The Royal Netherlands Navy has a rich history and a modern edge. With a vast fleet of ships, helicopters, boats, and submarines, they are a global presence, often stationed far from home on challenging missions. Their commitment to excellence and innovation keeps them at the forefront of maritime defense.<h2>Spare part and logistical challenges</h2>The Royal Netherlands Navy faces the significant challenge of maintaining their fleet, wherever they are. Their assets often require spare parts, presenting a logistical dilemma. Carrying large quantities of unused spares consumes valuable space, adds weight, and incurs high costs. Transporting these spares, especially via helicopters, can take weeks and is extremely expensive, if it’s possible at all. Additionally, suppliers sometimes cease production of essential spares, complicating operations.<iframe width="640" height="360" src="https://www.youtube.com/embed/gkNm7Sl7aew?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-gtm-yt-inspected-24="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h2 id="isPasted">3D printing as a solution</h2>To tackle this major challenge, the Royal Netherlands Navy has adopted 3D printing. This allows them to produce spare parts locally and on-demand. Each ship is equipped with UltiMaker 3D printers and a variety of materials, enabling them to print a wide range of applications.Parts are designed and tested at their headquarters in Den Helder. Once approved, they are added to a digital catalog. Crew members simply need to select and print the necessary parts directly on board. The Navy also prints optimized parts for better performance, which can be distributed digitally, and produced locally.The Royal Netherlands Navy uses UltiMaker's 3D printing software, Cura and Digital Factory, to meet strict operational requirements with secure and reliable production that aligns with IT security standards. Cura is the most popular slicing software used to prepare 3D models for printing, while UltiMaker's Digital Factory platform enables users to manage and monitor their 3D printers and print jobs remotely, enhancing workflow efficiency. Even with large teams, Digital Factory prioritizes security and ensures that data remains protected throughout the process without compromising accessibility.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087595130-the-royal-netherlands-navy-fleet-of-printers.webp" style="width: 100%px;" class="fr-fic fr-dib">The Royal Netherlands Navy uses a range of filaments, including ABS, PETG, and composite carbon fiber. For instance, PETG is selected for applications that require resistance to extreme temperature, wear, chemicals, and water and moisture absorption. In this instance, the Navy needed a material that would be resistant to saltwater. Using PETG, they 3D printed a new water filter to replace an old brass one<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087624501-1732087624501.png" class="fr-fic fr-dib">Composite carbon fiber filaments are used when parts need to be both strong and lightweight, such as a landing boat antenna bracket printed by the Royal Netherlands Navy. Marine antennas are essential for communications and safety. These mounts ensure they are securely in place and allow for the safe lowering and raising of the antenna. Carbon fiber is especially valuable as it allows traditionally heavy parts to be printed with a light material, reducing weight on the carrier as well as the need to transport heavy items across the globe.This variety of materials allows the Navy to create parts suitable for any environment or condition. Parts on ships primarily require strength and wear resistance, while parts for land or air troops often need to withstand extreme heat or cold. For example, brackets mounted on land vehicles must endure prolonged sun exposure. With the Royal Netherlands Navy's global presence, these parts must be prepared for a variety of demanding conditions.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087646194-the-royal-netherlands-navy-cura.webp" style="width: 100%px;" class="fr-fic fr-dib">Thanks to Cura software's capabilities, UltiMaker 3D printers can seamlessly use both UltiMaker’s and third-party filaments, providing greater flexibility for users. Cura provides a streamlined experience with UltiMaker printers, offering optimized print profiles and faster printing, while maintaining compatibility with third-party products. UltiMaker is committed to regular security updates and providing new feature updates to its Cura users.The Royal Netherlands Navy is a classic example where local manufacturing excels over traditional spare part solutions. Having printers on their ships prevents the need for large stocks of spares on the ships. Furthermore, many parts don't have to travel to remote locations, saving time and extremely high cost. These benefits also apply to many other industries. Factories can benefit from local part production, ensuring uptime of production processes, saving on industrial space and preventing parts to be flown in.

The Royal Netherlands Navy uses UltiMaker's 3D printing software, Cura and Digital Factory, to meet strict operational requirements with secure and reliable production that aligns with IT security standards.

On-Demand Spare Parts: The Royal Netherlands Navy's 3D Printing Solution

Kapsula is an innovative solution designed to provide extreme protection for electronic devices in harsh environments. Utilizing advanced materials like polyphenylene sulfide reinforced with carbon fiber (PPS CF), Kapsula offers unparalleled durability against physical impacts, high temperatures

Kapsula: Extreme Protection for Sensitive Devices

In a previous article, we talked about the benefits of&nbsp;<a href="https://ultimaker.com/learn/benefits-of-3d-printing-in-automated-packaging/">3D printing in automated packing</a> from a high-level overview outlining how the flexibility of additive manufacturing can save costs, simplify material components and improve the end-to-end process.More recently we’ve also hosted a webinar on how to&nbsp;<a href="https://ultimaker.com/learn/leverage-3d-printing-for-automated-packaging-with-real-life-applications/">leverage 3D printing for automated packaging with real life applications</a> (we highly recommend you check it out) and based on the interest generated and questions received during the presentation we wanted to provide you with a more comprehensive in-depth view over actual examples where 3D printing has made significant and sustained impact for several of our clients.So let’s dive into it!<h3>Automated Packaging Systems</h3>Leaning into the flexibility aspect previously covered, we want to be clear that 3D printing can be integrated in all types of automated packaging systems such as filling, sealing, labeling and wrapping machines, palletizing systems and many others. Clients such as Heineken, Krones, Ben&amp;Jerry’s, P&amp;G, Schubert, CocaCola, PepsiCo, Lego and Trivium to name a few, have all successfully integrated UltiMaker’s 3D printing solutions in their automated packaging processes and have all been part of our customer success stories.Below we’ll cover different wear parts, starwheels/sprockets, format specific tools such as infeed screws, LOTO/safety tools and ergonomic enhancements that have been made possible by 3D printing.Starwheel, infeed starwheel and sprockets:<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730169955965-UltiMaker-Packaging-starwheel-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib">Let’s start with one of the backbones of any production line, the starwheel used to drive conveyor/packaging lines, which was also featured on our&nbsp;<a href="https://ultimaker.com/learn/krones-optimized-3d-printed-parts-spares-for-customers-anywhere/">Krones success story</a>. The key requirements for a starwheel is for the part to have a high dimensional stability and high wear and tear resistance.When compared to traditional starwheels made out of POM, the 3D printed variant is cheaper (example part shown above was printed out of PET CF for around 44 €) and able to be optimized for each individual use case, which went coupled with the fact that these parts need to be replaced periodically, the fact that you can set the part to print at the end of your work schedule and have it ready the next day is a benefit that we simply don’t see with traditional sourcing or manufacturing methods.We also want to point out one of the cooler features that can be leveraged with 3D printing that is unavailable for other manufacturing processes (such as milling): dual material extrusion. The ability to print 2 different materials into one part, for example in an infeed starwheel, where the bulk of the part can be made out of a stiff high resistant material, and the outer wall can be printed out of a low friction material enables our clients to save up on material costs without compromising part integrity or functionality.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730169970195-UltiMaker-Packaging-infeed-starwheel-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib">Another benefit is the ability to optimize designs to use less material when printing, while part of this process is already accounted for when considering infill percentage (infill being the amount of material used to fill the internal volume of a part) the design process allows our clients to optimize the part further.One relevant example can be seen in the sprocket design below where the inside was printed out of a rigid technical material and a wear resistant material on the outside which allowed for reduced printing times while retaining part functionality and durability.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730169982608-UltiMaker-Packaging-sprocket-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Inverter tunnels</h3>Product orientation changes during the packaging process, for example expiration dates on ice cream cups are typically printed on the bottom which is obviously not the natural orientation of the product during the filling process. As their name indicates, inverter tunnels are used to flip or invert products as they pass through the production line, designed to rotate items 180 degrees allowing them to be positioned correctly for the next step in packaging process (typically used for labeling, sealing or further processing).Traditionally, most inverter tunnels are made out by milling large blocks of POM material which is both wasteful and time consuming, but with 3D printing inverter tunnels can be optimized to be printed without supports as a single funnel system as seen below (for reference the part in the image cost €15 to print out of UltiMaker PLA Blue).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730169996187-UltiMaker-Packaging-inverter-tunnel-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib">In case there are any concerns regarding the layer lines, please note that they do not cause any snagging or reduction in performance when compared to a traditional inverter. We’ll touch upon materials a bit later in the article but suffice to say that there is a plethora of low friction materials available that practically enable the item inside the tunnel to slide by itself.Inverter tunnels are also a prime example where the complex geometries of some products would make the part manufacturing through milling impossible due to the limitation in producing curved, non-uniform pathways. You can check out&nbsp;<a href="https://www.linkedin.com/posts/jeremy-evers-18a79bb1_3dprinting-additivemanufacturing-ultimaker-activity-7236632063146143744-upOx">this cool short presentation</a> made by our Senior Application Engineer, Jeremy Evers.<h3>Guide Rails</h3>One of the easiest things to optimize in a production line are product guide rails, whether it’s over longer distances or short corners; the flexibility that comes with 3D printing allows for the implementation of durable guide rails with several benefits over traditional options.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730170011020-UltiMaker-Packaging-guide-rails-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib">In the above example the guide rails were created for a bottle packaging line and printed in two materials, the tougher more rigid PET CF Gray for the structure and a more wear resistant low friction material on the inside as it would come in contact with the bottles. The best part in this use case is that when the wear strips need to be replaced you would only need to reprint them and slide them into place on the existing structure (for reference the part shown cost €25 to print with the cost of the wear strips alone being around €7-8).<h3>Infeed scroll/timing screws</h3>With previous parts we’ve touched upon the cost savings through reduced material use in manufacturing, faster lead times and design optimizations but what about instances where you are not able to source components for existing machinery? This was one of the challenges that our client Trivium faced when they were no longer able to source infeed worms to push aluminum cans forward on the production/packaging line.With UltiMaker they were able to quickly iterate and design their own infeed worms, 3D print them and ultimately print their optimized design using carbon reinforced nylon and keep their production rolling. For more information on how Trivium used 3D Printing to help replace parts in their automated packaging lines, you can also <a href="https://ultimaker.com/learn/trivium-3d-printing-replacement-parts-for-automated-packaging-lines/">check out this article</a>.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730170025902-UltiMaker-Packaging-indeed-scroll-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib">The ability to quickly design replacement parts for existing machines without compromising on part functionality or durability and have production back up and running within days without the need to externally source parts and get bogged down with delivery times is a critical benefit that becomes even more important when talking about remote locations such as Africa or South America. The best thing about UltiMaker’s 3D printing solution is that clients can send the digital part files to any connected location and have the part printed locally reducing the need of skilled onsite labor.<h3>LOTO safety tool</h3>At a glance the ability to optimize safety during maintenance with 3D printing by always having an affordable and adaptable safety LOTO (“lockout-tagout”) procedure for any valve, switch, latch, connector for any type of machine in bright visual colors cannot be overstated.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730170039983-UltiMaker-Packaging-LOTO-safety-tool-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib">For this application, it’s the flexibility that offers the biggest advantage as any potential risks that are identified can be resolved onsite, for example a chain cover that would normally require a lengthy delivery time, could easily be designed and printed onsite within hours optimizing worker’s safety.<h3>Wear parts</h3>From bottleneck grippers to can pushers, pack spinners to transition combs, 3D printing allows quick on-demand part replacement without taking up valuable warehouse space which as mentioned earlier is especially valuable when talking about remote plant locations.The intrinsic value of additive manufacturing in creating complex custom geometries means that not only can you replace individual parts but also complete assemblies creating a single, stronger part that is less likely to break or leak. One especially useful example we’ve seen is for top-loading machine (TLM) suctions assemblies.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730170057682-UltiMaker-Packaging-wear-parts-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h3 id="isPasted">Materials</h3>One of the most common concerns when it comes to 3D Printing materials is whether it can hold up to the same standard as metal milled parts and we want to be clear, you can replace metal with plastic. Working with hundreds of companies we’ve noticed that applications made of metal are often overkill for a part’s mechanical needs, and because of the mentioned benefit of 3D printing technology being able to create geometries that are not achievable through machined metal, clients are able to create lightweight parts using a wide range of available materials that are fit for purpose.That being said, when thinking about what material to use, you have to know the requirements:<ul><li>Functional: e.g. strength, flexibility, durability, rigidity</li><li>Environmental exposure: e.g. temperature, humidity, chemicals</li><li>Weight and size constraints</li><li>Industry standards, material certifications, safety or regulatory material constraints. .</li><li>Aesthetic or surface finish: e.g. color, texture</li><li>How long should the material last under normal usage conditions.</li></ul>While a full list of available materials can be referenced on our&nbsp;<a href="https://marketplace.ultimaker.com/app/cura/materials">UltiMaker Marketplace</a> where we’re confident that you’ll find everything you need to best suit your needs, from FDA and EU Food Contact certified materials, medical grade polymers to PPS CF steel and aluminum replacement alternatives, we also wanted to present some of the recommended materials we’ve seen used by our clients in the food and beverage industry:<ul><li><a href="https://marketplace.ultimaker.com/app/cura/materials/Nicolas_Tokotuu/Polymaker_PolyMide_CoPA_2019">Polymaker CoPA</a> - Low friction coefficient, impact resistant</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/NE/IGUS_iglidurI150">Igus iglidur i150</a> - EU 10/2011 certified for food contact, self-lubricating, easy to print</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/NE/IGUS_iglidurI180">Igus iglidur i180</a> - High load and wear resistance</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/thiagomedeiros/LUVOCOM3F50588">Lehvoss 50588</a> - Magnetically detectable, FDA food safe certified, available in blue</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/FVI/kimya_PETG">Kimya PETG-S</a> - Easy to print, FDA food contact certified, available in blue</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/UltimakerPPSCF">UltiMaker PPS CF</a> - Easy to print, extreme stiffness, high temperature resistance(HDT B of over 230℃ after printing)</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/ultimaker_pet_cf">UltiMaker PET CF</a> - Easy to print, dimensional stability, high toughness, available in blue</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/NE/IGUS_iglidurI190">Igus Iglidur i190</a> - High temperature resistance, wear resistance</li></ul><h3>Change the game</h3>With overall costs increasing in the manufacturing and packaging industry and supply chain instability further contributing to volatile market dynamics we know that 3D printing can help you not just adapt, but change the game.All of our clients so far have benefitted from safer working environments, decreased lead-times and costs, improved warehousing and stock management, increased factory line uptime, faster time to market and increased overall equipment efficiency.

Leaning into the flexibility aspect previously covered, we want to be clear that 3D printing can be integrated in all types of automated packaging systems such as filling, sealing, labeling and wrapping machines, palletizing systems and many others.

Applications of 3D Printing in Automated Packaging

This article compares HP Multi Jet Fusion (MJF) and Selective Laser Sintering (SLS) 3D printing technologies and provides insights on how to choose the optimal process for your specific parts.

MJF vs. SLS: Comparing Two Major 3D Printing Technologies

With the advent of 3D printing technology being more reliable and precise than ever, more and more production lines are seeking to leverage its unique benefits to decrease lead times, increase flexibility, save costs and boost delivery times. One of the key industries where 3D printing implementation is starting to show its potential is in the packaging industry, while each of the subjects we’ll cover here could easily be expanded into their own individual deep dives, we wanted to provide a holistic view of the main benefits.<h2>Saving Costs</h2>One of the ways 3D printing reduces packaging costs is through the reduced prototyping costs, whereas traditional prototyping often requires either lengthy setups for injection molding or expertise in die-casting, 3D printing allows for fast iterative designs to be created and improved overnight.Whether we’re talking about custom jigs or bespoke conveyor system parts*, like in our customer Krones’s case, having the possibility to manufacture parts without the need of tooling expertise, limiting expert personnel costs, while simultaneously benefiting from consistently verifiable outputs through Print Process Reporting, which provides detailed post-print reports that help with part validation before deployed, allow for both short term(through reduced material waste) and long term(reduced expert workforce required) cost savings.Another facet is that 3D printing allows for localized production closer to the end-user. The manufacturing and shipment of replacement maintenance parts, especially over long distances is both costly and ineffective when the end-goal is to ensure optimal production uptime. Having 3D printers such as the Factor 4 available at a local packaging facility would allow replacement parts to be created on demand with minimal material waste and little to no expertise required on the client’s part.Tying into the localized production, the ability to adaptively 3D print lightweight modular parts for production lines also allows for faster changeover times between packaging formats reducing machine downtimes and labor costs, e.g. switching a packaging inverter for a 3.6oz ice cream minicup to a 16oz pint one.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1729067241448-1729067241448.png" class="fr-fic fr-dib"><h2 id="isPasted">Simplifying material components&nbsp;</h2>While the intrinsic aspect of additive manufacturing being that you only use as much material as needed is what most people think of when it comes to part saving, the ability to consolidate multi-part assemblies is often overlooked.Packaging inserts, one of the most commonly used elements in packaging production lines, are traditionally made of multiple material components(foam, plastic, cardboard etc.) that individually need to be cut, shaped and assembled. 3D printing allows for the consolidation of a packaging insert into one component solution reducing the need for separate materials, assembly steps, machinery and labor involved in the process with the added benefit of a reduced carbon footprint as a result both through the use of durable biodegradable filaments such as the commonly used PLA and vastly reduced material waste.This also allows the integration of existing packaging solutions for non-standardized product shapes. When it comes to glass bottle manufacturing for example, production of limited-edition bottles with unique sometimes irregular shapes, often use custom foam inserts (which have their own production requirements) to ensure that the integrity of the design is maintained during transit. 3D printed inserts would reduce the need for additional padding or spacers and also allow production lines to use existing storage and transportation solutions like a 24x33cl beverage crate.<h2>End-to-End Process &amp; Knowledge&nbsp;</h2>Required Circling back to traditional product packaging techniques and manufacturing, we’re starting to see how 3D printing can benefit the entire End-to-End process through the reduced reliance or outright removal of need for experienced engineers and designers required to create and operate complex tooling and molds which often involves specialized software that not only adds to the cost but technical expertise as well.With 3D printing the design process is accessible through the myriad of CAD softwares available with some versions having a reduced learning curve with the chief advantage being the ability to directly translate a CAD design into a 3D-printed prototype. When exploring packaging options for new products multiple iterations of packaging concepts can be done over night instead of over days or even over multiple weeks. In practice, a single designer with basic CAD knowledge has the possibility of taking a project from concept to a physical prototype faster than with any of the traditional methods currently available.During assembly, the ability to iterate multiple prototypes quickly and efficiently also allow for less complex setups during the manufacturing phase, for example when testing various designs for bottle labels, 3D printers enable the production of several versions of a label mold in a day allowing for the ability to test multiple iterations without a high overhead.<h2>Flexibility </h2>This all boils down to the core advantage of 3D printers in the package manufacturing space, flexibility.Whether it’s the ability to adapt packaging lines to different sizes and shapes without the need of retooling, enhancing traditional mold-making for custom packaging with quick on-demand iterations, fixture creation for packaging lines or fast prototyping for packaging design testing, 3D printing allows you to design and implement various solutions at a fraction of the cost, time and downtime that traditional packaging processes require.

One of the key industries where 3D printing implementation is starting to show its potential is in the packaging industry, while each of the subjects we’ll cover here could easily be expanded into their own individual deep dives, we wanted to provide a holistic view of the main benefits.

Benefits of 3D printing in automated packaging

Modern desktop 3D printers have surprisingly versatile uses. This is demonstrated by Martin Tobiáš's project – hybrid casting of complex engine parts. He was able to significantly shorten the process from 3D scanning and CAD design to the final casting. In practice, it shows that thanks to 3D printing from polymers, it is not necessary to produce a very expensive permanent mold with complex shapes and cores. Every single casting can be original. This is very advantageous, for example, when developing prototypes of complex machine parts. In addition, the prepared 3D model of the casting is printed directly, including the inlet system, without the need to prepare drawing documentation. This results in a significant acceleration and cost reduction of the production process, especially in the case of piece and small-batch production of complicated castings.At his alma mater – Brno University of Technology – Martin Tobiáš has long been dedicated to design, reverse engineering, rapid prototyping, measurement and testing in the automotive industry. It uses 3D printing on the UltiMaker S3 (and S5) devices supplied by 3Dwiser and the subsequent technology of so-called hybrid casting. Martin's hobby and work became the production of prototype engines for motorsport and the production of increasingly sought-after replicas of historic vehicle parts, without which many veterans would no longer drive. In addition to fidelity and functionality, the production price plays a significant role here.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458878208-1_MartinTobias.jpg" style="width: 100%px;" class="fr-fic fr-dib">Martin Tobiáš with a cylinder casting of a prototype single-cylinder two-stroke engine with a displacement of 690 ccThe project of development and production of a prototype racing motorcycle engine would not have been created without the support of C.S.O. dedicated to the precise production of components for demanding industries. Foundry technology was provided by the Foundry Department of BUT and Alucast s.r.o. The experience of the practical use of hybrid casting led Martin Tobiáš to found the MTA engineering company, which will further specialize in this technology in cooperation with the aforementioned entities.<h2 id="isPasted">Application of 3D printing from prototyping to the production of replicas</h2>3D printing of polymers (FFF) on dual-material UltiMaker desktop printers was already used in the original project during the design phase, when selected components were printed to verify correct installation. Finally, the entire engine was also printed to verify its placement in the chassis frame. As part of the development, special cylinders were also printed to measure the efficiency and flow function doc. Karl Jaroš. It was already necessary to print such parts using temporary water-soluble supports, and this method of dual-material 3D printing then advantageously led to the production of castings - so-called hybrid casting.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458910564-3_HybridCastCylinderModel.jpg" style="width: 100%px;" class="fr-fic fr-dib">Polymaker PolyCast Hybrid Cast Cylinder Model printed on UltiMaker PVA Water Soluble Supports<h2 id="isPasted">Prototype engine cylinder production</h2>The cylinder of a modern water-cooled two-stroke motorcycle is complex in shape. In addition, it requires high manufacturing precision for optimal function and contains complicated water jacket cavities. The most suitable method of production is therefore casting."The hybrid casting method we use in ceramic molds makes it possible to move from the phase of a 3D CAD model to the phase of a dimensionally accurate product relatively quickly and cheaply. It allows the designer to realize complicated shapes and choose from many different materials. In combination with 3D printing of flushable supports, it is also possible to prepare structures with complicated cavities - while maintaining a high-quality surface," mentions Martin Tobiáš.Direct printing from metal materials is often demanding and expensive, requiring specialized technologies. The production of permanent molds for castings is also very expensive, as are any later changes to the molds, if they are even possible.“Our method requires printing a separate model for each individual casting, so it's easy to make each piece unique. In combination with casting simulations, we are able to design the technological process in such a way that we reliably achieve flawless results. In the case of the production of prototypes and functional samples of components, where later changes in the design can be assumed, these do not lead to high additional costs," reminds Martin Tobiáš.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458934755-4_Casting-made-of-AlSi7Mg.jpg" style="width: 100%px;" class="fr-fic fr-dib">Casting made of AlSi7Mg material prepared by a hybrid production process using 3D printing - functional surfaces machined by C.S.O.<h2 id="isPasted">Engine head for a pre-war Czech motorcycle</h2>The same approach has also proven itself for other castings produced with the help of 3D printing. For the engine head, it was, among other things, that the resulting surface faithfully imitated the shape of the original part, or that it was cast in sand. When casting in sand molds, it is necessary to create a permanent foundry model facility. It is traditionally made by hand from wood based on drawing documentation. In the case of castings with internal cavities, it is also necessary to produce cores for the production of sand cores. But again, this is time-consuming.Today, this method of production is uneconomical in many cases under domestic conditions. However, it is possible to help yourself by using modern 3D technologies. The original part can be reconstructed thanks to 3D scanning, the necessary technological modifications can be made on it, and it can then be printed. In simpler cases, the printout can be used directly to create a sand mold. In more demanding cases, it is used to create a negative for casting the model from a special, mechanically resistant foundry resin that can be molded into sand. In this case, it is also necessary to take into account the double shrinkage of the material."When producing replicas of historic vehicle parts, it can be advantageous for a number of reasons to approach production in the classic way - sand casting. After all, 3D printing enables us to effectively realize the production of model equipment," mentions Martin Tobiáš. "The process of producing replicas usually begins with the reconstruction of the original part from a three-dimensional scan. The original drawing documentation is no longer available, moreover, we can preserve the appearance of the original production by observing inaccuracies that do not affect the function."<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458990459-1728458990459.png" class="fr-fic fr-dib">Snapshots from production: for hybrid casting in a ceramic mold, the model and the sprue system are first printed from the 3D model; followed by their assembly, if they are composed of several copies. Then comes encapsulation of the model, firing of the model from the shell, gravity casting, controlled cooling, shell removal and heat treatment<h2 id="isPasted">Reliable 3D printing with supports is the foundation</h2>Printing complex shaped models with temporary supports (from water-soluble materials) would not be possible without solutions with high reliability and precision. The affordable and universal desktop 3D printers UltiMaker S3 and S5 have proven themselves in various projects, and they excel in this area - and that is why they have been seen in the automotive industry for years with the most famous European car manufacturers.But back to Martin Tobiáš, who is thinking about increasing the printing capacity by adding more UltiMaker printers."Cohesion of the layers, dimensional stability and overall reliability of the printing process are important to me. For example, 3D printing one piece of a two-stroke cylinder prototype takes three to six days, depending on the surface quality chosen. Any printing failure will have a very negative impact on the schedule of downstream production operations. Furthermore, the service and support of operating printers, as well as the supplier of original filaments, are also important to me. Consultations regarding news in the field of 3D technology are also advantageous," says Martin Tobiáš. "We use 3Dwiser's support as needed due to the operation of the printers, and in the future also with regard to plans to expand our printing capacities."As far as materials are concerned, mounting fixtures, holders for measuring devices on vehicles and similar parts are most often printed from PLA, PETG, ABS and Nylon strings. For these purposes, Martin Tobiáš was also interested in the printing technology of very durable composites with continuous fiber from Markforged. Polymaker PolyCast on UltiMaker PVA supports turned out to be the best for making casts.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728459033858-7_Motor.jpg" style="width: 100%px;" class="fr-fic fr-dib">Prototype single-cylinder two-stroke engine with a displacement of 690 cc for motorsport (all machining carried out by C.S.O.)<h2 id="isPasted">Hybrid casting - from model to casting</h2>If there is a CAD model of the part, it must be adjusted from the point of view of foundry technology, i.e. allowances for machining, shrinkage, the design of the inlet system, etc. must be taken into account. This is why 3D scanned objects must first be reconstructed into a CAD model.In hybrid casting in a ceramic mold, the model and sprue system are first printed from the 3D model; followed by their assembly, if they are composed of several copies. Then comes encasing the model with a shell, firing the model from the shell, gravity casting, controlled cooling, finally removing the shell. At the same time, the production of sand molds takes place using standard, generally known procedures, as well as the subsequent casting.Finishing work plays an important role, especially heat treatment, sandblasting, shot peening, precision machining at the partner company C.S.O. In the case of the cylinder, it was also treatment of the working surface with Nikasil technology."Examples of parts produced in this way for demanding applications are pistons, cylinders, heads and casings of internal combustion engines. We are not limited to light alloys, it is also possible to choose from different types of steel and cast iron. In terms of size, we focus on small to medium-sized parts. In principle, this is the so-called gravity casting, with which we achieve excellent results thanks to the possibilities of simulations and testing," reminds Martin Tobiáš. "It is worth noting that without additional finishing operations, the resulting cast surface is only as good as the model print."<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728459072181-8_CastingExamples.jpg" style="width: 100%px;" class="fr-fic fr-dib">Sample castings prepared using 3D technology<h2 id="isPasted">Hybrid casting vs. traditional methods</h2>Where are the main advantages of hybrid casting production using 3D printing compared to traditional methods? Above all, in the speed and cost of the entire process, in eliminating the need for construction and production of permanent molds. This difference multiplies with the shape complexity of the products, especially in the case of their piece and small series production.“The traditional method of shell casting, where a fusible model is produced by injecting wax into metal molds, is used in mass production. A 3D printer, however, makes it possible to produce a burnable model without the need to produce a permanent (mother) metal mold. The production method used by us allows us to solve the wrapping of the model manually so that it is not necessary to use ceramic cores to form complex shaped cavities. With the standard injection technology of wax models, flushable or ceramic cores must be used, which makes production significantly more expensive," summarizes Martin Tobiáš, founder of MTA engineering."For parts with very complex shapes, where it is not possible to produce a demountable mother mold, production using hybrid technologies may be the only possible solution. In the case of the production of replicas cast in sand, the procedure with the use of 3D printing is significantly accelerated, also in proportion to the complexity of the manufactured part."An example of the financial advantage of the mentioned procedure is the example with the above-mentioned prototype cylinder of a large-volume two-stroke engine, when the price of the product was reduced by an order of magnitude - from approx. using 3D printing). And this can be a crucial argument not only for replica parts for veterans.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728459098339-9_UMS3-UMS5.jpg" style="width: 100%px;" class="fr-fic fr-dib">The UltiMaker S5 (Pro Bundle) and UltiMaker S3 3D printers have found their way into many industries - from engineering to automotive

Models for hybrid production are created on two-material desktop 3D printers UltiMaker S3 and S5 from the fusible material Polymaker PolyCast

Modern desktop 3D printers have surprisingly versatile uses. This is demonstrated by Martin Tobiáš's project – hybrid casting of complex engine parts. He was able to significantly shorten the process from 3D scanning and CAD design to the final casting.

Significantly cheaper castings of engine parts, thanks to 3D printing

<blockquote>When it comes to 3D printing, there are different file formats to choose from, but the most common are STL, 3MF, AMF and OBJ. Which one you pick mostly depends on your role – whether you’re an engineer or a product designer who wants a 3D design printed, or if you’re the one running the 3D printer. If you’re looking to get a quote and order some 3D printed parts, <a href="https://get.xometry.eu/?locale=en" target="_blank" rel="noopener" id="isPasted">Xometry’s Instant Quoting Engine®</a> is a great tool. You can also upload STP files there, but keep in mind that the end manufacturers would need to convert such files into 3D printers’ friendly formats such as STL.<h4 id="isPasted">Nikolaus Mroncz, Head of Sales Engineering at Xometry</h4></blockquote><h2 data-counter-attr="value0" id="isPasted">3D Printing Workflow: What Files &amp; Software Needed?</h2>To better understand 3D printing file formats, it is essential to grasp how 3D printing itself works. 3D printers create objects by building them layer by layer. Therefore, after designing a model and saving it in a specific 3D printing file format, the next crucial step is slicing. Slicing is the process where the solid model is divided into numerous thin horizontal layers. This step is essential only if you operate a 3D printer yourself.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458453782-EN-3D-printing-file-formats-1536x460.webp" style="width: 100%px;" class="fr-fic fr-dib">Slicing software scans these layers and uses the information to generate the <a href="https://xometry.pro/en-eu/articles/3d-printing-file-formats/#gcode" target="_blank">G-Code</a> which is a set of detailed instructions dictating how the 3D printer should move to produce the desired object. This G-Code file is then sent to the printer for execution. Slicing software, essential for preparing a model for printing, does not work with standard 3D file formats such as STEP, IPT, and SLDPRT. These formats must first be converted to an additive manufacturing file format.Some 3D printers come equipped with their own native slicing software, allowing users to directly use the model in the 3D printing file format without needing third-party software. This integration can streamline the printing process and enhance compatibility between the model file and the printer’s capabilities.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458465367-g-code-3d-printing-1536x758.webp" style="width: 100%px;" class="fr-fic fr-dib">Example of a G-code (Source: 3Dpea.com)The information contained in the CAD file is crucial for successful 3D printing. The file format determines the specific data the file carries, which is used to generate the necessary machine code. Essential information includes geometry, texture, color, and material. Regular 3D CAD file formats often do not encode this data specifically for 3D printing, hence the need for specialized 3D printing file formats.Among the various 3D printing file formats available today, the most ubiquitous are STL, OBJ, AMF, and 3MF. Let’s see how they compare.<h3 data-counter-attr="value1">STL, 3MF, AMF, and OBJ Compared</h3><table><thead><tr><th>File format</th><th>Extension</th><th>Use case</th><th>Characteristics</th><th>Limitations</th><th>File size*</th></tr></thead><tbody><tr><td>STL</td><td>.stl</td><td>Prototyping and simple parts, e.g., basic mechanical components</td><td>Stores geometry as a collection of triangles; universally supported across 3D printing platforms</td><td>No support for color, texture, or detailed material properties</td><td>Typically 1-25 MB, can be optimized down to 100 KB with reduced detail</td></tr><tr><td>3MF</td><td>.3mf</td><td>Modern, versatile applications, e.g., consumer products with detailed features, mixed-material objects</td><td>Compact and efficient; supports advanced features like color, material, and complex geometries</td><td>Growing support but not yet as universal as STL; may require modern software</td><td>2-30 MB, efficient compression keeps sizes smaller</td></tr><tr><td>AMF</td><td>.amf</td><td>Advanced applications needing detailed attributes, e.g., multi-material prototypes, complex color patterns</td><td>Supports multiple materials, colors, and textures; ideal for intricate designs</td><td>Less widely supported by 3D printers and software; more complex than STL</td><td>Typically 10-100 MB, can be larger with complex data</td></tr><tr><td>OBJ</td><td>.obj</td><td>Detailed models requiring texture and color, e.g., character models in gaming, complex architectural designs</td><td>Supports texture, color, and material properties; allows for high-detail rendering</td><td>Can be large and complex due to additional data; may require managing multiple files (geometry, textures)</td><td>Without textures: 5-50 MB; with textures: up to several hundred MB</td></tr></tbody></table>*File size estimates are based on typical use cases and can vary significantly depending on the specific details and complexity of the model.<h2 data-counter-attr="value2">STL Files</h2>The STL file format (STereoLithography) is the most widely used format in 3D printing. Its simplicity and universal compatibility make it the go-to choice for a wide range of 3D CAD software and 3D printing applications.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458514273-stl-1536x864.webp" style="width: 100%px;" class="fr-fic fr-dib">Example of STL file (Source: all3dp.com)One key characteristic of STL is that it saves geometry using tessellations. Tessellation is the process of covering (tiling) a surface with a series of geometric shapes in such a way that there are no gaps or overlaps. In STL files, a 3D model’s geometry is encoded by numerous triangles covering the model’s surfaces.For curved surfaces, a large number of arbitrarily small triangles are required to cover the surfaces. However, the larger the number of triangles employed in a model, the bigger the file size.Another distinguishing characteristic of the STL format is that it only stores geometry data. Other data related to a model such as color, texture, and material are left out. This wasn’t a problem when printers could only print in one color and one material at a time. It may still not be a problem if you require a simple prototype. However, with advancements in 3D printing such as multi-color and multi-material printing, and with the use of 3D printing for producing fully functional, ready-to-use objects, the STL file format may well be on its way out.Pros<ul><li>Compatible with virtually every hardware and software in the world of 3D printing</li><li>Most widely used and shared file format for 3D printing. Millions of STL models are available for easy download online</li></ul>Cons<ul><li>Can only store geometry data. Color, texture, and material data are left out</li><li>The level of detail is limited. For example, curved surfaces are approximated</li><li>The higher the accuracy of the file, the larger it would be</li><li>There may be holes and overlapping triangles in the tessellation as the file format is error-prone. Note that imperfections can be detected and fixed using STL repair tools. This, however, is time-consuming</li><li>Scale and units are not specified</li></ul><h2 data-counter-attr="value3">AMF Files</h2>The AMF (Additive Manufacturing File) 3D printing file format is considered to be an updated version of STL. It was developed exclusively for additive manufacturing by the ASTM (American Society for Testing Materials) in 2013 to address the limitations of STL files.Like STL, AMF stores geometry data using triangular tessellation. However, the triangles in AMF can curve, resulting in accurate data representation. This also results in much smaller file sizes as a smaller amount of triangles are required to accurately represent curved surfaces.Also, AMF files can store color, texture, material, duplicate, orientation, and lattice data, as well as metadata. This makes them far more technically superior than their STL counterparts.Pros<ul><li>Can store all possible data and metadata about a model</li><li>Scale can be specified in various units</li><li>Very low possibility of error</li><li>Small file size</li></ul>Cons<ul><li>Has limited support</li><li>Adoption has been slow</li><li>Not supported by all 3D printing platforms and software.</li></ul><h2 data-counter-attr="value4">3MF Files</h2>After analysing the shortcomings and slow adoption of the AMF file format, some of the biggest names in 3D printing including Autodesk, 3D Systems, Stratasys, HP, Microsoft came together to form a body known as the 3MF consortium. This body developed the 3MF 3D printing file format which is very similar to but much more widely accepted than AMF.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458572146-slide-solid-back-man3.webp" style="width: 832px;" class="fr-fic fr-dib">Example of 3MF file (Source: ultimaker.com)The industry influence and extensive customer base of the 3MF consortium, as well as the functionality of the 3MF 3D printing file format, are responsible for its wide acceptance.3MF has all the technical properties of AMF. It used curved triangular tessellations to encode geometry. It can also store colour, texture, material, and orientation data, and is highly accurate.Data is stored in the human-readable XML format (as opposed to binary) for ease of development and modification. 3MF files are mostly error-free and are considered as ready-to-print, something that is very much appreciated in 3D printing.Pros<ul><li>Relatively popular and is compatible with dozens of softwares</li><li>Stores geometry data accurately</li><li>Can store all data related to a model</li><li>Stores all data, metadata, and properties in a single archive</li></ul>Cons<ul><li>Not compatible across all platforms</li><li>Too complex for simple applications</li><li>May become a proprietary file format</li></ul><h2 data-counter-attr="value5">OBJ Files</h2>Developed by WaveFront Technologies, the OBJ file format was originally used in graphics design as a neutral interchange file format. With the development of multicolor and multi-material printing, the file format was later adopted by the 3D printing industry.In terms of popularity, OBJ is well-known, but behind STL. However, unlike STL which only stores geometry data, OBJ can store geometry, color, texture, and material data. Color data is stored in a separate companion MTL (Material Template). An OBJ file has to be shared with its corresponding MTL file for color printing to be possible.Another key characteristic of the OBJ format is that it allows you to choose the way the geometry of your model is encoded. You can create tessellations using various shapes such as polygons and quadrilaterals, and not just triangles. You are also able to use more advanced and precise methods such as free-form curves and surfaces. These allow OBJ files to store models with far greater accuracy.Pros<ul><li>Stores geometry, color, texture, and material data accurately</li><li>Open-source, neutral standard file format widely supported by softwares</li></ul>Cons<ul><li>Contains a large amount of complex data. This makes sharing or editing time-consuming</li><li>Color and texture data are stored in a separate file</li></ul><h2 data-counter-attr="value6">STEP Files</h2>STEP (STP) files are a standard format used in CAD and engineering. They store detailed 3D models with precise geometries and are ideal for complex engineering designs and assemblies.&nbsp;<h3 data-counter-attr="value7">Can I use STP for 3D Printing?</h3>Yes, but with some caveats. These files can be used for getting a quote (for example, with the Xometry Instant Quoting Engine®), but they usually can’t be used directly for 3D printing and need to be converted into the formats native for 3D printing. This conversion can be done using various CAD software tools such as SolidWorks or online converters.<h3 data-counter-attr="value8">Can I convert STL into STP?</h3>Converting STL to STP is challenging because STL files only contain surface geometry without the parametric data used in STP. The reverse, converting STP to STL, is more straightforward using CAD software but may lose some of the original detail and complexity.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458604989-step-file-1536x864.webp" style="width: 100%px;" class="fr-fic fr-dib">Example of a STEP file (Source: Visao)<h2 data-counter-attr="value9" id="isPasted">How to Resize 3D Printing Files</h2><ul><li>Scaling tool: Import the model into a CAD of 3D modeling software (e.g. Blender, Tinkercad, or Fusion 360) and apply the scaling tool to adjust size proportionally</li><li>Adjust file resolution: Apply the “Reduce” or “Simplify” function of Meshmixer or similar tools to to lower detail while maintaining geometry (by reducing the the number of triangles in STL files)</li><li>Compress the file: Convert models to formats like 3MF for built-in compression. This reduces file size without changing dimensions</li></ul>When resizing 3D printing files, it’s important to maintain the model’s proportions to avoid distortion. Always check that the resized model fits within your printer’s build volume and meets your design requirements. For functional parts, ensure that resizing does not affect their ability to fit together or operate correctly. Additionally, be mindful of the model’s detail and resolution, especially when reducing file size, to preserve critical features and overall quality.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1728458627212-Xometry_AddInForSOLIDWORKS_Screenshot-1536x918.webp" style="width: 100%px;" class="fr-fic fr-dib">3D model in SOLIDWORKS with the Xometry add-in to get instant quotes<h2 data-counter-attr="value10" id="isPasted">Upload Your 3D Files and Get A Quote</h2>In conclusion, we recommend the STL formats for simple geometry and single-color prototypes. If you intend to print simple parts in color, then the OBJ is a better option (even if the texture and color data are stored in a separate file). The 3MF and AMF 3D printing file formats are the most technically superior of the lot as they both store every information on the model. They are great for complex multi-part, multicolor, and multi-material objects. They also stand out for their ease of file sharing as all data and metadata are stored in compact, compressed files. If you have compatible necessary supporting software, feel free to go for AMF. Otherwise, 3MF is the safer option as it is more popular and more likely to be compatible with supporting software.Xometry offers&nbsp;<a href="https://xometry.eu/en/3d-printing/" target="_blank" rel="noreferrer noopener">3D printing services</a> for 7 additive manufacturing technologies. Simply upload your CAD file to our&nbsp;<a href="https://get.xometry.eu/?locale=en" target="_blank" rel="noreferrer noopener">Instant Quotine Engine</a> to get a quote with prices and lead times.

This article outlines the most common file formats in 3D printing: STL, a standard in the industry; OBJ, known for its ability to include color and texture information; AMF, offering enhanced geometry and color representation; and 3MF, supporting multiple colors, materials, and other characteristics

3D Printing File Formats Compared: STL, AMF, 3MF and OBJ

Finland's largest 3D printing workshop is at Espoo's Aalto University School of Arts and Design, where a total of 35 UltiMaker 3D printers (UltiMaker 2+Connect and UltiMaker S7 ) are in use. In the 3D printing industry, such a unit is called a "farm". In this article, we get to know the operation of this farm/workshop, its versatile applications and how 3D printing affects Aalto University in general. For this customer story, we met Hector Velasquez (Industrial Designer, 3D Print Workshop Master - Aalto University), the person in charge of the workshop at Aalto.<iframe width="640" height="360" src="https://www.youtube.com/embed/1KeUK371cgY?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> The core idea of Aalto University's workshop focused on 3D printing is to combine the best aspects of traditional and digital manufacturing techniques. By learning about 3D printing and the application of technology and combining them with, for example, the manufacturing processes of mold and ceramic products, students have the opportunity to develop their creativity and promote a modern perspective for the implementation of design work. Many of today's new (so-called emerging) designers have taken this path.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1721804744816-aalto-uni.jpg" style="width: 100%px;" class="fr-fic fr-dib">Photo: Wenla NwajeiAalto University's cooperation with UltiMaker has been a significant factor in the development of students' creativity, which has contributed to the emergence of new innovations. UltiMaker's easy-to-use hardware and software keep the 3D printing process user-friendly, which provides excellent support for turning students' ideas into concrete pieces. The feel and way of working of the workshop is structured to be a dynamic and stimulating learning environment, which helps students acquire expertise in printing technology regardless of their skill level. During the visit, several students visited the place to continue their printing work. At the workshop, students also have access to a diverse selection of materials. The most commonly used material of all is the easy-to-use PLA, but for example the TPU material designed for industrial use is often used. The student had made shoes suitable for use from TPU. UltiMaker's openness and cooperation with material manufacturers has made the material selection enormous.<a href="https://ultimaker.com/materials/s-series-materials/" target="_blank">Read more about the materials</a>Aalto University's 3D printing workshop is an interdisciplinary space where, for example, fashion, architecture and product design students can work together and use UltiMaker 3D printers to realize their own ideas. The interdisciplinary cooperation of the workshop creates a lively exchange of ideas among the students and promotes the development of innovations.Aalto University has well recognized the importance of education in order to utilize the potential of 3D printing as widely as possible. Learning at the 3D printing workshop is done in a practical way. Students can independently design and produce printable pieces and get to follow the process from start to finish. The student is personally responsible for the success of his printout. The workshop also offers the capabilities to implement challenging and complex 3D printing projects.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1721804766992-aalto-uni-2.jpg" style="width: 100%px;" class="fr-fic fr-dib">Aalto University's 3D printing workshop has been shown to have a strong impact on the development of students' innovations and creative learning. In general, Aalto has invested in 3D printing research and training, which has made the institution also a significant player in the 3D printing field in the world. When knowledge, skills and technologies are combined with developing students, the possibilities for success are limitless.

Finland's largest 3D printing workshop is at Espoo's Aalto University School of Arts and Design, where a total of 35 UltiMaker 3D printers (UltiMaker 2+Connect and UltiMaker S7 ) are in use. In the 3D printing industry, such a unit is called a "farm".

Biggest 3D printing farm in Finland Aalto University's Innovative Workshop

In this episode, we discuss how Audi technicians and mechanics are leveraging a commonly available 3D printer to develop jigs and fixtures for assembling their high performance cars!

Podcast: Why Audi Uses 3D Printers For The R8

The industrial applications of engineering thermoplastics like PC and high-performance thermoplastics like PEEK are growing. In 3D printable filament form, these materials offer a lightweight alternative to metals like steel and aluminum in industries like aerospace and energy.Reinforcing these high-performance plastics with additives can further improve their performance. Chopped carbon fiber, for example, increases strength and stiffness and can be added to low- and mid-priced engineering plastics as well as high-performance plastics. As long as the 3D printer nozzle can handle abrasive materials, these composites can be printed in much the same way as ordinary thermoplastics.The main drawback of high-performance composites like reinforced PEEK is the high cost of the required 3D printing hardware. Such materials require extremely high extrusion and chamber temperatures, and the price of suitable hardware — typically reaching six figures — often nullifies the general cost benefits of plastic 3D printing technology.This article looks at <a href="https://ultimaker.com/materials/factor-series-pps-carbon-fiber/" target="_blank">carbon fiber reinforced PPS</a> as a means of achieving performance comparable to metal and PEEK but with lower temperature and cost demands.<h1 dir="ltr">What is PPS?</h1>Polyphenylene sulfide (PPS) is a semi-crystalline thermoplastic that can be classified as a high-performance plastic alongside materials like PEEK and PEI.Widely used in machining, molding, and additive manufacturing, PPS offers good mechanical properties, a high temperature resistance compared to standard and engineering thermoplastics, and flame retardancy. However, its most desirable characteristic is its excellent chemical resistance: PPS is resistant to many acids, alkalis, and solvents, as well as certain strong oxidants in certain conditions. For strong oxidants like chlorine dioxide, a coating or lining may be required.Due to its desirable characteristics and favorable price compared to PEEK, PPS has a wide range of applications across industries. Its mechanical and chemical properties make it useful in automotive, energy, and chemical processing, while its flame retardancy and self-extinguishing nature have contributed to its status as a go-to material for electrical and electronic parts like SMT devices, motor housings, and transistor sealings.Not only impressive from a thermoplastics standpoint, PPS is regularly used as a genuine alternative to metals like steel and aluminum. Its thermal stability and supreme chemical resistance make it usable in harsh chemical environments, while it is notably resistant to corrosion and the effects of automotive fluids.<h2 dir="ltr">PPS as a composite</h2>For added strength and stiffness, PPS can be reinforced with additives like chopped carbon fiber or fiberglass, forming a composite material. In fact, PPS is more commonly sold as a “filled” material than an unfilled one.According to researchers, the “addition of carbons can greatly improve the mechanical properties, tribological properties, post-fire structural integrity, and electrical/thermal conductivity of… PPS blends and composites.”Carbon fiber reinforced PPS can be used for similar applications to unfilled PPS. However, the improved mechanical properties make it a suitable material for components like tooling, jigs, and fixtures. PPS composites are particularly suited to industrial FFF additive manufacturing, as these 3D printers cannot print materials like pure carbon fiber.<h1 dir="ltr">3D printing PPS</h1>PPS, in both its unfilled and composite form, offers a fairly accessible route to the 3D printing of high-performance thermoplastic parts. This is thanks to its printing temperature of around 320 °C, which is high but not extremely so.While a 320 °C extrusion temperature is beyond the capacity of most FFF 3D printers, it is significantly lower than the temperature required for 3D printing PEEK, which is around 400 °C. (PEEK also requires a very high chamber temperature.) Accordingly, PPS parts have a lower temperature resistance than PEEK parts, but they can still be used for demanding applications in which temperatures reach up to around 230 °C.The type of 3D printer required for printing PPS is somewhere between an industrial-grade FFF printer and a specialist high-temperature FFF printer. Reliable production-level printers can cost around $10,000, while best-in-class high-temperature machines like the Stratasys Fortus 450mc cost around $150,000, which may be considered prohibitively expensive for small and midsize businesses.When printing carbon fiber reinforced PPS, nozzle durability must be considered as well as temperature, as the chopped fibers are more abrasive than the thermoplastic base material and can therefore damage ordinary brass hardware.A suitable build surface for PPS is PEI sheet, with the print bed heated to around 80 °C. For intricate 3D printed PPS parts printed on a dual-extrusion machine, the material is compatible with PVA support material.3D printed PPS reinforced with carbon fiber is suitable for applications such as functional prototypes, tooling for molding and other processes, and manufacturing aids like jigs and fixtures. Industries using reinforced PPS filament include automotive, rail, and aerospace.&nbsp;<iframe id="664b352562706314cc391e64" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/ultimaker-factor-4?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe><h2 dir="ltr">High performance, low cost</h2>New additive manufacturing systems are making PPS 3D printing accessible to a wider range of users. For example, the <a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank">UltiMaker Factor 4</a>, which began shipping in May 2024, has a highly wear-resistant print core that enables printing temperatures up to 340 °C — adequate for printing carbon fiber reinforced PPS and many engineering thermoplastics.What is unique about modern systems like the Factor 4 is their intermediate market positioning. Despite being able to print a genuine high-performance material like carbon fiber reinforced PPS, the Factor 4 is priced closer to an ordinary professional-grade desktop 3D printer than a high-temperature PEEK 3D printer.To meet the needs of users in industries like electronics and automotive, UltiMaker has also developed its own composite material, UltiMaker PPS CF, tailored for use in the Factor 4. With consistent flow and desirable material properties, the material is formulated to offer high performance while being easy to print. The combination of printer and material also results in excellent dimensional accuracy, exhibiting minimal shrinkage compared to PEEK.Like other carbon fiber PPS materials, UltiMaker PPS CF is highly recommended for functional prototypes and indirect manufacturing components, though its excellent chemical and heat resistance opens up a broad range of possible applications including end-use parts. The UltiMaker formulated PPS-CF is Flame retardant (V0-94) and guarantees low warpage also on large parts, setting it apart from alternative PPS CF filament providers.<h2 dir="ltr">Application examples</h2><h3 dir="ltr" id="isPasted">Air freight fastener</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIwNDMxMDg1Mjc0LXVsdGltYWtlci1wcHMtY2YtYWlyLWZyZWlnaHQtZmFzdGVuZXItM2QtcHJpbnQgKDEpLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib">This holder is used to securely fasten air freight or to safely stow components in the air freight packaging. Accordingly, it must be temperature-resistant, very strong and stable, and resistant to chemicals – application requirements that are all met with PPS CF. Another advantage of additive manufacturing is that the design can be adapted repeatedly, with all iterations meeting the necessary certifications thanks to the material used.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1720444566254-Air+freight+fastener2.jpg" style="width: 100%px;" class="fr-fic fr-dib"><h3>High-pressure pump valve</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIwNDMxNjU4ODMzLVB1bXBWYWx2ZTIuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">This pump valve is installed in a train to conduct liquids or chemicals. But because it had become an obsolete component (it was no longer produced), the entire pump assembly would need to be replaced – costing approximately €5,000. Using PPS CF, it can now be 3D printed, so that it still meets the UL94 V0 standard for non-flammability and also for use with hot acids.<h3 dir="ltr" id="isPasted">Sensor Bracket</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzIwNDMxMTYxMTgyLVNlbnNvciBCcmFja2V0IFBQUyBDRiAoMSkuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 100%px;" class="fr-fic fr-dib">This simple bracket is used in the production line and around the site to quickly mount sensors, cameras or other necessary extensions. Priority is given to ensure that the component can withstand extreme loads in outdoor use, including weather conditions, impact resistance or fire protection conditions.<h1 dir="ltr">New possibilities</h1>Carbon fiber-reinforced PPS is a high-performance material suited to some of the most demanding industrial applications. Some additive manufacturing end-users might assume that they need the most expensive materials and hardware to achieve engineering-grade quality coupled with high levels of design freedom. However, the UltiMaker Factor 4 and its specially formulated PPS CF material show that this is no longer the case.If you want to know more about the UltiMaker Factor 4 and the wide variety of engineering materials that can be printed on it, watch this<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank" rel="noopener noreferrer">&nbsp;video.</a>

High-performance thermoplastic composites can be used to replace metals. While PEEK is the benchmark for engineering performance, reinforced PPS is a genuine low-cost alternative.


Carbon Fiber Reinforced PPS as an alternative to PEEK and metal

<section id="isPasted">Three years ago, the <a href="https://www.tue.nl/en/news/news-overview/30-04-2021-first-resident-of-3d-printed-concrete-house-in-eindhoven-receives-key" target="_blank">first concrete-printed</a> house that met all the strict building requirements rolled out of the 3D printer. The house, known as Milestone, became the first 3D concrete printed house in Europe that is actually inhabited. Now the consortium - in which Eindhoven University of Technology plays a major role - announces that there will be a sequel. In the first quarter of 2025, construction will begin on four new and improved 3D-printed owner-occupied homes.</section><section tabindex="-1">The new homes will be located in the Bosrijk neighborhood in Eindhoven. After the summer vacations, the sale of the homes, which are between 110 and 125 square meters in size, will start. Realization of the homes will start in early 2025. Preparations are already in full swing. The planning says that the new residents will be able to move into the homes as early as the summer of 2025.&nbsp;The most striking feature of the four new homes is that they will be scaled up from one to two and even three floors. In addition, the lessons learned from the first home will be incorporated into the development of the next four houses.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1718671503386-csm_Milestone-01_699d7f3bc0.jpg" style="width: 100%px;" class="fr-fic fr-dib">Another sketch of the 3D printed houses.For example, the printed facade is now constructed separately from a load-bearing inner wall and a loose outer wall with insulation material in between, giving the concept a circular character and allowing the printed parts to be reused. In addition, this makes implementation a lot easier and allows designers to use the printed concrete separately in the future, in combination with other building materials.Another major development is guaranteeing consistent quality of the printed concrete. To this end, the researchers at TU/e have modeled all the processes in the printer and shared that knowledge with the printing factory of partner Saint-Gobain Weber Beamix. This combination of knowledge development and years of company experience makes it possible to make the step to printing four homes at the same time, with the assurance that the printed concrete meets the set quality requirements.<h2>Partnership</h2>Project Milestone is a unique partnership between the Municipality of Eindhoven, the Eindhoven University of Technology (TU/e) and industrial partners Saint-Gobain Weber Beamix, construction company Van Wijnen, Houben/Van Mierlo Architects and Witteveen+Bos. These parties have entered into the collaboration to realize a total of five concrete printed homes in Eindhoven.Professor Theo Salet leads the group at TU/e where research is being done on concrete printing and is one of the initiators behind this partnership. This innovative technique revolves around digitizing the entire construction process, from design to execution. This leads to time savings and therefore shorter construction project lead times, as well as higher productivity and associated lower construction costs.The concrete printing technique specifically adds two advantages. The technique is sustainable due to lower material consumption and allows industrial customization due to great freedom of form. "The focus is currently mainly on scaling up the technology. Only then will the technology also become widely available and the advantages can be exploited," Salet said.&nbsp;<h2>Upscaling</h2>Scaling up this innovative printing technology cannot be done alone. Concrete, printer and design must be closely aligned. This is only possible through the cooperation of all partners in a construction team. Salet is proud that the Milestone project is now getting a nice follow-up, and does not expect it to stop here. "There are still several things in development that we have not been able to apply at this point. Think of the sustainable and smart concrete compositions where the concrete measures what the condition is, but also reinforcement systems with which floors can also be printed in the future."At TU/e, for a subsequent project, work is also continuing on the development of a digital copy of reality (digital twin) with which, through artificial intelligence, the printer itself monitors the quality and adjusts where necessary.</section>

A sketch of the 3D printed homes appearing in the Bosrijk neighborhood in Eindhoven.

Construction project Milestone continues with four new and improved 3D-printed owner-occupied homes that now also go up in the air.

First 3D printed multi-story houses ready by 2025

With the launch of the&nbsp;<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank">UltiMaker Factor 4</a> came a new 3D printing material: UltiMaker PPS CF.As soon as you pick up a PPS CF part, you notice that this material is different. Give it a tap and its stiffness and density causes it to vibrate like metal. This metallic sound is also caused by the crystalline structure of PPS, where well-defined molecular arrangements contribute to its distinctive acoustic properties.Beyond this,&nbsp;<a href="https://ultimaker.com/materials/factor-series-pps-carbon-fiber/" target="_blank">UltiMaker PPS CF</a> is suitable for precision engineering, with high durability – all while being a cost-effective alternative for high-end metals and PEEK. The newest member of the UltiMaker material portfolio, it brings significant upgrades for various applications across automotive, aerospace, defense, and more.Let’s take a closer look at the material’s attributes and some examples of real-world PPS CF end-parts that are helping engineers and manufacturers save time and money.<h2>Extreme durability for industrial 3D printing with PPS CF</h2>In the world of industrial production, durability is paramount.PPS CF (polyphenylene sulfide, reinforced with 10% carbon fiber) is designed to withstand the harshest environments, offering exceptional chemical resistance, heat resistance, and dimensional stability. This high-performance material ensures that your industrial prototypes or functional end-use parts maintain their integrity over time, even under the most demanding conditions.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1717741756601-ultimaker-pps-cf-sensor-bracket-3d-printed-part.jpg" style="width: 100%px;" class="fr-fic fr-dib">PPS CF's chemical resistance makes it ideal for applications that are exposed to corrosive substances. Whether it's in the aggressive environments of the chemical processing industry or in automotive components exposed to harsh fluids, PPS CF remains resilient. Its robustness ensures that your parts won't degrade or fail prematurely, providing a reliable material solution that manufacturers can trust.Dimensional stability is equally important in high-precision manufacturing. PPS CF maintains its shape and size even under significant mechanical stress and temperature fluctuations. This property is vital for ensuring that components fit together perfectly and function as intended. With PPS CF, engineers and designers can achieve consistent, reliable results, reducing the need for frequent recalibration or part replacements.Now let’s turn to another stand-out feature of PPS CF – its heat resistance.<h2>High-temperature precision with UltiMaker PPS CF</h2>UltiMaker PPS CF opens the door to a new realm of 3D printing applications. Specifically designed for use with the UltiMaker Factor 4 and print core HT, this advanced material provides the precision and reliability that today's industrial demands require. As a semi-crystalline thermoplastic,&nbsp;<a href="https://ultimaker.com/materials/factor-series-pps-carbon-fiber/" target="_blank">UltiMaker PPS CF</a> boasts a heat deflection temperature exceeding 230 °C post-printing, making it an exceptional choice for high-temperature applications.In the field of precision engineering, temperature tolerance is a critical factor. UltiMaker PPS CF's ability to maintain structural integrity at temperatures above 230 °C ensures that your printed parts will perform reliably in demanding thermal environments. This makes it ideal for applications in the automotive and aerospace sectors, where components are routinely subjected to high heat. From engine parts to under-the-hood components, PPS CF delivers the stability and performance needed to meet stringent industry standards.Chemical resistance is another hallmark of UltiMaker PPS CF. This material is impervious to damage from solvents below 200 °C, making it suitable for use in chemically aggressive environments. Whether used in chemical processing equipment or in parts exposed to harsh cleaning agents, <a href="https://ultimaker.com/materials/factor-series-pps-carbon-fiber/" target="_blank">UltiMaker PPS CF</a> maintains its durability and integrity. This chemical resilience translates to longer-lasting parts that require less frequent replacement, enhancing overall efficiency and reducing downtime.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1717741772227-ultimaker-pps-cf-air-freight-fastener-3d-printed-part.jpg" style="width: 100%px;" class="fr-fic fr-dib">Meeting the&nbsp;<a href="https://www.ul.com/services/combustion-fire-tests-plastics" target="_blank">UL94 V0 standard</a> for flame retardancy, PPS CF provides an added layer of safety and reliability. Flame retardancy is crucial in applications where fire hazards are a concern, such as in the electronics and transportation industries. PPS CF's compliance with this standard ensures that your parts not only perform well but also contribute to a safer working environment.UltiMaker PPS CF's compatibility with the Factor 4 and print core HT further expands its utility in precision engineering. This integration allows for highly detailed and accurate parts, reducing the margin for error and ensuring that each component meets exact specifications. For engineers and designers, this means greater confidence in the manufacturing process and the final product.By integrating UltiMaker PPS CF into your precision engineering projects, you unlock new possibilities in 3D printing. This material's combination of high-temperature resistance, chemical durability, and flame retardancy ensures that your parts are not only precise but also robust and reliable. It's a powerful tool for those who demand the highest standards in their work.<h2>An ideal substitute for parts made of metal or PEEK</h2>UltiMaker PPS CF offers a compelling alternative to traditional materials like steel and aluminum. This means that you can harness the advantages of additive manufacturing, including light-weighting, reduced waste, and complete design freedom, thanks to its compatibility with soluble supports. The result is a versatile, cost-effective solution that doesn't compromise on performance.Light-weighting is a significant benefit in many industries, particularly automotive and aerospace, where reducing weight can lead to improved fuel efficiency and lower emissions. PPS CF's reinforced structure provides the strength needed for various applications while significantly reducing weight compared to metal counterparts. This makes it an excellent choice for components where every gram counts, enabling manufacturers to achieve their performance goals more efficiently.Reduced waste is another advantage of using PPS CF in additive manufacturing. Traditional manufacturing methods often involve substantial material waste, especially when machining metal parts. In contrast, 3D printing with PPS CF is an additive process, <a href="https://ultimaker.com/learn/what-is-3d-printing/" target="_blank">building parts layer by layer</a> only where material is needed. This not only minimizes waste but also reduces material costs and environmental impact, aligning with sustainable manufacturing practices.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1717741787653-ultimaker-pps-cf-3d-printed-bracket.jpg" style="width: 100%px;" class="fr-fic fr-dib">One of the standout features of PPS CF is its compatibility with soluble supports, like&nbsp;<a href="https://ultimaker.com/materials/s-series-pva/" target="_blank">UltiMaker PVA</a>. This compatibility enables full design freedom, allowing engineers to create complex geometries and intricate parts that would be challenging or impossible to produce with subtractive processes – opening up new possibilities for innovation and optimization.PPS CF also presents a viable alternative to PEEK, a high-performance thermoplastic known for its strength and resistance to extreme conditions. While PEEK is highly effective, it can be costly and challenging to 3D print. PPS CF, on the other hand, offers similar benefits in a more cost-effective and user-friendly package. Its ease of printing and reliable performance make it an attractive option for manufacturers looking to balance cost and quality.Incorporating UltiMaker&nbsp;<a href="https://ultimaker.com/materials/factor-series-pps-carbon-fiber/" target="_blank">UltiMaker PPS CF</a> into your production processes allows you to leverage the best of both worlds: the strength and durability traditionally associated with metals and the flexibility and efficiency of additive manufacturing. This material's unique properties ensure that you can produce high-quality, reliable parts without the drawbacks of conventional materials.For manufacturers and engineers across various industries, UltiMaker PPS CF represents a significant step forward. It provides new opportunities to innovate and optimize production while maintaining cost-effectiveness and reliability.<h2>3 examples of PPS CF 3D printing applications</h2><h3>Transportation grippers</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1717741809209-ultimaker-pps-cf-transportation-gripper-3d-print.jpg" style="width: 790px;" class="fr-fic fr-dib">3D printed grippers are popular in the food and packaging industry. Packaging geometries can change frequently, requiring grippers to be quickly adapted – sometimes across the entire production line. These grippers showcase the benefits of dual extrusion, combining flexible TPU and rigid PPS CF. This means the end-of-arm tooling will withstand long-term use, while also protecting the product during transportation. Another huge advantage is that, as the TPU wears down, operators can set a maintenance schedule for when the component needs replacing. This means that the component does not simply break and cause an unexpected disruption in the production line.<h3 id="isPasted">Air freight fastener</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1717741851613-ultimaker-pps-cf-air-freight-fastener-3d-print.jpg" style="width: 100%px;" class="fr-fic fr-dib">This holder is used to securely fasten air freight or to safely stow components in the air freight packaging. Accordingly, it must be temperature-resistant, very strong and stable, and resistant to chemicals – application requirements that are all met with PPS CF. Another advantage of additive manufacturing is that the design can be adapted repeatedly, with all iterations meeting the necessary certifications thanks to the material used.<h3>High-pressure pump valve</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1717741868550-ultimaker-pps-cf-high-pressure-pump-valve-3d-print.jpg" style="width: 100%px;" class="fr-fic fr-dib">This pump valve is installed in a train to conduct liquids or chemicals. But because it had become an obsolete component (it was no longer produced), the entire pump assembly would need to be replaced – costing approximately €5,000. Using PPS CF, it can now be 3D printed, so that it still meets the UL94 V0 standard for non-flammability and also for use with hot acids.<h2>How to start 3D printing with UltiMaker PPS CF</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1717741893051-ultimaker-pps-cf-factor-4-industrial-3d-printer.jpg" style="width: 100%px;" class="fr-fic fr-dib">3D printing with PPS CF is currently only possible using UltiMaker Factor 4 with the HT print core. If any of these application examples or material properties would be useful to you, click the button below to check out the Factor 4 product page or <a href="https://ultimaker.com/quote-request/" target="_blank">request a quote here</a>.<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank" class="button-main-action">EXPLORE FACTOR 4</a>

With the launch of the UltiMaker Factor 4 came a new 3D printing material: UltiMaker PPS CF.

The newest Factor 4 material: Industrial 3D printing with PPS CF

Imagine a portable 3D printer you could hold in the palm of your hand. The tiny device could enable a user to rapidly create customized, low-cost objects on the go, like a fastener to repair a wobbly bicycle wheel or a component for a critical medical operation.Researchers from MIT and the University of Texas at Austin took a major step toward making this idea a reality by demonstrating the first chip-based 3D printer. Their proof-of-concept device consists of a single, millimeter-scale photonic chip that emits reconfigurable beams of light into a well of resin that cures into a solid shape when light strikes it.The prototype chip has no moving parts, instead relying on an array of tiny optical antennas to steer a beam of light. The beam projects up into a liquid resin that has been designed to rapidly cure when exposed to the beam’s wavelength of visible light.By combining silicon photonics and photochemistry, the interdisciplinary research team was able to demonstrate a chip that can steer light beams to 3D print arbitrary two-dimensional patterns, including the letters M-I-T. Shapes can be fully formed in a matter of seconds.In the long run, they envision a system where a photonic chip sits at the bottom of a well of resin and emits a 3D hologram of visible light, rapidly curing an entire object in a single step.This type of portable 3D printer could have many applications, such as enabling clinicians to create tailor-made medical device components or allowing engineers to make rapid prototypes at a job site.“This system is completely rethinking what a 3D printer is. It is no longer a big box sitting on a bench in a lab creating objects, but something that is handheld and portable. It is exciting to think about the new applications that could come out of this and how the field of 3D printing could change,” says senior author Jelena Notaros, the Robert J. Shillman Career Development Professor in Electrical Engineering and Computer Science (EECS), and a member of the Research Laboratory of Electronics.Joining Notaros on the paper are Sabrina Corsetti, lead author and EECS graduate student; Milica Notaros PhD ’23; Tal Sneh, an EECS graduate student; Alex Safford, a recent graduate of the University of Texas at Austin; and Zak Page, an assistant professor in the Department of Chemical Engineering at UT Austin. The&nbsp;<a href="https://www.nature.com/articles/s41377-024-01478-2" target="_blank">research appears today</a> in&nbsp;Nature Light Science and Applications.<h2>Printing with a chip</h2>Experts in silicon photonics, the Notaros group previously developed integrated optical-phased-array systems that steer beams of light using a series of microscale antennas fabricated on a chip using semiconductor manufacturing processes. By speeding up or delaying the optical signal on either side of the antenna array, they can move the beam of emitted light in a certain direction.Such systems are key for lidar sensors, which map their surroundings by emitting infrared light beams that bounce off nearby objects. Recently, the group has focused on systems that emit and steer visible light for augmented-reality applications.They wondered if such a device could be used for a chip-based 3D printer.At about the same time they started brainstorming, the Page Group at UT Austin demonstrated specialized resins that can be rapidly cured using wavelengths of visible light for the first time. This was the missing piece that pushed the chip-based 3D printer into reality.“With photocurable resins, it is very hard to get them to cure all the way up at infrared wavelengths, which is where integrated optical-phased-array systems were operating in the past for lidar,” Corsetti says. “Here, we are meeting in the middle between standard photochemistry and silicon photonics by using visible-light-curable resins and visible-light-emitting chips to create this chip-based 3D printer. You have this merging of two technologies into a completely new idea.”Their prototype consists of a single photonic chip containing an array of 160-nanometer-thick optical antennas. (A sheet of paper is about 100,000 nanometers thick.) The entire chip fits onto a U.S. quarter.When powered by an off-chip laser, the antennas emit a steerable beam of visible light into the well of photocurable resin. The chip sits below a clear slide, like those used in microscopes, which contains a shallow indentation that holds the resin. The researchers use electrical signals to nonmechanically steer the light beam, causing the resin to solidify wherever the beam strikes it.<h2>A collaborative approach</h2>But effectively modulating visible-wavelength light, which involves modifying its amplitude and phase, is especially tricky. One common method requires heating the chip, but this is inefficient and takes a large amount of physical space.Instead, the researchers used liquid crystal to fashion compact modulators they integrate onto the chip. The material’s unique optical properties enable the modulators to be extremely efficient and only about 20 microns in length.A single waveguide on the chip holds the light from the off-chip laser. Running along the waveguide are tiny taps which tap off a little bit of light to each of the antennas.The researchers actively tune the modulators using an electric field, which reorients the liquid crystal molecules in a certain direction. In this way, they can precisely control the amplitude and phase of light being routed to the antennas.But forming and steering the beam is only half the battle. Interfacing with a novel photocurable resin was a completely different challenge.The Page Group at UT Austin worked closely with the Notaros Group at MIT, carefully adjusting the chemical combinations and concentrations to zero-in on a formula that provided a long shelf-life and rapid curing.In the end, the group used their prototype to 3D print arbitrary two-dimensional shapes within seconds.Building off this prototype, they want to move toward developing a system like the one they originally conceptualized — a chip that emits a hologram of visible light in a resin well to enable volumetric 3D printing in only one step.“To be able to do that, we need a completely new silicon-photonics chip design. We already laid out a lot of what that final system would look like in this paper. And, now, we are excited to continue working towards this ultimate demonstration,” Jelena Notaros says.

The tiny device could enable a user to rapidly create customized, low-cost objects on the go, like a fastener to repair a wobbly bicycle wheel or a component for a critical medical operation. Credit: Sampson Wilcox, RLE

Smaller than a coin, this optical device could enable rapid prototyping on the go.

Researchers demonstrate the first chip-based 3D printer

Companies are always seeking to streamline processes, enhance precision, and reduce the risk of human error. So much so that more manufacturers are turning to 3D printing to create custom jigs and fixtures, making them one of the most powerful applications for additive technology.But beyond the buzz of innovation, how can 3D printers directly address your production challenges?To answer that question, we caught up with Jesse Ippel, an Application Engineer at ERIKS. And what was his best advice for finding new, useful 3D printing applications?<h3>To socialize 3D printing within your company and to be a good listener.</h3><blockquote>Our production team often comes up to me with issues and challenges they face. They know that we can 3D print tools and so they ask if we can 3D print something like this.</blockquote>When you consider that these operators are working on production day in and day out, this makes perfect sense. Ultimately, they will figure out what works best for them.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714988956502-eriks-3d-printing-application-deep-dive-ultimaker-jesse.jpg" style="width: 100%px;" class="fr-fic fr-dib">Jesse (left) advises that 3D printing useful jigs and fixtures depends on listening well to the ERIKS production teamJesse explains, “Whenever I just walk onto the production floor, the operators always ask, ‘can we do this, can we do that?’ There are more things that they notice that I will never notice, and that's where the power of 3D printing really lies.”Let’s look at two 3D printing applications that were created from this collaboration between ERIK’s application engineers and production team.<h2>Examples of time-saving 3D printing applications</h2>As a multi-product specialist, ERIKS offers a wide range of mechanical engineering components and technical services to all sections of industry. And the company has embraced 3D printing to enhance their production efficiency.By integrating custom jigs and fixtures into their workflow, they have streamlined their processes and reduced manual labor. To get a comprehensive view of how ERIKS is making the most of 3D printing, be sure to read&nbsp;<a href="https://ultimaker.com/learn/eriks-leveraging-3d-printing-to-improve-manufacturing-processes/" target="_blank">their customer success story</a>. <h2>Box drilling jig</h2><iframe width="640" height="360" src="https://www.youtube.com/embed/84xiq3R_Dlc?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>The production team at ERIKS needed to drill four precise holes in each corner of a small plastic box. This task used to take up to two minutes to measure by hand.To accelerate this process, Jesse designed a custom 3D printed jig, reducing the hole preparation to just seconds. The design included openings to reduce material use and to make it easy for operators to see that the jig was flush against the box. UltiMaker PLA in the company's brand color provided the durability needed for frequent use while maintaining a professional appearance consistent with ERIKS' branding.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714988994315-eriks-3d-printing-application-deep-dive-ultimaker-drill-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib">The blue 3D printed drilling jig allows operators to drill accurate holes in the black boxes in seconds rather than minutes<blockquote id="isPasted">We like to use PLA because it's super convenient. We just throw it in the 3D printer. And it always works.</blockquote>Jesse then went into more detail about the process of creating the box drilling jig.“So we had a couple of iterations of the design. The first one didn't quite fit snugly enough on the box. So we adjusted it slightly. Then we also added the small metal tube as a press-fit insert.”This allows ERIKS operators to drill without worrying that jig’s guide holes will become larger, affecting their accurate positioning. Jesse also added magnetic inserts into a holder for the box and jig. This then snaps onto a metal vice on the workbench, providing a stable platform for the assembly while drilling. <h2>Motor support jig</h2><iframe width="640" height="360" src="https://www.youtube.com/embed/K-UGeihfxQw?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe>To more easily fix a motor to a metal plate and add an electronic component to the motor, ERIKS developed a support jig to aid the process. Before the creation of this jig, the production team would balance the motor and plate on a roll of duct tape to keep the motor axle off the work surface. The 3D printed jig offers a far superior solution.It features a hole which fits the motor axle perfectly, keeping the motor stable off the work surface and not allowing it to turn. The 3D printed side column supports the addition of an electric component without the assembly tipping over. This simplifies the process for operators and minimizes the chance of assembly errors.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714989091911-eriks-3d-printing-application-deep-dive-ultimaker-motor-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib">A custom 3D printed jig perfectly supports adding an electrical component to a motor. Before, operators balanced the assembly on a roll of duct tapeThe jig was also easy to design using Trinckle software. This allowed an ERIKS engineer with less CAD experience to load a model of the motor into Trinckle and easily create a mesh for the 3D printed part around it.The result? This jig has cut assembly time from two to three minutes down to one, making the job significantly easier for the production staff.For both applications, the 3D printing team at ERIKS always adds unique reference code to the 3D printed design. This helps engineers and operators to easily identify the correct and most recent jig iteration to be used on the production floor. <h2>Why ERIKS chose UltiMaker S7 for manufacturing aids</h2>The decision to use the UltiMaker S7 for creating these manufacturing aids was rooted in the printer's versatility, ease of use, and material compatibility. The printer's reliability and consistent performance ensure that these jigs can be created quickly and withstand the rigors of a fast-paced production environment.<blockquote>For us the primary benefit of 3D printing is speed. How quickly can we get something? And that is where 3D printers are the fastest option you can get. I can turn on a print job at 2 pm one day, and the next morning I come into the office and now I have the tools ready. So that is the main factor why we choose 3D printing over conventional methods, whenever we can. Cost is a side benefit for us.</blockquote><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714989112975-eriks-3d-printing-application-deep-dive-ultimaker-ecosystem.jpg" style="width: 100%px;" class="fr-fic fr-dib">The reliability of the UltiMaker ecosystem allows the ERIKS application engineers to start a print job in the afternoon and it’s ready the next morning<h2 id="isPasted">Conclusion</h2>The use of custom 3D printed jigs and fixtures is transforming manufacturing workflows by improving efficiency, consistency, and quality. The examples from ERIKS illustrate the significant benefits that can be realized by adopting these practices. Other companies can look to these success stories as inspiration for optimizing their own production processes, leveraging the power of 3D printing with tools like&nbsp;<a href="https://ultimaker.com/3d-printers/s-series/ultimaker-s7/" target="_blank">UltiMaker S7</a> or&nbsp;<a href="https://ultimaker.com/3d-printers/factor-series/ultimaker-factor-4/" target="_blank">UltiMaker Factor 4</a>.

Companies are always seeking to streamline processes, enhance precision, and reduce the risk of human error. So much so that more manufacturers are turning to 3D printing to create custom jigs and fixtures, making them one of the most powerful applications for additive technology.

Application deep-dive: Maximizing production efficiency with custom jigs at ERIKS

3D printing infill refers to the inner framework of a 3D printed component, which can be crafted using a variety of shapes. Its primary objective is to enhance part efficiency in terms of weight, strength, and print duration. There are numerous infill patterns.<h2 data-counter-attr="value0">What is Infill in 3D Printing?</h2>In 3D printing, “infill” denotes the internal structures present within the majority of 3D printed components. Unlike certain manufacturing techniques such as injection moulding, which necessitate either full solidity or complete hollowness, parts produced via fused deposition modelling (FDM) 3D printing offer flexibility in employing diverse structural patterns that partially occupy the interior space enclosed by the outer printed walls.<h2 data-counter-attr="value1">What is the Purpose of Infill in 3D Printing?</h2>In 3D printing, infill serves to economize both printing time and material by establishing a lattice structure within a printed part. Printing parts with full density is often unnecessary, leading to material wastage. Infill can be strategically positioned to reinforce areas where the part experiences the highest loads, with higher infill densities indicating a greater percentage of infill material.<h2 data-counter-attr="value2">What Are the Key Elements of Infill in 3D Printing?</h2>A standard 3D printed part consists of an outer shell with a predetermined thickness. Enclosed within this shell, the infill structure remains unseen upon completion of the print. Infill is evenly dispersed throughout the part and is typically printed at higher speeds than the outer shell to expedite printing. Moreover, the lattice structure of infill is thinner compared to the shell.<h2 data-counter-attr="value3">What Are the Different Types of Infill in 3D Printing?</h2>Various types of 3D printer infill patterns are utilized to achieve the common goal of reducing print time and material consumption. Below are several examples of prevalent 3D printing infill patterns:<ul><li>Concentric</li><li>Grid</li><li>Linear</li><li>Gyroid</li><li>Octet</li><li>Lightening</li><li>Triangular</li><li>Tri-Hexagon</li><li>Cubic</li><li>Cross</li></ul><h3 data-counter-attr="value4">Concentric Infill Pattern</h3>The concentric 3D printing infill stands out as one of the quickest patterns to print, consuming minimal material. However, this efficiency compromises part strength, particularly when subjected to loads in the x or y-directions. Compared to other infill types, the concentric pattern exhibits reduced strength.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055882410-concentric-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Concentric infill<h3 data-counter-attr="value5" id="isPasted">Grid Infill Pattern</h3>The grid stands as one of the most prevalent infill types, characterized by a cubic grid pattern where plastic is deposited, intersecting at 90-degree angles. This pattern is particularly suitable for prints featuring expansive, level surfaces. However, gridded infill patterns may lead to nozzle clogging due to the overlapping lines within the same layer.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055901754-grid-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Grid infill<h3 data-counter-attr="value6" id="isPasted">Line Infill Pattern</h3>Line infill contains multiple parallel lines per layer, intersecting the preceding layer at a 90-degree angle. Unlike some patterns, lines do not intersect on the same layer, enhancing part strength in two dimensions. Line infill is slightly faster than grid and triangular patterns.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055927508-line-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Line infill<h3 data-counter-attr="value7" id="isPasted">Gyroid Infill Pattern</h3>The gyroid 3D printing infill pattern generates alternating wavy lines or curves, contributing to its distinct appearance. Although this pattern requires more time to print compared to others, its unique internal structure offers nearly isotropic mechanical properties. While prints may remain weaker on the z-axis, the gyroid pattern enhances shear strength along the x and y-axes. Additionally, this infill pattern is well-suited for use with flexible materials.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055956169-gyroid-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Gyroid infill<h3 data-counter-attr="value8" id="isPasted">Octet Infill Pattern</h3>The octet 3D printing infill pattern forms tetrahedral (pyramid-like) volumes within the part, making it ideal for components with expansive horizontal surfaces. The tapered nature of these pyramid-like volumes enables smaller gaps between infill walls, reducing the likelihood of material sagging and allowing for shorter span distances. Consequently, improved top surfaces can be attained without necessitating an increase in infill density.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055974469-octlet-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Octlet infill<h3 data-counter-attr="value9" id="isPasted">Lightning Infill Pattern</h3>This distinctive infill type prioritizes the fastest print time, albeit compromising part strength. Supports are incorporated in a lightning bolt structure, strategically positioned solely where essential. Components primarily consist of shells, except in areas requiring support for horizontal features or internal overhangs.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714055994397-lightning-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Lightning infill<h3 data-counter-attr="value10" id="isPasted">Triangular Infill Pattern</h3>The triangular 3D printing infill pattern deposits plastic in a triangular grid, intersecting at 60-degree angles. It is well-suited for parts featuring extensive, level surfaces and offers performance comparable to the grid pattern. However, the triangular infill may lead to nozzle clogging due to the intersecting lines within the same layer.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056014491-triangular-infill.webp" style="width: 100%px;" class="fr-fic fr-dib">Triangular infill<h3 data-counter-attr="value11" id="isPasted">Tri-Hexagon Infill Pattern</h3>The tri-hexagon infill pattern is renowned for its exceptional strength. Similar to the grid and triangular infill types, it forms a hexagonal pattern interspersed with triangles by crossing over itself. However, the crossing of lines within the same layer often leads to nozzle clogging during printing.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056035171-tri-hexagon-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Tri hexagon infill<h3 data-counter-attr="value12" id="isPasted">Cubic Infill Pattern</h3>The cubic infill type innovatively forms cubic volumes within the part by adopting a layered pattern reminiscent of triangular infill. Each subsequent layer is strategically offset to construct enclosed cube-shaped volumes within the part. These cubic volumes are precisely oriented, balanced on a single corner, thereby bolstering structural integrity.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056057177-cubic-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Cubic infill<h3 data-counter-attr="value13" id="isPasted">Cross Infill Pattern</h3>The cross pattern produces multiple cross shapes as infill within the 3D printed part. This infill pattern is well-suited for flexible part shapes, allowing for bending and twisting. However, it may not be optimal for more rigid plastics. Moreover, an alternative 3D version of the cross is available to bolster the part’s strength further.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1714056075047-cross-infill.jpg" style="width: 100%px;" class="fr-fic fr-dib">Cross infill<h3 data-counter-attr="value14" id="isPasted">What is an Optimal Infill Density?</h3>Typically, an infill density ranging from 20% to 50% is considered advantageous. Below 20%, parts tend to become flimsy, while exceeding 50% leads to extended printing times and excessive material consumption.<h3 data-counter-attr="value15">How Does Infill Pattern Choice Affect the Overall Aesthetics of a 3D Printed Part?</h3>The choice of infill pattern can significantly impact the visual appearance of a 3D printed part. Some infill patterns, such as grid or concentric, may result in a uniform and aesthetically pleasing internal structure, while others, like gyroid or organic patterns, can create visually intricate and unique textures. Additionally, infill density and pattern can affect the transparency, surface finish, and overall perceived quality of the finished part.<h3 data-counter-attr="value16">What Are the Infill Patterns That Maximize the Strength of the Part?</h3>Several infill patterns are known for maximizing the strength of 3D printed parts. Patterns such as honeycomb, tri-hexagon, and gyroid are popular choices for enhancing structural integrity due to their uniform distribution of material and efficient load-bearing capabilities.But the print orientation also plays a major role in the strength of the part. FDM parts exhibit reduced strength along the z-axis because of weaker interlayer bonding. When a load is applied in the z-direction, the primary factor influencing its tensile strength is the quality of interlayer bonding, with the infill percentage having minimal impact in this scenario.<h2 data-counter-attr="value17">How to Choose the Best Infill Pattern</h2>The process of selecting the optimal infill pattern involves several steps:<ol><li>Evaluate the requirements of the part and determine the necessary infill percentage.</li><li>Consider your available resources, such as material and time per part.</li><li>Narrow down the infill patterns that align with your requirements and resources.</li><li>Choose the most suitable infill pattern for your part.</li></ol>Selecting the ideal infill pattern often involves experimentation. Conducting trial prints on small parts can help determine the best settings. Generally, opting for simpler patterns like grid or line patterns tends to yield satisfactory outcomes.<h2 data-counter-attr="value18">Is Infill Important for 3D Printing?</h2>Yes, infill plays a crucial role in 3D printing. It ensures the viability of printing certain parts by providing support for otherwise unsupported surfaces in the design. Infill also enhances strength where necessary, striking a balance between print time and material usage. While some parts can be printed without infill, such as hollow shells like vases, they are generally unsuitable for structural applications due to their lack of internal support.<h2 data-counter-attr="value19">Conclusion</h2>The article covers the significance of infill in 3D printing, outlines various types of infill patterns available, and offers guidance on pattern selection.Xometry offers extensive manufacturing capabilities, including&nbsp;<a href="https://xometry.eu/en/3d-printing/" target="_blank">3D printing services</a> and value-added options for prototyping and production requirements.&nbsp;<a href="https://get.xometry.eu/?locale=en" target="_blank">Simply upload your CAD file</a> to receive an instant quote for your 3D print.

This article will elucidate the concept of 3D printing infill, explore methods for choosing the appropriate infill pattern and density, and detail the array of available infill patterns.

Infill in 3D Printing: Definition, Main Parts, and Different Types

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