gears. Unclean gears can grind stationary filament and collect filament debris. During the print, a stuck filament can cause blockage problems. If you have short-wire-brushed filament spools, you can fix this problem. Spool knots are inevitable in the 3D printing process.

Tangled filament

There are several simple steps you can take to untangle tangled filament under extrusion. First, unmount your spool and take it closer to the feeder. Pull the filament back through the knot until it is free. If this doesn’t work, stop your print and remove the tangled filament from the spool holder. Then, repeat steps 2 and 3 to reinstall the spool.

If the problem persists, try to unwind the filament to see if it is still tangled. This will further exacerbate the problem. Another option is to use a drill attachment to rotate the spool. You can also make your own hand-cranked winder. There are also off-the-shelf tools available for this purpose. If you have your own device, feel free to share your experience.

The next step is to make sure you do not uncoil the entire filament. If you uncoil the filament to get to the knot, you will only make the tangle even tighter. It’s better to leave enough slack to pull whole loops over the edge of the spool. In this way, you can fix tangled filament with less hassle. While the above-mentioned steps may not work for everyone, they do work for most users.

Blockage in the nozzle

Under-extrusion is the result of filaments that do not fully exit the nozzle. This can result in layers with irregular recesses and weak materials. Under-extrusion is relatively easy to diagnose. The filament has a blockage in the nozzle, and it can be dissolved in acetone to remove it. Replace the nozzle if necessary. Hopefully this article has given you some insight into the causes and solutions to under-extrusion.

The most common cause of a clog in the nozzle is heat creep. This is caused by an imbalance in temperature. As a result, the filament becomes soft within the nozzle and pushes around the outer extrusion path. This can happen when the PTFE tube has become worn or if the heatsink is not working properly to dissipate heat away from the nozzle.