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SLA Parts Are Cheaper than You Think

Stereolithography, widely known as “SLA,” is one of the most exciting forms of 3D printing technology on the market. It’s precise, it can produce smooth and detailed parts, and it can even be used to make parts indirectly via patterns for casting and injection molding.

Much more than an obscure cousin to FDM, Stereolithography is a practical, versatile process for a wide range of applications.

So why isn’t SLA as widely used as FDM? In a word: cost. Though companies like Formlabs have driven down the cost of desktop Stereolithography 3D printers for the mass market, resin printing machines are generally far more expensive than their polymer-extruding counterparts. So unless your parts and prototypes demand the use of SLA, it is often more economical to go with FDM. Besides, the range of FDM 3D printers out there is far greater than the range of SLA machines.

But what if you’re not investing in a 3D printer at all? What if you simply have a project that requires one, five or 500 SLA-printed parts? What if you could get somebody else — an expert in additive manufacturing — to invest in and operate the machinery for you?

SLA parts may be less common than FDM parts, but the cost-prohibitive nature of SLA printers does not make SLA parts cost-prohibitive. In fact, with an on-demand manufacturing partner like 3ERP, ordering resin parts and prototypes can be comparable in price to ordering FDM parts.

What Is Stereolithography?

Stereolithography is an additive manufacturing process in which a light-emitting device — usually a laser — is used to solidify a photosensitive resin in a layer-by-layer fashion. This unique approach offers numerous advantages over other 3D printing methods.

Most SLA machines use an ultraviolet laser, which, like the nozzle of an FDM printer, is controlled by computer instructions. Following those instructions, the laser “draws” a 2D shape onto the photosensitive resin, which is stored in a vat in the lower section of the printer. When the 2D shape has been drawn onto the resin (either on its surface or at the bottom of the vat), that thin section of resin solidifies. A build platform then moves the solidified layer up or down, allowing the laser to draw the next “layer” of the part onto the resin. When every layer has been created, the end result is a fully 3D printed object.

Having been invented in the 1980s by 3D Systems founder Chuck Hull, Stereolithography is actually one of the oldest additive manufacturing technologies around — despite being less widely used than several other processes.

Why Is Stereolithography So Desirable?

There are several reasons why SLA 3D printers may be preferred to FDM 3D printers.

Some of the advantages of Stereolithography include:

Accuracy and precision
Typical layer heights of 25-100 microns
Extremely detailed features
Strong adhesion between layers
Isotropy (parts strong in all directions)
Watertightness

SLA parts can be made with detailed features and a smooth surface finish, and they sidestep some of the more common issues associated with FDM 3D printing, such as visible layer lines and anisotropy (weakness along certain axes because of gaps between layers).

3D printed parts made with Stereolithography can also be useful for specific functions such as maintaining air flow or water flow, since they are highly watertight. And SLA can even be used to create master patterns for casting and molding process, which makes the technology popular in fields as diverse as dentistry and jewelry making.

Affordable SLA Parts with 3ERP

Ordering Stereolithography parts is more affordable than you think. That’s because 3ERP, an established manufacturing company with a fleet of manufacturing machines and experienced engineers, does not need to subsidize the cost of its SLA 3D printers by charging high prices to customers.

When you order SLA 3D printed parts from 3ERP, you pay for the resin, the labor and not much else. That means your resin parts and prototypes can be comparable in price to simple FDM parts.

Above all, ordering parts through 3ERP is a risk-free way of incorporating SLA into your production cycle. Since even a consumer-level machine may cost around $5,000 to purchase, and since engineers need to be trained to get the most out of a complex 3D printer, it may be more financially viable to use a third-party manufacturer to carry out production or prototyping of SLA parts.

With 3ERP, you even have several resin options at your fingertips. 3ERP can make SLA parts from Resins 8119, 8118H, 8228 and 8228, giving you the options of nylon-like parts, ABS-like parts and even parts that are resistant to temperatures up to 120°C.

Request a free quote from 3ERP to see for yourself how SLA parts are cheaper than you think. Asides from Additive manufacturing, 3ERP also offers:

The post SLA Parts Are Cheaper than You Think appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Musical Chairs: GKN Buys Forecast3D

We’ve known already for a number of years that aerospace, automotive and defense company GKN is serious about 3D printing. The company acquired one of the first Additive Industries systems, collaborated with GE Additive also, set up a powdered metals sales and production business, printed new steels with Porsche, opened the prerequisite to be one of the big boys: the center of excellence. Now the firm has doubled down once again acquiring Forecast3D.

Carlsbad California based Forecast3D was long focussed on short-run production, molds and 3D printing. The firm moved and expanded into 3D printing early, bet big on HP MJF, bet more on MJF, and in an interview with us seemed to really know where they were headed. With a strong focus on manufacturing end use parts, especially out of polymers and deep experience Forecast3D seems to complement GKN well. It could let GKN make millions of polymer parts for its automotive business in PA 11 GF grades for automotive for example. Or it could let GKN do more polymer mold making in house. The firm could also let GKN enter very different new businesses such as footwear manufacturing.

On the whole, this looks like an astute move by both parties. Increasingly manufacturing as a service looks to be either a super niche or global business. Either you’re the best 3D printing shop in Juneau Alaska or the most specialized EOS titanium acetabular cup producer on the niche end or you have a true global network and the scale and scope to compete. Essentially this completely changes the 3D printing service market. Strong regional players and national powerhouses now have to fear that GKN will play in their backyard while direct to customer firms such as Shapeways, Materialise and Xometry now have a 500 pound gorilla playing in their space. The combination of GKN with a strong direct to customer firm such as Shapeways would make the firm seem damn neigh unstoppable in 3D printing as a service.

We’re faced with the reality that GKN could make this move based solely on a strong polymer 3D Printing commitment by one automotive customer such as Volkswagen. Our industry is but small fry in the world of giant corporates. Along with established regional service bureaus and players such as FKM and Pro-Fit the service industry looks to be dominated by Jabil and GKN. What will the people at FKM and companies such as 3TRPD do? Will 3D printing as service be a two or three-horse race? or is it even a winner takes all? Or could firms using clusters of much cheaper desktop systems still make inroads? Or will local service and production mean that granular local companies will still stay strong? I believe that Jabil and GKN will play a huge role perhaps together with UPS, Shapeways and Xometry. Although the hunters now look like the hunted. Meanwhile, super trusted niche players will dominate their respective niches eg FIT for cutting edge orthopedics and Materialise for cutting edge medical devices. And for local hands-on services that offer high quality, there will always be a place.

Peter Oberparleiter, CEO, GKN Powder Metallurgy said,

“FORECAST 3D is a perfect fit…They are everywhere we aren’t – geographies, markets, technologies and base materials. Combining our individual capabilities will present unparalleled advantages to our customer bases and enable us to cross-promote additive manufacturing in metal and plastic over more diversified markets. It is an important step on our journey to become No. 1 in this high growth market.”

“At FORECAST 3D, our roots run deep in the world of nimble, low volume polymer additive manufacturing. As we continue to branch out and focus on high volume additive production, what better partner to pair with than GKN; a company that produces over 13 million parts per day?GKN’s resources, production experience and footprint will be the perfect fuel for this new FORECAST 3D engine as we prime it for the new world of local, on-demand manufacturing.” Corey Weber, CEO and co-founder, FORECAST 3D stated.

This will have everyone toss their business plan into the trash and has big ramifications for the industrialization of manufacturing for 3D printing. It also brings together two large HP customers which could be good for HP in giving them a quasi instant network but also could put pressure on their margins.

The post Musical Chairs: GKN Buys Forecast3D appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

Xometry: On-Demand Manufacturing Marketplace Completes $50MM Funding Round

Led by Greenspring Associates, Xometry has just announced $50MM raised in equity funding. Also funding the on-demand manufacturing marketplace are:

Founded in 2014 as a manufacturing startup and headquartered in Maryland, Xometry has now raised a total of $113MM, leading us to wonder how they will designate these funds in relation to research and development—a question answered succinctly by Randy Altschuler, co-founder and CEO of Xometry:

“Xometry’s vast network, massive data sets and AI breakthroughs make it easier for engineers and designers to buy custom manufacturing and help manufacturers more efficiently operate their businesses. We’re planning to invest these funds behind growth initiatives, product development and global expansion.”

Allowing for everyone to benefit from custom manufacturing, Xometry has created a successful building model for being able to produce smaller, detailed numbers of parts for consumers rather than requiring mass orders due to profitability requirements like most product manufacturers today—and especially those still using more conventional methods aside from 3D printing and additive manufacturing. The Xometry team is able to meet on-demand needs for parts to a customer base spanning from startups to Fortune 100 companies.

“Xometry has quickly become a key player in the $80B custom manufacturing market,” said Hunter Somerville, General Partner for Greenspring Associates, who will also join Xometry’s Board of Directors.. “We’re thrilled to invest in helping them expand the reach and breadth of their marketplace and the services it offers.”

Xometry maintains a network of over 3,000 partnering facilities for manufacturing, allowing them to produce parts for companies like BMW, Dell, NASA, and GE through:

3D printing services
Traditional CNC machining processes
Sheet metal fabrication
Injection molding
Die casting
Stamping
Extrusion
Urethane casting

“Xometry is yet another example of how machine learning based intelligent software is driving huge efficiency gains across many different industries,” said Daniel Docter, Managing Director Dell Technologies Capital. “We look forward to helping Xometry expand into new verticals that leverage the expertise of Dell Technologies.”

Their growth has continued at rapid speed, with revenue doubling in just the past year. The Xometry team has also created a spin-off with Xometry Supplies—meant to offer Xometry customers with materials and tools for manufacturing more rapidly, and affordably.

We have been following Xometry’s 3D printing progress for years, since they transformed from NextLine Manufacturing into their current and dynamic state, as the largest custom manufacturing marketplace available to consumers today. From streamlining the way engineers order 3D printed parts to changing the rules in manufacturing and even guiding us in choosing the best 3D printing materials, Xometry is geared toward making life easier for engineers and designers, catering to their specific needs.

What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

[Source / Images: Xometry]

Wisconsin: Zero Barrier Labs is Trying to Make Metal 3D Printing 17 Times Cheaper

While many companies are keenly interested in the advances 3D printing is encouraging today—along with additive manufacturing processes making use of a variety of different metal powders to create strong, durable, yet lightweight parts—startup costs can be cost-prohibitive. The team at Wisconsin’s Zero Barrier aims to help others learn more about 3D printing, along with bridging the gap in challenges for others to actually make use of the technology.

Currently, they have plans to open a factory in Madison, WI, where others can send in their 3D designs for printing and then pick them up after a swift turnaround time. They also hope to commercialize their own metal 3D printers subsequently. The startup, founded two years ago, is comprised of a team of engineering students from UW-Madison who met through the university Hyperloop Team. Fast forward to the present moment, and they have created a metal 3D printer meant to streamline the fabrication process further—and especially for other designers and companies who would like to farm out the work.

“There are lots of companies out there that aren’t able to easily prototype, before they get an idea of whether they’ll be able to make a lot of money in the market,” said Evan Wolfenden, co-founder and CEO of Zero Barrier. “By having a technology that is able to allow mass production on such a large basis, and make it affordable…I’m opening up the field to all kinds of products to enter the market.”

Not only does Zero Barrier allow Wolfenden, an already experienced mechanical engineer, to keep his hands in a wide range of different projects pertaining to 3D printing with metal, he also enjoys being able to offer services to others that would not be affordable if they had to buy all the hardware and software on their own; in fact, he reports asking one company for a price to 3D print a 1kg object, and receiving a quote of $2,600 (which they apparently found expensive and we wouldn’t necessarily depending on the object!).

The new startup, currently funded by Wolfenden and friends and family, will offer 3D metal printing services which they project will be 60 times faster and 17 times cheaper than existing technologies. The Zero Barrier 3D printer builds objects out of inexpensive metal powder that contains light curable polymers that are hardened by UV light. The inexpensive metal powder may point to them using MIM powders for their builds. Their technology is not binder jet or SLM/DMLS powder bed fusion nor is it the FDM/FFF polymer filaments with metal inside but another way of printing metal. We’re not sure how it works exactly but looking at the prototype the assumption is that either the system works with UV curable silver or other metal photopolymers/UV inks cured through a DLP projector that can be turned into a green state model which is then sintered.

Solid Ground Curing by Cubital was a technology that could print metal and ceramics in the nineties; check out this mid-1990’s video below. You can also 3D print metal parts using stereolithography and this 1997 paper details how this can be done. A resin with photoinitiators for “photocurability, dispersants to maintain low viscosities at high solids loadings and the sinterable ceramic or metal powder” is turned into an SLA object which is then cured. Then the “photopolymer binder is removed by thermal decomposition and the part is sintered to impart high density and give the desired metal or ceramic properties.” A 2008 paper by Bartolo and Gaspar describes recipes and methods for using stereolithography to make metal parts. We’re not sure if it is this technology and UV curable inks and resins have come a long way over the last 25 years. The team will have issues with part deformation and warping during the build as well as further problems with sintering however and will get variable results at different wall thicknesses, geometries, and part sizes if this is the path that they chose.

Light-based metal printing solutions are also being attempted by Photocentric and BASF is working on trying to make metal and ceramic UV curables as well. 3D Systems also has the venerable multi-step Keltool process in place and this 3D Systems patent details a more direct curable paste method. There is also a MIM industry that is injection molding polymer/metal combos as well and they have yet to fully control the sintering stuff either. One can also go directly from the photopolymer to lost wax casting as well which is being done for millions of 3D printed dental and jewelry models, this process usually requires manual finishing and a strong manual labor component but it remains to be seen how Zero Barrier Labs’ technology will outperform this,

“I’ve been really blessed in my life,” Wolfenden said. “I’ve had a world-class education at a world-class university. I have all these things available to me. So I feel like I have an obligation to do the best I can, so that I can give back to others, and build a foundation for others to follow in.”

While they currently have a workshop at the UW-Madison Makerspace at the Engineering Building, Wolfenden and his team of three other engineers plan to refine their 3D printer further and move into a facility of their own in Madison. Their company is also currently a finalist in the Governor’s Business Plan Competition, a contest that encourages technologically-based startups.

“My future customers are going to be the smaller guys,” says Wolfenden. “Students, researchers, people working out of their garage.”

3D printing in metal is no longer the wave of the future, but is a manufacturing many businesses—from smaller to those leading in industry—are relying on to provide parts that can be easily customized and then printed in low volume or mass production, whether they are making history with voluminous 3D printed gear wheels for automated processes, more efficient heat exchangers, or satellite antennas. Find out more about Zero Barrier and their plans for 3D printing with metal here.

What do you think of this news? Let us know your thoughts! Join the discussion of this and other 3D printing topics at 3DPrintBoard.com.

[Source / Images: The Cap Times]

Five Reasons Why Companies Are Turning to 3D Printing Service Bureaus

Additive manufacturing of metal is popular, but some end user companies are reticent about in-house printing of metals parts. This is, we believe, a powerful factor creating opportunities for metal AM service bureaus. This article defines five factors that have some service bureaus planning for a doubling the number of metal machines this year (2019) according to SmarTech.

#1 Metals Printing Can be Trouble

In the future service bureaus are likely to lose business to in-house 3D printer deployments for polymer printing, but their metals business may increase. Additive manufacturing with polymers is more user-friendly than metals printing making the capital and expertise easier for end users to move the process in-house. There are more process parameters and knowledge involved with metal printing. And, on the materials side, new metals may require special techniques and expertise that are not easily or quickly achieved in-house. This “tribal” knowledge will help service bureaus keep their competitive advantage longer as metal AM becomes more cost-effective and user-friendly.

Metal 3D printers will reduce in cost in the next few years – we have already seen how this could happen from the latest HP and Desktop Metal products. Nonetheless, SmarTech Analysis believes that the combination service provider knowledge, supply chain efficiencies, and high-capital cost will keep metal service bureaus competitive for the foreseeable future.

#2 The “Hot Topic Effect”

The current high level of publicity being afforded to metal printing automatically enhances the prospects for metal service bureaus. Hot topics are, by definition, of immediate importance, but they tend to cool down relatively quickly. It is to be expected that metal additive manufacturing will eventually become less hot as it matures and becomes just another process in the engineering toolbox. Yet, less attention doesn’t necessarily mean that market growth would stop, just that investors’ enthusiasm might shrink.

#3 Lack of User Capital and Low ROI

A classic driver for companies to not 3D print in-house is that some companies just don’t have the capital. The impact of this market driver in metal AM is likely to intensify in the future as more end-user firms find they have a need for metal AM but cannot justify the capex.

Service bureaus also offer a way for companies to dip their toes in the AM metals business without having to invest heavily in the equipment, expertise, or time associated with bringing the process in-house. Some companies may even have the capital, but due to fluctuations and volumes the return on investment (ROI) of in-house metal AM is too low to make it viable. Offering metal 3D printing won’t tie down a service bureau, and a company can test the market to verify a parts value before investing the capital to move production in-house.

#4 Size, Complexity and Service Bureaus

Service bureaus may be able to handle large and complex parts more effectively and efficiently than in-house printing can. Being able to process large parts will give a service bureau additional value. Bringing metal printing in-house is already difficult enough, adding larger more expensive equipment adds complexity.

Finally, understanding different materials, process capabilities, and how complex features can change a design will be the experience service bureaus should have that will prevent or delay companies from moving in-house. Simple design concepts, post processing, and even part orientation can help produce a better product.

#5 Industry Focus Helps

Expertise in a particular industry provides a competitive advantage for service bureaus. It enables a service bureau to better understand its customers and for both customers and service bureaus to interact in a more effective way. As a result, some service bureaus are specializing in customers from the aerospace industry or the medical sector. Specialized automotive service bureaus are also expected to appear in the near future.

These comments apply to polymer AM as well as metals AM, but we note that specialist aerospace and automotive bureaus both have a strong metals orientation. Metals service bureaus that understand the needs, operations and traditions of big metal-using industry sectors are in a better position to win customers than those who don’t.

For more on the topic of AM metals service providers see “Metal 3D Printing Services: Service Revenues, Printer Purchases, and Materials Consumption – 2018-2027,” one of SmarTech’s latest reports. Metal 3D printing is disrupting multiple industries and service providers with a focus on metals will have the opportunities to take advantage of the technology.

3DPrint.com is an equity holder in SmarTech.