Why Choose SLS?
ULTIMATE 3D in 2024: Pioneering 3D Printing Excellence
As pioneers in the 3D printing industry, we’re always looking for ways to deliver the best possible products and services. Today, we want to spotlight the superior benefits of Selective Laser Sintering (SLS) 3D printing technology, especially when compared to other methods like Multi Jet Fusion (MJF).
Why Choose SLS?
Material Versatility: SLS supports a broader range of materials, including high-performance thermoplastics, allowing for more diverse applications.(see datasheets below)
Color Customization: Unlike MJF parts which are typically printed in black, SLS parts can be dyed in a variety of colors, offering greater flexibility for aesthetic customization.
Complex Geometries: SLS excels at producing intricate designs and complex geometries that are challenging for other manufacturing methods.
High Durability: Parts made with SLS are known for their robustness, making them ideal for functional prototypes and end-use components.
SLS vs. MJF: SLS is the clear choice, while MJF is a newer technology with its own merits, SLS has stood the test of time, offering:
Proven Reliability: With decades of successful applications, SLS is a tried-and-true method that you can trust for your most critical projects.
Cost-Effectiveness: SLS is generally more cost-effective for producing medium-sized functional parts and visual prototypes.
Join the SLS Revolution We invite you to experience the SLS difference. Whether you’re looking to create durable parts, intricate designs,or colorful prototypes, our SLS 3D printing services are here to turn your visions into reality.
Let’s build the future together with SLS 3D printing. Contact us to explore how our services can benefit your next project.
Connect with Us:
- Call us at (503)-848-8227
- Email us at info@ult3d.hookdm.net
Let’s explore how our SLS process can best meet your needs. Together, we’ll shape the future of 3D printing! 🚀🔧🌟
Ultimate 3D now offers TPE Material in SLS
Thermoplastic Elastomers (TPEs) and Selective Laser Sintering (SLS) 3D printing can be a powerful combination, offering several benefits. Here's an outline of the advantages of using TPE with SLS 3D printing:
- Material Flexibility:
- TPEs are known for their flexibility and elasticity, making them suitable for applications that require rubber-like properties.
- SLS 3D printing allows for the creation of intricate and complex geometries, enhancing the design flexibility of TPE-based parts.
- Durable and Tough Parts:
- TPE materials exhibit excellent toughness and durability, providing resilience against impact and wear.
- SLS produces strong and durable parts by sintering successive layers of powder, ensuring that TPE-based components maintain their mechanical properties.
- Complex Geometries:
- SLS is capable of producing complex and intricate designs without the need for support structures, enabling the fabrication of TPE parts with intricate features.
- Prototyping and Low-Volume Production:
- TPEs are suitable for prototyping due to their flexibility and ease of iteration in design.
- SLS is well-suited for low-volume production runs, making it cost-effective for small batches of TPE parts.
- Customization and Personalization:
- TPE materials can be tailored to specific hardness levels, allowing for the customization of the mechanical properties of printed parts.
- SLS enables the production of customized and personalized parts, making it ideal for applications where individualized solutions are required.
- Reduced Tooling Costs:
- Unlike traditional manufacturing methods that often require expensive molds and tooling, SLS 3D printing eliminates the need for such tools, reducing upfront costs.
- TPEs in SLS can be used without the need for additional processing steps, further streamlining the production process.
- Material Efficiency:
- SLS is an additive manufacturing process that generates minimal waste as unused powder can be recycled.
- TPE powders used in SLS can be efficiently utilized, contributing to a more sustainable and cost-effective manufacturing process.
- Time Efficiency:
- SLS 3D printing is a relatively fast process, allowing for the rapid production of TPE parts.
- The layer-by-layer additive nature of SLS eliminates the need for traditional tooling, reducing lead times compared to traditional manufacturing methods.
- Applications in Various Industries:
- The combination of TPEs and SLS opens up possibilities for applications in industries such as automotive, consumer goods, medical devices, and more, where flexible and durable components are required.
By leveraging the benefits of TPEs with SLS 3D printing, manufacturers can produce functional and customized parts with enhanced design freedom and cost-effectiveness.
To learn more about how TPE can best suit your needs call us (503)-848-8227, or email us at info@ult3d.hookdm.net. We are happy to discuss and explore how the SLS process can best meet your needs with TPE’s exceptional flexibility.
UL 94 / V-0 SLS Material for your projects!
So, we wrote about this a couple of months ago and it is catching on!
We now have a Nylon 12 that is UL 94 / V-0 certified for your electronic enclosures and holders.
The material properties are similar to Nylon12, we can provide a material datasheet upon request.
We just finished an order for one of our customers that consisted of 1036 parts in the PA 2210-FR, the parts were fairly small, but we were able to hold +/_ .004" using sample testing.
We have the ability to handle large orders and maintain consistency throughout the production run.
Over the years we have received request for a UL 94 material, but until recent it was not available for SLS in the United States.
Contact us, we would love to discuss your project and help you achieve your goals!
Call us 503-848-8227 or email us info@ult3d.hookdm.net or visit our website ult3d.hookdm.net to start the conversation.
3D Printing for a world on fire!
OK, so I don't think we will be in the business of printing bomb shelters, given the current events, it may not be a bad idea though!
In SLS we have had "fire retardant" materials that meet FAA's FAR 25.853 burn requirements. This has allowed us opportunity to print parts for the aviation world but have had to turn away projects for electronic equipment that required the UL 94 / V-0 certification.
We now have in-house a "fire retardant" that is not only FAR 25.853 certified, but also UL 94 / V-0 certified.
The material has been in use in Europe for some time now, but the manufacturer had not brought it to the US market.
Thanks to a persistent local customer that was determined to 3D print their parts in this UL 94 / V-0 certified material, together we were able to convince the powder manufacturer to make it available here in the states.
We have successfully qualified the material on our machine and ran the first production run for our local customer. The finish is somewhat smoother than straight up Nylon 12 and the parts measure well within spec.
If you have a project that must meet UL 94 approval and need production 3D printed parts, give us a call to discuss your project. We are capable of meeting small to medium sized production runs and can meet strict delivery dates.
Email ( info@ult3d.hookdm.net ) or call us (503-848-8227) we will gladly share the material data sheet with you.
We look forward to partnering with you,
Ultimate 3D!
Ultimate 3d-Changing how we price lower quantity part runs!
At Ultimate 3D we excel at large production runs. As a result, we compete with injection molding prices when you amortize the tooling into the mix.
We have come to realize that our pricing structure is inhibitive to the onesie, twosie quantities. Hence, we have restructured how we price your parts.
That said, if you have sent us parts to quote for small quantity runs and prototypes and found our price to be slightly too high, give us another shot at your projects!
With 1 week or less lead times, you have your parts in hand very fast. Put us to the test and see why we are an industry leader when it comes to customer service and competitive pricing.
Email us your files, tell us how many parts you want pricing for and which material you prefer. Include your contact info so we can give you a call to discuss how we can best serve your project needs!
Giving you something to Dance about!
Our mission is to provide 3D printing customers with extraordinary products and services from a team that loves doing their job. We want people to be excited about 3D printing with us.
WHAT WE DO
Rapid Prototyping: Once your CAD file is ready, we will usually print your parts in 1 week or less.
(Higher volume orders may require extra time).
We specialize in high quantity production parts and are very competitive with injection molding on lower volumes. Consequently, it is possible to make thousands a part faster and lower priced than injection molding.
We print parts that are impossible to injection mold.
We gladly review all models for printability and cost effectiveness and give constructive feedback for your benefit.
Ultimate 3D now Finishing 3D Printed Parts
Finishing 3D Printed Parts
We have teamed up with a world class Painter/Finisher to help bring your prototype and production parts to life. Finishing 3D printed price.
We offer a full spectrum of colors, once the color is decided you can chose a finish from Flat to Full Gloss finishes.
Your parts are sanded smooth, then filler primer is applied. At this point the parts are wet sanded. Then the color of choice is sprayed on. Once the color is on, a clear coat is applied in the desired finish (Flat to Full Gloss).
If you have a proof-of-concept project that you need in a hurry, we can print the parts in a week. They painted in a matter of days and shipped to you overnight!
The project below was printed in our SLS machines using Nylon 12 material. The parts also received 2mm heat staked threaded inserts for assembly purposes.
Our mission is to provide 3D printing customers with extraordinary products and services from a team that loves doing their job. We want people to be excited about 3D printing with us.
WHAT WE DO
It is called “rapid prototyping” for a good reason. Once your CAD file ready, we will usually print your parts within three to four days – faster if necessary.
(Higher volume orders may require extra time).
We specialize in high quantity production parts and are very competitive with injection molding on lower volumes. It is possible to make thousands of one part faster and lower priced than injection molding when you amortize the cost of tooling into the part cost in many cases.
We can print parts that cannot be injection molded, due to under-cuts, hollows, holes on an angle and complex geometries.
We gladly review all models for printability and cost effectiveness and give constructive feedback for your benefit.
Ultimate 3D Has Expanded
Our New Prodways P4000X printer has arrived and is up and running!
What does this mean for you? It means we can print twice as many parts keeping
our outstanding lead-time to 1 week or less.
From the beginning we have situated ourselves to be your number one supplier of 3D Printed parts, this is our way of staying at the top of your supplier list.
Our mission is to provide 3D printing customers with extraordinary products and services from a team that loves doing their job. We want people to be excited about 3D printing with us.
It is called “rapid prototyping” for a good reason. If you have your Cad file ready, we will usually print your parts within three to four days – faster if necessary.
(Higher volume orders may require extra time).
We specialize in high quantity production parts and are very competitive with injection molding on lower volumes. We can make thousands of one part and are faster and lower priced than injection molding when you amortize the cost of tooling into the part cost in many cases.
We can print parts that cannot be injection molded, due to under cuts, hollows, holes on an angle, complex geometries.
We gladly review all models for printability and cost effectiveness and give constructive feedback for your benefit.
Do you create CAD models?
While we have extensive experience and understand CAD, it is not the focus of our business. However, if you have the need for design work, several of our customers are also designers that we recommend for such services. If you have a model you need someone to look over to make sure it’s fit for printing, we can definitely do that and make suggestions when needed.
Can you print in color?
We don’t print with colored materials, but we can dye the finished products a variety of colors. We can also paint parts and apply hydrographic patterns.
What materials do you use?
Our standard material is Nylon 12, with composite variations.
Nylon 12 (durable white plastic)
Glass-filled nylon
Carbon fiber-filled nylon
Fire retardant nylon
Alumide (Aluminum filled Nylon)
* For more detailed information about our materials, check out the data sheets on our website – ult3d.hookdm.net
If you have a project that requires 3D Printing give us a call at 503-848-8227 we will gladly discuss the options for your project. Pricing will be determined after evaluation of each project. Prior to calling, email your models to quotes@ult3d.hookdm.net so we can look at them while we talk!
We are a friendly bunch and genuinely want to help!
Address: 5575 SE Alexander St, Hillsboro, OR 97123 (click to map it)
Ultimate 3D now printing with ALUMIDE
Alumide is a material used in 3D printing consisting of nylon filled with aluminum particles, its name being a combination of the words aluminum and polymide.
The aluminum in the plastic creates a unique feel and look. Your part will have a slight "sparkle" to it in a grey metallic tint. The aluminum makes it easier to "polish" the part, not a shiny polish, but a very smooth polish. We have wet sanded the material with 800 grit paper to get an almost glass feel.
The surfaces of Alumide parts can be refined very easily by grinding, polishing or coating. The machining of Alumide laser-sintered parts is simplified through the cut breaking effect of the aluminium filling.
- excellent dimensional accuracy
- well-balanced ratio of density and stiffness
- increased thermal conductivity good machinability
Applications
- Manufacture of stiff parts of metallic appearance for applications in automotive manufacture (e.g. wind tunnel tests or parts that are not safety-relevant)
- Tool inserts for injecting and moulding small production runs
- Illustrative models (metallic appearance)
- Education and jig manufacture
Alumide can also be dyed different colors. The Polymide takes on the color, while the Aluminum adds contrast.
Alumide is finding it's way into many segments of the industry for 3D printed parts, it is very strong and has a higher heat deflection than most other Nylons and filled Nylons.
If you have a part that you believe would benefit from the characteristics of Alumide, email your file(s) to quotes@ult3d.hookdm.net and we will work up a quote within an hour.
We specialize in high quantity production parts and are very competitive with injection molding on lower volumes. We can make thousands of one part and are faster and lower priced than injection molding when you amortize the cost of tooling into the part cost in many cases.
We can print parts that cannot be injection molded, due to under cuts, hollows, holes on an angle, complex geometries.
We gladly review all models for printability and cost effectiveness and give constructive feedback for your benefit.
Office Phone
503-848-8227
Quotes: quotes@ult3d.hookdm.net
Questions: info@ult3d.hookdm.net
Hydrographic Print Finishes
The Team at Ultimate 3 D are now offering Hydrographic Print Finishes!
If you have a project that requires a custom finish we now offer hydrographic prints from TWN Industries.
We have taken on the task to learn and implement this discipline into our mix of finishes which include:
Dyeing parts – Black, Red, Blue, Green, Yellow, Orange, Purple and fucsia.
Painting parts – most any color available at a quality paint store.
Among the many Hydrographic prints available, Carbon Fiber is the most requested, first we dye the part black, then take the part thru the “dipping” process to adhere the Carbon pattern to the part. Once dry the part is coated with either a Matte Clear or a Gloss Clear, your choice. Our opinion is that the matte clear gives the most Carbon Fiber like look.
Below are a few of the patterns available from TWN Industries.
For a more exhaustive list please visit http://www.watertransferprinting.com/film-gallery .
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A Couple Of Quadcopter Parts Before And After:
A Prosthetic Finger with 527-Cork pattern applied.
Pricing will depend and the size of the part and the complexity of the shape. The minimum per part will be $50 and going up from there after evaluating the project.
Visit the TWN gallery: http://www.watertransferprinting.com/film-gallery , tell us which pattern you desire when you submit your model for a 3D Print quotation, we will quote your part with and without the pattern,
There are few companies that offer this service and we are proud to be counted amongst the few and to stand out not just for our excellent 3D printing capabilities, but also for our unique finishing abilities!
Submit quotes to info@ult3d.hookdm.net then give us a call, we will be happy to discuss your project with you!
Ultimate 3D Open House
A little over a year ago we became Ultimate 3D LLC, in celebration we want to throw a party and you are invited!
Please RSVP at info@ult3d.hookdm.net so we know how many to plan for.
Many have already committed, but we don"t want anyone left out! We will have locally grown grass fed hamburger and all the fixin"s and a tour of the facility!
Meet the crew: Robin and Patty, Tom and Tammy, Mike and Julie.
Our Mascot online casino will be here too!
Here are the details!
Everyone is welcome to show up anytime after 11:30 with lunch provided at noon. You will see where and how your parts are created, we may even have a build scheduled to change out during that time so you can see what a fun mess this process is.
For those that ride and want to explore some really cool and obscure roads west of Portland, Robin, Mike & Tom will lead a 2-3 hour ride. We will leave the shop at 8:30 am returning between 11:00 - 11:30. So be here at by 8:00 or soon after so we can go over some of the particulars of the ride.
What to bring: your appetite and questions and if you ride, bring your motorcycle.
Please RSVP info@ult3d.hookdm.net so we know how many to prepare for and let us know if you plan to be here for the ride.
Address: 5575 SE Alexander St, Hillsboro, OR 97123 (click to map it)
If you have a project that requires 3D Printing or if you are not sure if your project can be 3D printed, give us a call 503-848-8227 we will gladly discuss your project and help point you in the right direction. Prior to calling email your models to quote@ult3d.hookdm.net so we can look at them while we talk!
We are friendly and genuinely want to help!
Ultimate 3D is proud to sponsor Palatov Motorsports as they take on Heavy Hitters for another win in this year’s Pike’s Peak International Hill Climb
The Ultimate 3D team has a history and love for racing, so we’re excited to sponsor Palotov Motorsport as they once again take on the challenge Pike’s Peak International Hill Climb on June 28, 2015.
Also known as “The Race to the Clouds,” The Pike’s Peak International Hill Climb is an annual race to the summit of Colorado’s renowned Pike’s Peak. Since 1916, cars and motorcycles have gathered to race 12.4 miles to ascend nearly 15,000 feet along a route that includes more than 150 turns. This race is the third oldest motorsport event in the Western Hemisphere, after the Indianapolis 500 and the Isle of Man TT.
The Pike’s Peak IHC is a unique and exciting race, known for its highly skilled drivers and innovative engineering used to push the limits in this steep, uphill race. To support Palotov, Ultimate 3D created custom wing ribs for the uniquely designed Palatov D2RS. The wing ribs were made with carbon fiber filled nylon and bonded into a carbon fiber wing assembly.
Here is an excerpt from Palatov Motorsports referring to the use of Ultimate 3D’s parts.
“I designed the parts in SolidWorks and made sure everything fits in the virtual world. The angles are very odd and there is no good way for me to machine or otherwise fabricate the needed shapes. Perfect job for 3D printing though, where there is no need to be constrained in shape by manufacturability. I've been talking to Robin at Ultimate3D about doing something for our cars and this was the right opportunity. He was eager to demonstrate what they can do. So I sent the files yesterday and this morning we have the parts - printed in carbon-reinforced nylon."
"These are basically wing ribs and endcaps combined. Their purpose is to locate the wing skins in space, attach them structurally to the steel tubular spars, and define the overall shape of the wings. In case that wasn't enough, the parts also serve as mounting surfaces for the endplates, with holes for helicoils designed in from the start.” -Dennis Palatov
The D2RS, designed specifically for the hill climb competition and driven by Jonathan Frost, is currently entered in the Pikes Peak Open Division and will be competing against heavy hitters like Honda Performance Development's ARX-04b LMP2 coupe for the overall win. Palotov Racing won the Pikes Peak International Hill Climb Unlimited Class in 2012, and on June 28th, we’re stoked to see this local car builder go for another win against larger factory teams.
Ultimate 3D is looking forward to continuing to build relationships with other companies in the racing sector and beyond. In addition to sponsoring Palatov racing, Ultimate 3D has made parts for Andretti Auto Sports, which races in the IndyCar series and includes the Indianapolis 500. One day we hope to make parts that are used in Isle of Man TT races, the UK’s unparalleled motorcycle race along a 37-mile open road mountain course and some of the best riders in the world.
Please stay tuned as next week we will be posting the results of Palatov’s efforts from this weekend.
3D Printing Assemblies no assembly required!
As 3D printing becomes more prevalent in the manufacturing arena and as we continue to master the art, new doors open and new ways of thinking emerge.
Designers and engineers can create assemblies with fewer nuts and bolts, fewer items on a bill of materials and fewer steps to a finished product.
Think about the savings in managing inventory control!
First example of a printed assembly: Ultimate 3D"s Engineering card
While it is not a practical product, it is a great way to show off the technology and what can be accomplished when design is incorporated with 3d printing.
Notice the crankshaft, connecting rod and piston attached to the gear. Then notice the handle on the far right attached to another gear.
When the card is folded a the hinge between the two gears, they mesh and are held together by the strap that snaps into the rectangle hole.
Now when the handle is turned the crankshaft spins moving the piston inside the cylinder.
By the way, we will be glad to send you one of these really cool Engineering card if you will send us an email info@ult3d.hookdm.net and put in the subject line: "Send me an Engineering Card" along with the shipping address and we will pop one into UPS for you to play with and show your friends.
With the right amount of clearance, you can put most any parts together and have them function as an assembled part, minus the assembling part! This is tricky due to the amount of variables involved, but lucky for you we have a great deal of experience in this area of 3d printing and can give you great advice as to the functionality of your design.
Examples of what can be done and what we have seen done are as follows:
Hinges (most basic)
Shafts in bushings
Butterfly valves inside of tubing
Destaco Clamps
Cable management inside of a housing
Chains
Clasp
Constant velocity shaft joints
Tracks for a robot
Ferris Wheels
Prosthetic"s
Crescent Wrench
And the list goes on and with your help and creativity it will continue to grow.
We are here to assist you in your design and prototype, and remember we are perfectly priced for low volume production.
Give us a call when you are ready to explore 3d printing your creation! 503-848-8227
Keys to a Cost effective 3D Printed Project
Often we receive models that are bulky and rather large. Take the Sioux Falls Cathedral for instance, a great architectural piece.
- Sioux Falls Cathedral
The bounding box is 141mm x 183mm x 189mm tall, with a solid volume of 1283 cubic centimeters. As is, this will not be a cost effective 3D printed project as a solid, given the volume of powder that is Selective Laser Sintered to make the part.
- SFCathedral Solid
Upon receiving this model, the question was asked; can this be Hollow?
At Ultimate 3D we have CAD software that allows us to hollow a part and create holes to remove the loose Nylon powder from inside the shell.
Once hollowed…………………………………………………….
- SFCathedral Hollow
The bounding box measurements remain the same, but the volume is now 299 cubic centimeters. This is ¼ the volumetric value of the 3D printed solid part.
What does this mean for price?
At Ultimate 3D we quote a part based on the volume of actual Sintered material because we can recycle the unused powder. Meaning the price of the hollow model is ~1/3 the price of the solid model. Volume and price are not on a linear scale.
The walls of the hollowed model are 2mm thick. For our materials, (Nylon 12, Glass Filled Nylon, Carbon Filled Nylon), and process (SLS) the walls are very strong at this thickness.
This principal applies to a variety of product from figurines to fighter jets. If you are uncertain about the possibility of your design being hollowed, send us the file and ask us to price it solid and hollow. Chances are when we look at the model, even if you don’t ask, we will know if it can be hollow or not and ask you if you want a price for both.
Some items however are better solid for the added weight and or added strength (i.e. Trophy Bases, hydroforming dies, etc.).
Ultimate 3D wants you to get the best bang for your buck when it comes to 3D printing so send your CAD files to quotes@ult3d.hookdm.net knowing that we will look out for your best interest when quoting and printing your parts.
Reaching New Heights: 3D Printing in Aerospace & Why it's Catching On
Today, 3D printing is streamlining processes in companies of all sizes, with particular prominence in the automotive, aerospace, medical, and defense sectors. In this post we will focus on 3D printing in aerospace, including how and why the technology has gained so much traction in the sector.
Why doesn’t aerospace just stick to traditional manufacturing of its components? For one, 3D printing reduces material waste and fuel emissions, so that’s a big plus especially in an age when everyone wants to build smarter. In addition, additive manufacturing reduces lead times and streamlines production cycles.
3D Printed Replacement Parts
Let’s dive into some examples. During the lifetime of an aircraft, it’s likely that parts will need to be replaced. Traditionally, aircraft manufacturers keep an inventory of parts to meet demand for replacements. However, companies in need of replacement parts may not want to wait as long as it typically takes for them to arrive, so they keep an inventory in-house, solving one problem but sometimes creating a new challenge in the form of storing and managing all of those parts—before they even need them. In this scenario, 3D printing can reduce the time it takes to get replacement parts, without having to keep extra inventory on hand.
As of March 2015, Boeing has already installed more than 20,000 plastic 3D printed parts in its airplanes. To give just one example, selective laser sintering has been used to create about 150 separate parts for the forward fuselage of Boeing’s F/A-18 Super Hornet.
Boeing proactively incorporates 3D printed parts into many of its vehicles, so much that the company is now trying to patent a whole system for 3D printed replacement aircraft parts, including everything from a parts library and management system to 3D printing itself. The proposed system is simply titled, “Three Dimensional Printing of Parts.”
Original aerospace components made with additive manufacturing
Over the years, we’ve seen numerous examples of 3D printed aerospace parts, and some major aerospace companies have taken the technology into their own hands and implemented in-house 3D printing facilities. GE has built an additive manufacturing facility to make 3D printed nozzles for advanced LEAP jet engines.
Another big hitter, Rolls-Royce plans to flight test the largest 3D printed aircraft engine component (for the Trent XWB-97 engine). This titanium component, 1.5 meters in diameter and half a meter thick, is 3D printed using Arcam’s electron beam melting technology, which makes dense components from metal powder.
Rocket engines & the first flight-qualified ALM component
Aerojet Rocketdyne, a Sacramento, California-based manufacturer, has recently announced test firings of 3D printed rocket engine parts. Its goal is to have a certified AR1 engine (an American-made thrust-class liquid oxygen/kerosene booster engine) in production by 2019.
Meanwhile, UK defense manufacturer AirBus Defence and Space spent two years on R&D for space-qualified satellite components. 3D printing with an aluminum alloy, AirBus created a structural bracket for Eurostar E3000 telecommunications satellites. The bracket mounts telemetry and telecommand antennas on the satellites. Made with traditional manufacturing, the original design is composed of four separate parts and 44 rivets, while the new 3D printed bracket, qualified to launch with the next E3000 satellite, is 40% stiffer and 35% lighter. AirBus is now considering 3D printing a variety of other aerospace parts and secondary structures.
While end-use 3D printing for aircraft is in full swing for some manufacturers, among other aerospace companies, additive manufacturing is simply being used to save time and money on prototyping before reaching the desired future scalability. By significantly reducing production time, additive manufacturing opens up a whole new range of possibilities for countless firms. According to Alan Newby, Rolls-Royce chief engineer for future programs and technology, “Shortening the manufacturing time by almost a third gives us more time to design, which is always a benefit. We are also able to produce designs that we wouldn’t otherwise be able to do.”
As the aerospace sector evolves to integrate with additive manufacturing technology, it seems that even the sky isn’t the limit. We look forward to seeing how manufacturers continue to adopt 3D printing in aerospace, in turn changing the way we approach design and explore the world.
Comparing SLS (Selective Laser Sintering) with injection molding
Before you manufacture anything, you need to decide two major things:
- What material(s) your product will be made of.
- How to manufacture it.
This post will contrast injection molding and 3D printing, specifically looking at the costs associated with each. As a common 3D production method, we're using selective laser sintering as our example.
If you want to build something out of nylon, there are a couple of popular options.
Injection molding is the process of filling the cavity of a mold with molten nylon or other material. The nylon comes in the form of beads that are typically a couple millimeters in diameter. The beads are poured into a hopper that feeds them into a heating chamber that uses an auger to move the heating beads, which are in the process of melting, to the injector(s). The injectors fill the mold. When the mold is cool enough it is split open to remove the product.
The costs involved with injection molding are based on the material and equipment used, along with the creation of the mold. The largest chunk of the cost comes from producing the mold. This is because the mold needs to be milled, typically with expensive CNC equipment to get the most accurate result. Because of the large initial cost of injection molding there is also a high cost associated with a product that is not going to be produced in mass quantities. Typically, you’ll need quantities in the tens of thousands, if not hundreds of thousands, to offset molding costs and have a good return on investment.
3D printing with SLS (selective laser sintering), on the other hand, involves using a CAD file to communicate with the 3D printer software, then adding the required material to the tool. The material, in powder form, is evenly spread across the print bed. The laser sinters, or melts, the powder for the designated cross section of a thin layer and then another layer is added. This process is repeated until the entire volume of the build is completed. The build can include many separate parts. Whatever we can fit in the build area, we will, in order to maximize volume efficiency.
3D printing costs are based on the material used, the volume of the part to be printed, and finishing. If a large quantity is requested, such as a few hundred parts, then a discount is applied. Finishing costs are all about labor and materials. For example, if you want it painted, how much does the paint cost and how much time does it take to paint all the parts?
A part with a specific volume that is manufactured with a quantity of 1,000 units to be shipped in less than 5 days will cost approximately $23 per unit using injection molding.
The same part, done by Ultimate 3D using SLS, would cost approximately $3 per unit.
Seven Reasons Businesses Prefer Using 3D Printing for Production
You've probably heard. Many companies have switched over from traditional manufacturing, thrilled about the way 3D printing has streamlined their production processes. But those who are still warming up to 3D printing may have their reservations about how it can be used for end-use parts. Are the materials strong enough to create a durable part? Will the parts look professional? Is it really cost-effective? These are good questions to ask since quality and price are central to purchasing decisions.
Today, additive manufacturing, or 3D printing, is an excellent alternative to traditional manufacturing in a variety of situations. You can get durable, professionally finished parts, simplify the design process, gain better control of your inventory, and save a lot of money.
1. Rapid turnaround
Traditional manufacturing is a time-intensive process. Simple molds can often be completed in a few weeks, while more complex molds tend to take several months. On top of that, if you change your design, you have to wait out the tooling process again, which makes it hard to operate flexibly. In a sense, having 3D printing at your service makes you lighter on your feet and quicker to pivot, enabling you to respond to consumer demand, unforeseen market challenges, and technological developments.
2. Comparatively low costs
While 3D printing can absolutely cut costs compared to traditional manufacturing, it’s important to understand how 3D printing saves you money, and that it isn’t always more affordable. It really depends on your needs. The primary ways that you save money with 3D printing are through circumventing tooling costs—making product development significantly more affordable and low volume production a viable option. Depending on the functional use of your product, you may also save money on materials.
In addition, if you end up needing to adjust your product, traditional manufacturing requires that you pay expensive injection molding costs all over again. Using 3D printing for production, you don’t pay to change your product—except for any cost associated with creating a new CAD model of course. You pay for volume, not complexity or variety.
3. Production-grade materials
Obviously, 3D printing would be no good for end-use parts if the materials couldn't withstand normal use and even extreme conditions like high temperatures. That's what makes thermoplastics like nylon so great. Nylon is one of the most popular printing materials for production-level parts because it's strong, flexible, and highly tolerant to heat. You can also use different composites to achieve other product characteristics. For example, carbon-fiber and glass-filled nylon composites are popular among products built with SLS.
4. Highly controlled inventory
Predicting and managing inventory is a major task for any company. Excess inventory can absorb valuable space and capital, while lacking the proper inventory can cost sales and credibility. This is where 3D printing becomes extremely helpful, allowing businesses to control their inventory like never before. 3D printing allows suppliers in numerous industries to order additional parts very quickly, and in specific numbers. In addition to rapid manufacturing and custom order quantities, 3D printing enables companies to redesign or change their parts spontaneously, based on market needs.
5. Flexible volume
Most of the time, in order to have tooling done for your product, companies set specific volume requirements before they will make your molds. And it makes sense. Every business sector has to determine how to maintain their desired profitability based on their own technology and labor. The setback for designers and innovators is that they’re sometimes required to order a significantly higher volume of product than they need. They will certainly hope to sell all that product to make it worth the initial cost.
6. Simple or no assembly
Another reason business prefer to use 3D printing for production is that it often eliminates or reduces the need for assembly. Selective laser sintering (SLS) is a 3D printing method that prints objects in powder, creating a reliable support structure that enables parts to be built “inside of each other” without touching. You can imagine how this could eliminate the need for printing and assembling separate parts, instead allowing for the printing of functional products. Some fun and impressive examples include the 3D-printed cube with 28 working gears, and the fully assembled wind-up car, both printed using selective laser sintering and requiring no assembly at all. Whether you escape assembly altogether or simply create stronger designs with fewer pieces, designing for 3D printing is unique and opens up a world of experimentation and new possibilities in product development.
7. Domestic Production
People love to buy local products. If your product is affordable and made in the USA, this can help create brand loyalty and also give you better communication during the production process. Manufacturing is a totally different game when you can do it yourself or call up your manufacturer with questions and insights.
As you can see, 3D printing has created some amazing possibilities in the realm of manufacturing, making it an excellent alternative not only for prototypes but also for final production. If you have any questions about the technology or if 3D printing is right for your project, call us up and we’ll gladly give you a free consultation.
Happy printing,
3D Printing with Nylon: Why we love it, and you should too
As many of you may already know, nylon is a thermoplastic. If you're 3D printing with nylon materials, you're either using a powder that hardens into durable plastic when melted by a laser, or you're using a plastic filament that's extruded through a nozzle. Nylon has unique properties that make it a preferable material to print with in many cases.
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Why should you print with nylon?
Compared to other common 3D printing materials, nylon has quite a few advantages, which we will discuss in this post. Whether you’re considering printing your own products, or you want to order products from a third party, this should give you an introductory understanding of 3D printing with nylon.
Nylon is a thermoplastic, which allows it to be reused—whether printing via FDM or SLS. In an FDM context, the plastic can be melted and re-melted. However, the properties will change with heat and begin to break down. Most of the excess powder from SLS can be reused. Reusing nylon in the context of selective laser sintering means recycling the unaffected powder and mixing it proportionately with virgin powder to ensure that the materials continually perform their best during the build process.
We’ve made a basic list of the benefits of nylon in 3D printing. If you have any questions about these benefits or other properties of nylon, feel free to call or email us with your questions.
Benefits of 3D printing with nylon:
- 3D printing with nylon makes a much stronger part, if your other variables are correct.
- You’ll get better pliability with nylon, which can make for a more functional part.
- Typical nylon parts can be drilled, tapped, and tumbled without risking breaking or scratching the parts (unless they have incredibly thin details or appendages, in which case you want to handle parts carefully). This allows you to explore different finishing and assembly options with a low risk of breaking or damaging parts.
- Nylon is lightweight compared to many other traditional materials.
- Nylon is relatively absorbent, so dying parts printed with nylon works very well because a scratch won’t ruin the exterior. However, this also means if you print something like a coffee cup in nylon, it can end up stained unless you give it a protective finish.
- Nylon can be reused for 3D printing, which looks different depending on the type of 3D printing you’re doing.
Printing with nylon will be different depending on the method—be it selective laser sintering or fused deposition modeling. However, most of the benefits are the same, to different degrees. Keep in mind that different 3D printing technologies have different strengths and limitations, regardless of the printing material.
Pro tip! Nylon easily absorbs water from the air, so it needs to be kept in a dry storage environment.
Anything you love about printing with nylon that we didn't mention? Share in the comments below!
3D Printing Takes the Stage: How 3D printing is used today in theater & movies
Every day, it seems a new industry is experimenting with 3D printing, whether it’s to save time and money, or to simply have fun pushing the limits with a new technology. We’ve seen 3D printing in architecture, both in architectural models and in real world building applications. We’ve seen 3D printed prosthetics and medical innovations, and the technology has even entered the fashion world. Lately we’ve been studying the ways 3D printing is being used in movies and theater, and it’s awesome.
3D printing for theater has actually been happening for several years and has become more common as the technology advances, making it more affordable.
How is 3d printing being used in theater?
One of the most popular applications of 3D printing in theater is prototyping for sets. You can see the work of scenic designers like Kacie Hultgren who showcases her products on Pretty Small Things. Scenic designers will print their own miniature props to visualize how a finished set will look. After creating a scaled down model of a custom set, they then have something tangible to present to directors and set builders who make the final full-size furniture and props.
3D printing for movies
We got particularly excited when we learned about how special effects studio Legacy Effects uses 3D printing to create life-size prototypes of popular movie costumes and props for major films like Pacific Rim and Iron Man. Everything from monsters and aliens to superheroes and soldiers have been created digitally and 3D printed, saving weeks and even months of time that would otherwise be spent handcrafting props. Talk about a dream job!—to decide how to bring imagined characters into reality, and deciding how they will look and move.
A notable challenge with 3D printing props is knowing when it will save you time and when it will cost you. Complex 3D assemblies, if only created for a single prop, could end up taking more time than creating something out of clay or another standard material—although 3D printing might be more fun.
To outsource, or not to outsource?
As we consider the possibilities that 3D printing creates for different industries, time is a factor in deciding if the technology will be helpful or not. 3D printing in-house and outsourcing 3D printing services both have their advantages and disadvantages for a company using the service on a regular basis. While you have more direct control and supervision of in-house 3D printing, and you can probably come to understand the technology more intimately, it’s also time consuming to learn the technology and deal with the hiccups. You don’t simply buy a 3D printer, scan a model, and hit print. You must take your time learning the functionality to get the most out of the tech, and you can almost bet you’ll be dealing with some unexpected challenges.
If you hire an outside company to 3D print parts, you save a lot of time and gray hair on learning and troubleshooting the technology. You can trust a good 3D printing company to give you the professional parts you want, though you might also end up spending more money, and you don’t get to play with the machines.
A great time to hire an outside company is if you want a more professional part than a consumer-grade printer like the Makerbot will create. SLS, which we do at Ultimate 3D, is a sophisticated 3D printing technology that creates parts with a nicer finish and far more durable material than FDM, which uses filament. So for prototypes, you might be golden with a mid-level 3D printer, but for something that can withstand some more wear and tear, like a prop for final production, you might look to a company with a high-grade 3D printer.
Kickstarter Fuels 3D Printing Innovation
If you’re someone who keeps your eye on Kickstarter projects, you’ve probably noticed that people are constantly innovating in the 3D printing industry, especially on the consumer level. We’re excited to live in a world where people support each other’s ideas and help bring them to life, and one place this happens every day is Kickstarter.
Over the past few years, we’ve seen designers working to improve the home 3D printer on a variety of levels—on price, aesthetic, and material uses. Many people who work in design fields have found that common consumer-grade printers just don’t cut it when they want to make professional-looking 3D prototypes.
While even the nicest of the smaller extruder-style printers are rough compared to professional-grade 3D printers, there are noticeable aesthetic differences among consumer machines when it comes to precision and “resolution,” or how noticeable the layer lines are. As consumer technology evolves, designers are able to print better products at home and in their workspaces, which makes it a lot more fun.
People have been experimenting with some pretty cool features! Take the FLUX All-in-One 3D Printer, created in San Francisco, California. The unique printer was successfully funded last December, raising about 10 times more than its goal. This FDM printer makes a better finished part than most of its consumer predecessors and also does 3D scanning and laser engraving. Props for mixing it up, and with a sleek design to boot.
The Peachy Printer, funded in 2013, also received more than ten times its funding goal as the world’s first 3D printer for $100, small enough to hold in one hand. This little guy, designed by an innovator in Saskatchewan, Canada got a lot of press! While it’s capabilities are naturally limited by its caliber, it’s a great example of what innovators can do when they think outside the box to make 3D printing accessible to the masses, even if only for the sake of having fun with the technology.
Kickstarter is loaded with other innovations in the 3D printing sphere, not just 3D printers. Hopeful creators are seeking crowd funding for all sorts of 3D projects, including eco-friendly filament for FDM printers, electrically conductive PLA filament, online marketplaces for 3D files, and plug-and-play 3D printing devices that address many of the issues beginning designers face.
What about you? How would you change or improve the 3D printing industry? What are some of your favorite 3D printing innovations?
Feel free to let us know in the comments!
From our 3D Workshop: Motorbike inventions
As a 3D printing company, we’d be crazy not to bring some of our own designs into reality. As humans, we’re continually encountering challenges in the way we live, work, travel, everything. You might have noticed innovation is one of our core values, and we put it to work devising solutions for all sorts of applications.
A few us frequently ride motorcycles and dirt bikes, and Ultimate 3D co-owner Mike Larkin has designed a variety of products to improve the riding experience. He started with a cell phone holder that can be mounted to the handlebars of a motorcycle, allowing him to record video of the ride or easily snap a photo without digging around for his phone. This device was printed using SLS then dyed.
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Next, Mike created a solution for a dirt bike with a smaller gas tank. The original design is a simple reserve tank that mounts to the front of the bike and extends the fuel capacity by one gallon. Also printed using SLS, Mike mounted this tank to his two-stroke Yamaha YZ 250, which he often rides through the trails and backwoods of Oregon, including Bend, Newport, Pacific City, and beyond. Instead of running out of gas alongside riders who have larger fuel capacity on their bikes, Mike now rides as free as a bird, even ending his runs with extra fuel. A little innovation goes a long way.
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What would you make if you could create any product to make your life better? Let us know in the comments!
Want to know some of the best places to ride dirt bikes in Oregon? Try China Hat, Millikan Valley, and Christmas Valley in Bend, Sand Lake in Pacific City, Spin Reel in Newport, Washougal, Portland International Raceway, Browns Camp, and Rogers Camp.