Comparing 3D Printing Technologies

3D printing technologies offer consumers various methods for manufacturing products, but the technical jargon can be confusing for those unfamiliar with the topic. This post aims to simplify the subject, helping you choose the right technology for your project. We will focus only on additive manufacturing of commonly used plastic materials. Other materials and less common technologies are not covered here.

1. Range of Technologies

Fused Filament Fabrication (FFF), also known as Fused Deposition Manufacture (FDM): This technology uses plastic filaments, which are heated to a semi-liquid state and deposited in layers from the bottom up.

StereoLithography (SLA): This method uses liquid resin with a photosensitive chemical that solidifies when exposed to light. The product is formed layer by layer from the bottom up, attached to a plate that rises from a vat of resin.

Multi Jet Fusion (MJF): This technique uses plastic powder. A laser scans the top surface, melting and binding particles together. New powder layers are added, forming the product from the bottom up.

There are many other additive manufacturing technologies and materials, such as food (e.g., chocolate), metals, and concrete not covered in this article.

2. Choosing a Technology

From a consumer perspective, here are key characteristics to consider for each technology:

FFF Printing:

• Resolution: Smallest detail around 0.1 mm (100 microns)

• Max Size: Typically ~200 mm x 200 mm x 200 mm, with larger sizes up to 500 mm x 500 mm x 500 mm readily available

• Temperature Resistance: 60°C to 300°C, with higher temperatures in more expensive printers

• Materials: Commonly PLA, PETG, ABS, ASA, PP, PC, with various color and admixture options like carbon, wood, metal, and glass fibers

• Surface Quality: Fine surface texture, with modern filaments minimizing layer lines.

• Printing Time: Depends on volume; a 40 mm cube can be printed in under an hour.

SLA Printing:

• Resolution: Smallest detail around 0.03 mm (30 to 140 microns), depending on the printer

• Max Size: Varies widely; common models around 127×80×150 mm, with some up to 900 mm

• Temperature Resistance: 40°C to 150°C, with specialist materials up to 500°C

• Materials: Wide range of resins, typically limited in color (black, white, gray) and harder to switch materials

• Surface Quality: Near-mirror finish with invisible layer lines

• Printing Time: Depends on Product height. Consistent across products; around 2-3 seconds per layer. Product availability after printing is extended by the need for a washing and curing process.

MJF Printing:

• Resolution: 0.08mm to 0.5 mm (80 to 500 microns).

• Max Size: 284 mm x 380 mm x 380 mm

• Temperature Resistance: 95°C to 175°C for Nylon 12

• Materials: Nylon 11, Nylon 12, Nylon 12 with glass beads, polypropylene

• Surface Quality: Fine matte texture; no glossy finish

• Printing Time: Generally fast; can produce functional parts in as little as one day, including post-processing

Conclusions

Each 3D printing technology has its strengths and weaknesses. Here's a summary:

• Cost: FDM is the least expensive, followed by SLA, then MJF.

• Material Range: FDM offers the widest variety of colors and materials, making it the most adaptable.

• Surface Quality: SLA offers the best surface quality, followed by MJF, with FDM having the most visible surface defects.

• Physical Characteristics: FDM provides the widest range of material properties. MJF parts are strong but less flexible, while SLA excels in fine details.

• Max Size: FDM can print very large items with custom-built printers, unlike SLA and MJF.

• Printing Time: FDM varies by product volume and can be very fast; SLA varies by product height; MJF is typically fast and consistent.

• Overall product availability: FDM prints may be available for delivery immediately after printing, with added time needed only when supports need to be removed. SLA and MJF both incur an extended delay after printing due to a requirement for post processing to clean and cure the products.

Strengths by Technology:

• FDM: Flexible with a wide variety of materials and faster production times, ideal for large items and cost-effective setups. Least cost setup leads to a lower overall cost to the end customer.

• SLA: Superior surface finish and fine resolution, minimal material wastage due to lack of supports.

• MJF: No need for supports, offering design freedom and strong, isotropic parts with consistent mechanical properties.

Each technology has unique advantages, so choose the one that best fits your specific project requirements and budget.

We at Christchurch Technical 3D Printing Services offer exclusively FDM/FFF technology. Our costing includes supports when they are required. We offer a wide range of available materials including colours and Carbon Fibre filled materials. Our printers currently have a maximum size limit of 250 mm x 205 mm x 210 mm and a resolution of up to ~0.1 mm. Surface finishes range from Glossy to fine Matt. Due to variance of client products, each project is individually quoted.