From entry-level FDM machines to industrial-grade metal printers, this guide demystifies the many types of 3D printers available to businesses and consumers.

Types of 3D Printers: The Ultimate Guide to Additive Manufacturing Technologies

An FDM 3D printer is a great tool for making all manner of parts and products. The technology is particularly notable for its ability to create hollow or complex geometries on demand. However, the geometry and design of a print is only part of the equation, materials are a major consideration when planning a 3D printing project. The choice of 3D printing filament will influence all sorts of factors, including the cost of a project, the appearance of a print, and, most importantly, the mechanical properties of the final part. For example, if you are looking to make a flexible object, such as a wearable or gasket, it is imperative that you work with a filament that has flexible properties.Polylactic acid (PLA), while the most commonly used filament today, is not known for its flexibility. In fact, the material is highly rigid and in some cases even brittle. This means that it can fracture when stressed, with little deformation before breaking. In this article, we’ll be diving deeper into PLA’s properties to understand if it can be more flexible. We’ll also be looking at flexible filaments that can be used as an alternative to PLA when flexibility is needed.<h2 dir="ltr">PLA filament properties&nbsp;</h2>Neat PLA filament is a rigid thermoplastic known for its easy printability and high strength. Despite a tensile strength of around 50 MPa (<a href="https://www.wevolver.com/article/comparison-of-pla-abs-and-petg-filaments-for-3d-printing" target="_blank">ABS, for comparison has a tensile strength of about 30 MPa</a>), PLA is rigid, offering little flexibility and can actually become more brittle if subjected to stress over time or under extreme conditions. To put that into perspective, PLA has among the lowest elongation at break measurements of the common 3D printing filaments.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733489740277-3d_printed_objects_on_table.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="PLA 3D prints in different colors">PLA is the most commonly used 3D printing filament, though it is not known for its flexibility.What is elongation at break? Elongation at break is a material property that refers to the ability of a material to stretch or elongate before it breaks or fractures. It is typically expressed as a percentage of the material's original length and is a measure of ductility or plasticity. In a standard tensile test, a sample of the material is pulled in tension until it breaks. The elongation at break is calculated by measuring the change in length of the sample and dividing it by the original length, then multiplying by 100.Of course, the specific elongation at break measurement varies depending on the brand of filament used, print settings such as infill and print speed, and geometry of the 3D print.[2] Generally speaking, however, this is how the most common 3D printing filaments compare when it comes to flexibility:<div dir="ltr" align="left"><table><tbody><tr><td>3D Printing Filament</td><td>Elongation at Break (%)</td></tr><tr><td>PLA</td><td>1-6%</td></tr><tr><td>ABS</td><td>20%</td></tr><tr><td>PETG</td><td>15-30%</td></tr><tr><td>TPU</td><td>300–700%</td></tr></tbody></table></div>Another key property of <a href="https://www.wevolver.com/article/pla-bed-temperature" target="_blank">PLA is its low melting point</a> and glass transition temperature. This means that the material is easy to process on a desktop FDM 3D printer, since it does not necessarily require a heated print bed or high nozzle temperatures (PLA prints best between 200-220 °C). However, the polymer’s low glass transition temperature of 60 °C also means that printed PLA components cannot be used in applications that require heat resistance.&nbsp;Recommended reading:<a href="https://www.wevolver.com/article/is-pla-food-safe" target="_blank">&nbsp;Food-grade 3D printing: Is PLA Food-Safe?</a><h2 dir="ltr">PLA+, Flexible PLA, and Soft PLA</h2>As we’ve seen, neat PLA is not known for its flexibility, however there are some PLA 3D printing products that have been engineered for increased flexibility through the use of special additives. For example, PLA+ (or PLA Plus) is an enhanced version of PLA that integrates plasticizers and toughening agents for better impact resistance and some degree of flexibility. Generally, PLA+ is not highly flexible, but it is somewhat more flexible than standard PLA. It is also designed to be tougher, more impact-resistant, and less prone to breaking under stress. For applications where true flexibility is required, however, PLA+ is still limited. For example, eSun’s PLA+ 3D printing material has an elongation at break of 20%, comparable to ABS.Flexible PLA is a variation of PLA mixed with flexible materials, such as thermoplastic elastomers (TPE) or thermoplastic polyurethane (TPU). It retains the ease of use associated with PLA, offering low printing temperatures and reduced warping. Flexible PLA filament can stretch and return to its original shape, making it suitable for gaskets, wristbands, and protective covers or phone cases. While it’s easier to print than highly flexible filaments like TPU or TPE, it is still more rigid than those materials.Soft PLA is another type of filament that typically combines PLA with other additives to improve elasticity and bendability, making it ideal for items like soft toys, flexible parts, or protective covers. However, "soft" in this context doesn't mean highly flexible—the material is still relatively rigid compared to true flexible filaments. It’s worth noting that while Soft PLA is more flexible than neat PLA, the material does not have the same elasticity as elastomers such as TPU.Recommended reading: <a href="https://www.wevolver.com/article/tpu-vs-pla" target="_blank">TPU vs PLA: Choosing Between Flexible and Rigid Filament for 3D Printing</a><h2 dir="ltr">Flexible alternatives to PLA filament</h2>For applications that require a high degree of elasticity, such as footwear, orthopedic models, tubes, seals, and more, there are elastomer filaments like TPU and TPE to consider.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733489800010-3d_printer_creating_object+%281%29.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="3D printing footwear flexible filament">Flexible filaments are useful for 3D printing wearables, such as footwear.<h3 dir="ltr">TPU and TPE Filaments</h3>TPU (thermoplastic polyurethane) is a highly flexible, rubber-like 3D printing filament known for its elasticity, strength, and abrasion resistance. It is a type of thermoplastic elastomer (TPE), meaning it combines the flexibility of rubber with the processing ease of a polymer. TPU can stretch significantly and return to its original shape, making it ideal for parts that require high durability, impact resistance, and flexibility.Key Features of TPU:<ul><li dir="ltr">Flexibility &amp; Elasticity: TPU can stretch in the range of 600% of its original length without breaking, making it perfect for flexible and elastic parts like phone cases, shoe soles, gaskets, and bumpers.</li><li dir="ltr">Durability: TPU is highly abrasion-resistant, tear-resistant, and impact-resistant, which gives it a long lifespan even in harsh conditions.</li><li dir="ltr">Chemical Resistance: It also has good resistance to oils, greases, and various chemicals.</li></ul>Recommended reading: <a href="https://www.wevolver.com/article/what-is-tpu-material-in-3d-printing-material-properties-applications-and-technologies" target="_blank">What is TPU Material in 3D printing: material properties, applications, and technologies</a>TPE (thermoplastic elastomer) is a flexible 3D printing filament that combines the elasticity and rubber-like properties of traditional elastomers with the processability of thermoplastics. Like TPU (a similar material), TPE is designed to provide high flexibility, stretchability, and reliability in applications requiring soft, bendable parts.Key Features of TPE:<ul><li dir="ltr">Flexibility and Softness: TPE can stretch significantly, offering rubber-like elasticity. It is commonly used to print parts like soft toys, wearables, gaskets, flexible hinges, and grips.</li><li dir="ltr">Durability: TPE is abrasion-resistant, impact-resistant, and has excellent fatigue resistance, making it suitable for items that endure frequent bending or compression.</li><li dir="ltr">Chemical Resistance: TPE is resistant to oils, greases, and various chemicals, offering good durability in environments where such substances are present.</li></ul>The main drawbacks of using elastic 3D printing filaments is that they are a) more expensive than PLA spools and b) they are more challenging to 3D print. Specifically, TPU and TPE’s elasticity can cause issues like <a href="https://www.wevolver.com/article/3d-printer-stringing" target="_blank">stringing</a>, <a href="https://www.wevolver.com/article/how-to-clean-3d-printer-nozzle" target="_blank">clogs, or jamming</a>, especially with Bowden extruders, which struggle to push flexible filament through the tube. Direct-drive extruders are therefore recommended for smoother printing. Flexible filaments also require slower print speeds (typically 20-30 mm/s) and lower <a href="https://www.wevolver.com/article/cura-retraction-settings" target="_blank">retraction settings</a> to avoid extrusion problems. Additionally, TPU and TPE print at higher temperatures compared to PLA. TPE and TPU also come with more limited post-processing options that more rigid filaments.Ultimately, while PLA is user-friendly and forgiving, TPU demands more careful settings and attention during printing for optimal results. Below are some 3D printing tips for flexible filaments:3D Printing with TPU:<ul><li dir="ltr">Print Settings: TPU requires slower print speeds (typically around 20-30 mm/s) to prevent issues like stringing or clogging. It also requires lower retraction settings due to its flexibility.</li><li dir="ltr">Print Temperature: TPU filament prints best at 224–250 °C.</li><li dir="ltr">Extruder Compatibility: Direct-drive extruders are generally recommended for TPU, as Bowden setups may struggle with the filament’s flexibility.[1]</li></ul><h3 dir="ltr"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733489815675-man_using_3d_printer.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="Man troubleshooting 3D printer">TPE and TPU can be tricky to 3D print and makers should be aware of problems like stringing and nozzle clogs.</h3><h3 dir="ltr">Polypropylene (PP)</h3>Polypropylene (PP) filament is flexible, but it has a distinct set of characteristics compared to other flexible filaments like TPU or TPE. Polypropylene is a lightweight, durable, and flexible thermoplastic known for its high impact resistance, chemical resistance, and fatigue resistance. It can bend and stretch without cracking, making it ideal for applications like hinges, living hinges, containers, and flexible parts that need to withstand repeated stress.In tests, PP filament has demonstrated an elongation at break in the range of &gt;800% and an elongation at yield in the range of 35%.[3] It also tends to be more challenging to print due to its low surface adhesion and tendency to warp. PP generally requires a heated bed (around 100-110°C) and sometimes a heated chamber for optimal results.&nbsp;<h2 dir="ltr">Conclusion</h2>In the end, while PLA is a popular and easy-to-use filament, it is not particularly flexible and can become brittle under stress. For applications requiring flexibility, alternatives like PLA+, Flexible PLA, and Soft PLA offer some improved flexibility, though they are still not as elastic as elastomeric materials. TPU and TPE are a suitable option for applications that require flexibility, such as phone cases, gaskets, or wearables. However, they come with their own set of challenges, including difficult printing conditions, higher temperatures, and more intricate print settings. Materials like Polypropylene (PP) offer flexibility with high impact and chemical resistance but can also be tricky to print. Ultimately, the choice of filament depends on the specific requirements of the project, including flexibility, durability, and ease of printing. For maximum flexibility and durability, TPU and TPE are recommended, but users should be prepared for a steeper learning curve compared to PLA.<h2 dir="ltr">Frequently Asked Questions (FAQs)</h2><h4 dir="ltr">Q: Is PLA flexible?</h4>A: No, PLA is a rigid filament and is not known for its flexibility. It is brittle and can break under stress with little deformation. It has a low elongation at break (1-6%), meaning it doesn’t stretch much before snapping.<h4 dir="ltr">Q: What is PLA+ and how flexible is it?</h4>A: PLA+ (or PLA Plus) is an enhanced version of PLA that incorporates toughening agents and plasticizers for better impact resistance and some flexibility. PLA+ has an elongation at break of around 20%, making it tougher and more resilient than standard PLA but still not highly flexible.<h4 dir="ltr">Q: What is Flexible PLA?</h4>A: Flexible PLA is a blend of PLA mixed with elastomers like TPU or TPE, making it more flexible than regular PLA. It is suitable for items like gaskets and phone cases. However, it is still more rigid than true flexible filaments and lacks the stretchability of materials like TPU or TPE.Q: What are the challenges of 3D printing with TPU and TPE?A: TPU and TPE filaments are more challenging to print compared to PLA due to their flexibility, which can cause issues like stringing, clogs, and jamming, especially with Bowden extruders. These filaments require slower print speeds (around 20-30 mm/s) and lower retraction settings to avoid extrusion problems. Additionally, TPU and TPE require higher print temperatures and are less forgiving during the post-processing stage compared to rigid filaments like PLA.<h2 dir="ltr">References</h2>[1] Flexible Materials Guide [Internet]. Simplify3D, 2024. Available from: <a href="https://www.simplify3d.com/resources/materials-guide/flexible/" target="_blank">https://www.simplify3d.com/resources/materials-guide/flexible/</a>&nbsp;[2] Leite M, Fernandes J, Deus AM, Reis L, Vaz MF. Study of the influence of 3D printing parameters on the mechanical properties of PLA.[3] Ultimaker PP Technical data sheet [Internet]. UltiMaker, April 20, 2022. Available from: <a href="https://um-support-files.ultimaker.com/materials/2.85mm/tds/PP/Ultimaker-PP-TDS-v3.00.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">https://um-support-files.ultimaker.com/materials/2.85mm/tds/PP/Ultimaker-PP-TDS-v3.00.pdf</a>&nbsp;

The most commonly used 3D printing filament, PLA is not known for its flexibility. We explore why that is and list some alternative 3D printing materials can be used when flexibility is needed.

Flexible 3D printer filaments: is PLA flexible?

The design process in metal 3D printing is a blend of creativity, engineering precision, and innovative technology. Unlike traditional manufacturing, where designs are often constrained by the limitations of subtractive methods, metal 3D printing allows for unparalleled freedom in creating complex geometries. One of the most transformative elements in this design process is the integration of lattice structures. These intricate, web-like frameworks can drastically improve the efficiency and performance of a component, leading to significant savings in material, cost, and printing time. The Design Process in Metal 3D PrintingWhen designing for metal 3D printing, engineers and designers are encouraged to think beyond the constraints of traditional manufacturing. This process begins with conceptualizing the part’s function and determining the best way to achieve its purpose using additive manufacturing techniques. The freedom offered by 3D printing allows for the creation of internal features, complex shapes, and optimized structures that would be impossible or highly impractical to produce using conventional methods.This is where lattice structures come into play. By integrating these lightweight, yet strong, frameworks into the design, engineers can enhance a component’s performance while simultaneously reducing the amount of material used. Benefits of Integrating Lattice Structures<ol><li data-list-indent="1" data-list-type="bulleted">Material Savings: One of the most significant advantages of using lattice structures is the reduction in material usage. By replacing solid sections of a component with a lattice framework, the overall volume of material required is greatly decreased. This not only lowers the cost of raw materials but also reduces the weight of the component, which can be particularly beneficial in industries such as aerospace and automotive where every gram counts.</li><li data-list-indent="1" data-list-type="bulleted">Cost Reduction: Material savings naturally lead to cost reduction. The fewer raw materials needed, the lower the production cost. Additionally, because lattice structures reduce the overall mass of a part, the time required to print the component is also reduced, leading to further cost savings in terms of machine time and energy consumption.</li><li data-list-indent="1" data-list-type="bulleted">Improved Performance: Lattice structures are not just about saving material—they also enhance the mechanical performance of components. These structures can be designed to distribute stress more evenly, improve energy absorption, and increase the overall strength-to-weight ratio of a part. This makes them ideal for components that need to withstand high loads or impacts while maintaining a low weight.</li></ol> Easy Integration with Autodesk Lattice ToolsIntegrating lattice structures into component designs has never been easier, thanks to advanced design tools like Autodesk’s lattice generation features.<a href="https://www.autodesk.com/asean/products" target="_blank" rel="noopener noreferrer"> Autodesk</a> software, such as Fusion 360, offers intuitive tools that allow designers to easily incorporate lattice structures into their 3D models. These tools enable the automatic generation of lattices based on the desired density, cell shape, and mechanical properties, ensuring that the final design is optimized for both performance and manufacturability.With Autodesk’s lattice tools, designers can quickly explore different lattice configurations, simulate their performance, and make adjustments as needed before finalizing the design for printing. This seamless integration of lattice structures into the design process not only speeds up development but also ensures that the final component is both efficient and effective. Conclusion: Lattice Structures as a Design RevolutionThe integration of lattice structures in metal 3D printing represents a significant advancement in the way components are designed and manufactured. By leveraging the benefits of reduced material usage, lower costs, and enhanced performance, designers can create optimized parts that meet the highest standards of efficiency and functionality. Tools like Autodesk’s lattice generation features make it easier than ever to incorporate these structures into designs, paving the way for more innovative and cost-effective solutions in a wide range of industries. As metal 3D printing continues to evolve, the use of lattice structures will undoubtedly play a central role in pushing the boundaries of what is possible in component design.

Integrating lattices in the component design

One of the most transformative elements in the design process for metal 3D printed parts is the integration of lattice structures as these can drastically improve the efficiency and performance of a component.

Optimizing Component Design with Lattice Structures in Metal 3D Printing

As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of the additive manufacturing space as a cost-efficient, reliable and flexible tool that is changing how people and companies view workflow optimization and production uptimes.One of the key areas where&nbsp;<a href="https://ultimaker.com/">UltiMaker’s 3D printing solutions</a> are being leveraged is in manufacturing components with complex geometries(including lattices or internal channels), small production runs and various tooling, jigs, and fixtures used to improve existing traditional manufacturing workflows. Let’s dive into some of the key benefits that 3D printing provides and go over some application examples:<h2>Reducing material waste</h2>When compared to traditional subtractive manufacturing methods such as milling or CNC routing, which will always result in wasted material as part of the part-shaping process, 3D printers will only use as much material as needed for the part, layer by layer. This is further compounded when taking into consideration complex assemblies that often require The ability to produce parts as needed translates directly into reduced costs associated with maintaining large inventories.<h2>Accelerated prototyping and iterations</h2>UltiMaker allows companies to exponentially increase the speed with which they can prototype, test, and refine designs. This is done without needing to rely on expensive external suppliers, which, as we’ve seen in recent years, are vulnerable to supply chain delays or interruptions.Global brands such as <a href="https://ultimaker.com/learn/heineken-ensuring-production-continuity-with-3d-printing/">Heineken have ensured production continuity with 3D printing</a> and decreased lead times (by as much as nine months) and production costs by 3D printing spare parts for their packaging and assembly machinery.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216290885-1733216290885.png" class="fr-fic fr-dib"><h2 id="isPasted">Eliminating tooling costs</h2>Traditional manufacturing methods often require expensive molds, dies, or tooling for each part design and more and more manufacturers are turning to 3D printing technologies to create mold inserts, assembly aids and jigs in order to streamline their production. With a market value estimated at over $73.60 billion the tooling application area is one of the fastest growing: whereas only 37% of manufacturers reported using additive manufacturing for tooling in 2019 that number grew to 57% in 2021.UltiMaker 3D printers allowed companies like <a href="https://ultimaker.com/learn/volkswagen-autoeuropa-maximizing-production-efficiency-with-3d-printed-tools-jigs-and-fixtures/">Volkswagen Autoeuropa to produce tools and fixtures in-house</a> and within two years see assembly-tooling cost savings increased from 70% to 95% (saving an estimated $375,000 per year).<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216309556-3d-printed-wheel-protection-jig.jpg" style="width: 100%px;" class="fr-fic fr-dib">In fact, the ability to tune in and dynamically address the needs of operators working on production lines by creating various custom jigs and fixtures allows companies to streamline processes, enhance precision, and reduce the risk of human error. With more and more customer success stories such as Audi Sport’s implementation of UltiMaker’s 3D printing technology to<a href="https://ultimaker.com/learn/audi-sport-3d-printed-tools-jigs-and-fixtures-in-a-day-instead-of-weeks/" id="isPasted">&nbsp;create almost 200 new tools, jigs and fixtures</a> or <a href="https://ultimaker.com/learn/eriks-leveraging-3d-printing-to-improve-manufacturing-processes/">ERIKS’s improvement to their manufacturing process</a>, it’s evident that additive manufacturing is one of the key investments for businesses that want to stay ahead of the curve.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1733216327298-1733216327298.png" class="fr-fic fr-dib"><h2 id="isPasted">On-demand manufacturing</h2>UltiMaker's accessible ecosystem enables distributed manufacturing for custom or low-volume parts. Businesses print just-in-time components instead of mass-producing and storing potentially unused inventory and with over 200+ materials available on our&nbsp;<a href="https://marketplace.ultimaker.com/app/cura/materials">UltiMaker Marketplace</a> we’re already seeing costly metal parts like conveyor infeed worms being replaced.This is especially relevant when taking into consideration situations where certain machine parts can no longer be sourced as 3D printing allows manufacturers to reverse engineer obsolete parts and far extend the lifespan of existing legacy systems. Just ask one of our clients Trivium, who turned to 3D printing replacement parts for their automated packaging lines.If possible insert an image with the infeed worm that Trivium 3D printed or maybe grab a still from the video with the part being used in the production line?<h2>Easy to implement, easy to scale</h2>Leveraging 3D printing in production processes is also incredibly easy especially when compared to traditional manufacturing techniques that require experienced engineers and designers to create and operate the complex tooling involved which often comes with complicated specialized software that not only adds to the cost but technical expertise as well.With UltiMaker the design process is easily accessible through the various 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 faster than with any of the traditional methods currently available.Coupled with an unparalleled scaling capability through distributed manufacturing, a single engineer can upload 3D parts in Digital Factory making it available in any of the connected locations for localized production as the operation of the 3D printer itself is extremely simple.<h2>The future of manufacturing</h2>From rapid prototyping to on-demand production, 3D printing is reshaping the way manufacturers innovate, save costs, decrease lead times, maintain production uptimes, and minimize waste. If you’re looking to leverage the unique benefits of 3D printing, the Ultimaker Factor 4 printer combines state-of-the-art features with unmatched reliability, empowering your business to achieve more with less.

As global supply chains face increasing pressure and manufacturing demands grow more complex, 3D printing is moving to the forefront of additive manufacturing as a cost-efficient, reliable, and flexible tool that is changing how companies view workflow optimization and production uptimes.

Benefits of 3D Printing in Manufacturing

Every day, more companies discover the transformative benefits of 3D printing. Although the technology has become significantly more accessible over the years, some businesses may still encounter initial challenges in adopting 3D printing.

IMES3D: Expert Support for Industry-Level 3D Printing

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

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Pickit 3D-Thu Aug 31 2023 23:59:59 GMT+0200 (Central European Summer Time)

Pickit 3D-Sat Sep 30 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

3D Printing in Medicine-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

3D Printing in Medicine-Mon Jul 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

3D Printing in Medicine-Thu Aug 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

3D Printing in Medicine-Thu Aug 31 2023 23:59:59 GMT+0200 (Central European Summer Time)

3D Printing in Medicine-Sat Sep 30 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Creaform-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

Creaform-Mon Jul 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Creaform-Thu Aug 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Creaform-Thu Aug 31 2023 23:59:59 GMT+0200 (Central European Summer Time)

Creaform-Sat Sep 30 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Creaform-Tue Oct 31 2023 23:59:59 GMT+0200 (Eastern European Standard Time)

Intrinsic ID-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

Intrinsic ID-Mon Jul 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Intrinsic ID-Thu Aug 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Intrinsic ID-Thu Aug 31 2023 23:59:59 GMT+0200 (Central European Summer Time)

Intrinsic ID-Sat Sep 30 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

AESUB Scanningspray-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

AESUB Scanningspray-Mon Jul 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

AESUB Scanningspray-Thu Aug 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

AESUB Scanningspray-Thu Aug 31 2023 23:59:59 GMT+0200 (Central European Summer Time)

AESUB Scanningspray-Sat Sep 30 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Sculpteo-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

Sculpteo-Mon Jul 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Sculpteo-Thu Aug 31 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Sculpteo-Thu Aug 31 2023 23:59:59 GMT+0200 (Central European Summer Time)

Sculpteo-Sat Sep 30 2023 23:59:59 GMT+0300 (Eastern European Summer Time)

Sculpteo-Tue Oct 31 2023 23:59:59 GMT+0200 (Eastern European Standard Time)

3d printers

3d printers

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