Types of 3D Printers: The Ultimate Guide to Additive Manufacturing Technologies
From entry-level FDM machines to industrial-grade metal printers, this guide demystifies the many types of 3D printers available to businesses and consumers.
11 Dec, 2024. 11 min read
3D printing, also known as additive manufacturing, involves creating three-dimensional objects layer by layer from digital models. This technology has had a big impact on industries like aerospace, healthcare, automotive, and consumer goods. By enabling on-demand production, 3D printing reduces waste, lowers costs, and supports customized designs.[1]
Various types of 3D printers cater to different applications, from hobbyist-level desktop models to industrial-scale machines. Each printer type uses specific 3D printing materials and printing processes, offering unique advantages and limitations. Some of these technologies are vastly different from one another, and some don’t seem to resemble “printing” at all. Understanding these differences is essential when choosing the right printer for a particular business or project.
This article explores main types of 3D printers, including extrusion-based models like FDM, resin-based printers such as SLA, and advanced industrial technologies like SLS and DMLS. We'll also cover considerations for selecting the best printer based on application, budget, and material compatibility.
The Evolution of 3D Printing Technologies
The history of 3D printing began in the 1980s with the development of stereolithography (SLA), the first additive manufacturing process. In 1986, Charles Hull patented SLA, which uses ultraviolet (UV) light to cure liquid resin layer by layer into solid objects. This breakthrough allowed for the creation of precise prototypes and marked the beginning of modern 3D printing. Hull also founded 3D Systems, which remains a major player in the industry.
In the late 1980s and early 1990s, new processes emerged. Selective laser sintering (SLS), developed by Carl Deckard, used lasers to fuse powdered materials like nylons. This method enabled the production of durable, functional parts. Around the same time, Scott Crump invented Fused Deposition Modeling (FDM), where thermoplastic filaments are extruded through a heated nozzle. His company, Stratasys, helped popularize FDM, making 3D printing accessible to a broader audience. The first commercial metal 3D printer emerged in the mid-1990s.
The 2000s saw the rise of industrial metal printing technologies like direct metal laser sintering (DMLS) and electron beam melting (EBM), enabling aerospace and medical applications. Binder jetting and material jetting also emerged, allowing full-color and multi-material printing. By the 2010s, the expiration of key patents fueled the explosion of desktop 3D printers, transforming the technology from an industrial tool into a consumer-level innovation. However, since that period, industrial uses have again become the focus of 3D printing.
Types of 3D Printers
Today’s 3D printing technologies cater to a wide range of users, from hobbyists to industrial manufacturers.
FDM printers, for example, are affordable and ideal for beginners creating prototypes with plastics like PLA and PETG — though many industrial users deploy extrusion 3D printers as well. Resin-based SLA printers offer high-detail models for designers, dentists, and jewelers, while DMLS enables industrial production with durable metals for the aerospace and automotive industries. Each technology serves unique needs, balancing precision, material compatibility, and budget requirements.
Below is a quick guide to the six major categories of 3D printing technologies. Sheet lamination can also be considered a form of 3D printing, though it is less prominent and arguably of a different category altogether.
Extrusion
Extrusion 3D printing, also known as Fused Deposition Modeling (FDM) or fused filament fabrication (FFF), involves melting thermoplastic filament and depositing it layer by layer through a heated nozzle.[2] As each layer cools, it solidifies, creating a 3D object. This method is popular due to its affordability, simplicity, and compatibility with a range of materials, including PLA, PETG, ABS, ASA, and even high-performance polymers like PEEK (though expensive machines costing tens or hundreds of thousands of dollars are required for such materials).
FDM printers are widely used for prototyping, hobby projects, and functional parts in industries like automotive, aerospace, and product development. Their accessibility makes them ideal for both beginners and professionals.
Leading brands in extrusion 3D printing include Creality, known for budget-friendly models like the Ender 3 series, and Prusa Research, famous for its reliable, open-source Prusa i3 MK4. UltiMaker (formerly MakerBot and Ultimaker) offers professional-grade printers like the UltiMaker S7, which features advanced material compatibility, automated bed leveling, and enclosed printing for industrial applications.
The combination of versatility, cost-effectiveness, and scalability makes extrusion 3D printing a key technology across educational, engineering, and manufacturing sectors. Its continuous evolution supports a growing range of applications, from hobbyist creations to precision-engineered components.
Some companies, including Desktop Metal, have developed systems capable of extruding metal filament. More affordable than other types of metal 3D printing, these systems use filament comprising metal particles within a sacrificial thermoplastic binder material. The plastic must be removed during post-processing.
Recommended reading: FFF vs FDM: Is There Any Difference?
Vat Photopolymerization
Vat photopolymerization is a category of 3D printing processes that use liquid photopolymer resins cured by a light source to create objects layer by layer. The main technologies in this category are stereolithography (SLA), digital light processing (DLP), and masked stereolithography (mSLA). In SLA, a laser traces the design, curing the resin precisely. DLP uses a projector to flash entire layers simultaneously, making it faster. mSLA, the most affordable of the three technologies, employs an LCD screen with UV light.
Vat photopolymerization is renowned for producing highly detailed, smooth-surfaced prints.[3] It excels in applications requiring precision, such as dental models, jewelry, prototypes, and miniatures. However, post-processing is necessary, including rinsing in isopropyl alcohol and curing with additional UV light.
Popular printers in this category include the Formlabs Form 3+ (SLA), known for industrial reliability, and Anycubic Photon Mono X (mSLA), valued for affordability and high resolution. Elegoo Mars series printers are also popular among hobbyists. Although resin printing can be messy and requires careful handling due to toxic materials, its ability to deliver exceptional accuracy and fine details makes it a top choice for professionals and enthusiasts alike in industries like healthcare, product design, and model making.
Advanced vat photopolymerization methods like Carbon’s Continuous Liquid Interface Production (CLIP) are capable of faster, high-resolution production of printed parts with a high level of dimensional accuracy. Unlike traditional SLA, CLIP uses a permeable window and UV-curable resin, maintaining a “dead zone” where resin stays liquid. This allows continuous printing while reducing visible layer lines.
Powder Bed Fusion
Powder bed fusion (PBF) refers to a group of 3D printing processes that use a heat source, typically a laser or electron beam, to fuse powdered materials layer by layer. Common technologies include selective laser sintering (SLS) for plastics (mainly polyamides) and direct metal laser sintering (DMLS) or electron beam melting (EBM) for metals. SLS and DMLS may also be grouped under the broader category of laser powder bed fusion (LPBF).
In all forms of powder bed fusion, the build area is filled with a thin layer of powder, and the heat source selectively fuses sections based on the 3D model. After each layer, more powder is applied, and the process repeats until the part is complete.
In the world of thermoplastics, SLS is widely used for functional plastic prototypes and end-use parts due to its durability and ability to print complex geometries without support structures. HP’s Multi Jet Fusion technology is a more recent innovation, combining PBF and binder jetting technologies.
PBF is also used for metals. DMLS, sometimes referred to more precisely as Selective Laser Melting (SLM), a term owned by the Nikon SLM Solutions company, is common in aerospace, automotive, and medical industries, producing strong, lightweight metal components. EBM can be used for similar applications. In most PBF processes, post-processing such as powder removal and heat treatment is required.
Notable SLS systems include the Formlabs Fuse 1+ and EOS P3 NEXT, while metal printers like the EOS M 290 and 3D Systems DMP Flex 350 are common in the industrial sector. While PBF offers exceptional mechanical properties and design freedom, it requires specialized equipment, skilled operators, and considerable post-processing, making it ideal for industrial use but less suitable for beginners or budget-conscious users.
Directed Energy Deposition
Directed energy deposition (DED) is an advanced 3D printing process that uses focused energy, typically a laser, electron beam, or plasma arc, to melt material as it is deposited. DED systems feed metal powder or wire directly into the heat source, which fuses the material onto a substrate or existing part layer by layer. This technology excels in producing large-scale components, repairing damaged parts, and adding features to existing structures.[4]
DED is commonly used in industries such as aerospace, defense, and heavy manufacturing, where high-strength metal parts and component repairs are critical. The process can work with various metals, including titanium, stainless steel, and Inconel, enabling applications in high-performance environments. It supports multi-axis deposition, making it suitable for complex geometries.
Leading DED systems include Optomec’s LENS series and DMG MORI’s Lasertec machines. While DED offers exceptional scalability and material flexibility, its limitations include lower surface finish quality compared to other metal 3D printing methods and the need for extensive post-processing like machining and heat treatment. DED is ideal for large, custom, or mission-critical components but is less practical for small or highly detailed parts due to its resolution constraints and operational complexity.
Material Jetting
Material jetting is a category of 3D printing processes that involves spraying liquid photopolymers or wax-like materials in precise droplets, which are cured by UV light. The printer’s printhead moves back and forth, depositing material layer by layer, similar to inkjet printing. This process supports multiple materials and colors, enabling the creation of highly detailed, multi-material, full-color objects.
Material jetting is widely used in industries like product design, dental, and medical modeling due to its ability to produce accurate, high-resolution prototypes. It excels in applications requiring complex geometries, fine details, and smooth surface finishes. Support structures, made from dissolvable materials, are printed simultaneously and easily removed post-printing.
Popular material jetting systems include Stratasys PolyJet printers, including the J-series line of printers with full-color and multi-material capabilities, and 3D Systems’ ProJet MJP models, used for creating precision parts. Despite its precision, material jetting has limitations, including higher material costs and slower build speeds compared to other methods. Parts can also be brittle, limiting its use for functional prototypes. Nonetheless, its ability to create visually striking, highly detailed models makes material jetting a top choice in design, marketing, and specialized industries like dentistry and jewelry manufacturing.
Binder Jetting
Binder jetting is a 3D printing process that uses a liquid binder to selectively bond layers of powdered material. A printhead deposits the binder onto a thin layer of powder, solidifying it in the desired shape. After each layer, more powder is spread, and the process repeats until the part is complete. Post-processing typically involves curing and sintering to strengthen the final object.
Binder jetting supports a variety of materials, including metals, ceramics, and even sand for casting molds, making it an important indirect manufacturing method for metal part production. The key advantage of binder jetting is its ability to produce large, complex, and lightweight parts without the need for support structures. It is commonly used in industries such as automotive, aerospace, and consumer goods for both prototyping and full-scale production.
Notable Binder Jetting systems include Desktop Metal’s Shop System and ExOne’s X1 25Pro, both recognized for producing industrial-grade metal components. The process is highly efficient, enabling mass production with lower material costs compared to other metal printing methods. However, parts require extensive post-processing, including debinding and sintering, which can add time and cost. Despite these challenges, Binder Jetting’s scalability and versatility make it a powerful tool for high-volume manufacturing and custom product creation.
Recommended reading: Binder Jetting: A Comprehensive Guide to the Additive Manufacturing Process
Quick Comparison of Types of 3D Printers
3D Printing Technology | Entry-Level Machine Cost | Industrial Machine Cost | Material Type | Industries |
Powder Bed Fusion (SLS/DMLS) | N/A | Very High | Plastics (SLS), Metals (DMLS) | Aerospace, Automotive, Medical, Consumer Goods |
Directed Energy Deposition (DED) | N/A | Very High | Metals (Titanium, Inconel, Steel) | Aerospace, Defense, Heavy Manufacturing |
Material Jetting | N/A | High to Very High | Photopolymers, Waxes | Product Design, Dental, Medical, Jewelry |
Binder Jetting | N/A | Medium to High | Metals, Ceramics, Sand | Automotive, Aerospace, Industrial Manufacturing |
Vat Photopolymerization | Low | Medium | Photopolymers | Dental, Jewelry, Product Design, Prototyping |
Extrusion (FDM/FFF) | Low | Medium to High | Thermoplastics (PLA, PETG, ABS, PEEK), Composites | Education, Prototyping, Manufacturing, Hobbyist |
Conclusion
The diverse range of 3D printing technologies available today offers solutions for various needs, from consumer-level prototyping to industrial-scale manufacturing. Entry-level systems like extrusion (FDM/FFF) and vat photopolymerization are accessible to hobbyists, educators, and small businesses, providing affordable options for creating models and prototypes. These technologies are easy to use and support a variety of materials, making them ideal for design iterations, educational purposes, and low-volume production.
In contrast, industrial-grade technologies such as powder bed fusion (SLS/DMLS), directed energy deposition (DED), and binder jetting cater to sectors that demand high precision, material strength, and scalability. These methods are used in aerospace, automotive, and healthcare industries, where performance and durability are paramount. Despite their high costs, these systems enable the production of complex geometries, metal parts, and tight tolerances that other methods cannot achieve.
Each technology serves a distinct purpose based on the materials, cost, and complexity of the project. Understanding these differences allows users to select the right 3D printing technology for their needs, balancing affordability, quality, and scalability for a wide range of applications.
Frequently Asked Questions
What is the main difference between entry-level and industrial-level 3D printers?
Entry-level resin or FDM 3D printers are low-cost, user-friendly, and designed for hobbyists, educators, or small businesses. They typically offer lower resolution and limited material options. Industrial-level 3D printers are high-cost, high-performance machines used for complex, large-scale, or high-precision applications in industries like aerospace, automotive, and medical fields.
Which 3D printing technology is best for beginners?
FDM/FFF (extrusion) printers are best for beginners due to their affordability, ease of use, and broad material compatibility. They are widely available at entry-level prices and suitable for simple rapid prototyping, educational projects, and hobbyist applications.
What are the advantages of powder bed fusion over other technologies?
PBF technologies like SLS and DMLS provide high precision, durability, and the ability to create complex geometries. They are ideal for functional prototypes and end-use parts, especially in industries requiring strong, lightweight components, such as aerospace and automotive.
Can material jetting be used for mass production?
While Material Jetting is excellent for creating highly detailed, multi-material prototypes, it is not typically used for large-scale mass production due to its slower build speeds and high material costs. It is more suited to design and marketing, dental, and jewelry applications.
How does directed energy deposition differ from other metal 3D printing methods?
Directed energy deposition (DED) has many similarities with DMLS in terms of cost and post-processing requirements but is capable of adding material to existing parts, allowing for repairs, modifications, or the creation of large metal structures.
References
[1] Nadagouda MN, Ginn M, Rastogi V. A review of 3D printing techniques for environmental applications. Current opinion in chemical engineering. 2020 Jun 1;28:173-8.
[2] Kuznetsov VE, Solonin AN, Tavitov A, Urzhumtsev O, Vakulik A. Increasing strength of FFF three-dimensional printed parts by influencing on temperature-related parameters of the process. Rapid Prototyping Journal. 2020 Jan 8;26(1):107-21.
[3] Lakkala P, Munnangi SR, Bandari S, Repka M. Additive manufacturing technologies with emphasis on stereolithography 3D printing in pharmaceutical and medical applications: A review. International journal of pharmaceutics: X. 2023 Dec 1;5:100159.
[4] Saboori A, Aversa A, Marchese G, Biamino S, Lombardi M, Fino P. Application of directed energy deposition-based additive manufacturing in repair. Applied Sciences. 2019 Aug 13;9(16):3316.