3D Printing Step-by-Step

3D printing is usually talked about as a “magical” technology. You design something in CAD, hit print, and out comes a fully formed object a few minutes later. In reality the 3D printing process requires a lot of manul labor. A tremendous amount of pre-preparation and post processing are required to make a quality printed piece. The gameblog Neoseeker has a great video which shows the 3D printing process in depth, from beginning to end, including all the drudge work.

The video demonstrates the production process used by a company called FigurePrints that turns video game characters into sculptures using a ZCorp 3D printer. Each 3D printer utilizes a slightly different process, but most of the steps in this overview carry over to printers made by other companies.

1. CAD Preperation

Most 3D printers require a special file (typically .stl format) to print. Additionally, you usually need to modify the design to make up for limitations of the printer and build material. For instance, the materials used by 3D printers are typically weaker than injection molded plastics so the parts you print need to be thicker, or reinforced.

2. 3D Printing

The 3D printer runs automatically, depositing materials at layers ~.003″ thick. This is roughly the thickness of a human hair or sheet of paper. The time it takes to print a given object depends primarily on the height of the design, but most designs take a minimum of several hours. The ZCorp printers are unique in that they can print in full color.

3. Cleaning 3D Printouts

Every 3D printer uses some sort of material to support parts of the design that have an overhang. Some use plastics that can be broken off, others use wax based materials that are melted off. The ZCorp printers use a loose powder which can be blown off and reused in future models.

Here you have the “Han Solo in Carbonite” stage…

This is the sculpture with most of the support dust removed. ZCorp printers embed the color in the material and it is enhanced through a process of chemical infiltration.

4. Post Processing

ZCorp 3D printouts are dipped in a special glue that makes them stronger and more colorful. Objects made by other 3D printers (Stratasys, 3D Systems, Objet) don’t require this step, but do require some sanding or painting for finalization.

The difference between pre/post infiltration is striking.

5. Post Processing Continued

This step is unique to the ZCorp process. The infiltrated models are heated to set the glue. It is funny to see the oven in this picture is a standard consumer grade and not some exotic device created specifically for industrial use or 3D printers. If you can swing the $65K for the printer you can handle the rest of the manufacturing in your kitchen!

6. Finishing Touches

The output of all existing 3D printers is rough. The textures vary from pronounced “woodgrain” to merely “sandy”, but if you want a polished look that resembles a manufactured article you need to spend time sanding, sealing, buffing and painting the output. With a little elbow grease you can get stunning results that look like molded parts (even transparent parts). However, we are still far from the day when you can print replacement parts like we print photos at home.

7. Final 3D Printout

There is a “Monet” like quality to most current generation 3D print outs. They look great from a couple paces, but the limitations of the process are apparent on closer inspection. As a result few of the 3D printer companies provide many high resolution photos.

8. Packaging

Parts produced in 3D printers, especially the ZCorp are more fragile than products produced via traditional means like injection molding. Forums created around these Figure Prints or Rockband’s “BandMates” have horror stories of figures arriving broken at the ankles. The Spore Sculptor service bars entire kinds of designs based on durability, so extra care needs to be taken in the packaging and shipping phases.

That is the basic 3D printing process. If you found this interesting definitely check out the Neoseeker video, it is a great demonstration of the process.

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Tagged as: 3d printing, AutoCAD, CAD and CAM, CAD Systems, Carbonite, Computer-aided design, Injection molding, Stratasys, Video game