3D Printing Manufacturing

Fathom is a trusted manufacturing partner that has worked with a vast range of industries to provide 3D printing and additive manufacturing service. Fathom offers award-winning expertise, speed, and quality with a focus on accelerated product development and design processes. Fathom can help your team can go from design to 3D printed prototype and then straight into production in a matter of days or weeks instead of months. Work with Fathom and discover how digital manufacturing can benefit your business, revolutionize your workflow, and save you time and money.

What is 3D Printing?

3D printing, also known as additive layer manufacturing, additive manufacturing, or digital manufacturing, starts with a Computer Aided Design (CAD) file or a 3D model. The CAD drawing acts as a set of instructions or blueprints, illustrating all the intricacies of the product. The CAD file instructs the machine where and when to place the material as the part is built from the ground up, layer-by-layer.  

3D printing can produce complex objects that would otherwise be impossible to make with conventional machining methods. Designers and engineers, not hampered by manufacturing restrictions, can improve functionality through increased complexity. 3D printing technology has become incredibly advanced in recent years, allowing Fathom to offer low- to mid-volume production with a variety of materials including metals and plastics. 3D printed parts can be made with the same material used in conventional manufacturing, including plastics and metals. Depending on the type of machine, 3D printed parts can be fully dense and put to immediate use.  

Updating designs or correcting errors is a simple process with digital manufacturing. Changes can quickly be made to the CAD file and sent directly to the 3D printing machine. Making equivalent design changes with conventional manufacturing methods would take weeks or months. These changes can also be expensive since it would require new tooling or machining. In the past, such errors or changes could mean starting over completely. Additive manufacturing will minimize these costly mistakes while allowing for complex designs and reiterative prototyping. 

3D printing has mostly been used for prototyping. Over the last decade, materials have steadily matured to produce production-quality allowing for the manufacturing of end-use parts—a process termed Direct Digital Manufacturing (DDM). New technology and machinery brings 3D printing that much closer to high-volume production. Fathom has entered into an exclusive agreement with Evolve Additive Solutions to present the Evolve Scaled Volume Production (SVP™) system. The Evolve SVP™ is the next generation of 3D printing technology, marrying the speed and design freedom of additive manufacturing with the robust durability of traditional manufacturing. The Evolve SVP™ is the first 3D printing machine to feature the revolutionary Selective Thermoplastic Electrophotographic Process (STEP). The STEP process, like many 3D printers, builds part layer by layer. The Evolve SVP is unique in the way it prints ‘voxels’ or 3D pixels. These voxels are 22-microns thick and can be laid down with extreme accuracy. The printing technology is so precise to can put down voxels of different colors and different materials in one shot. The Evolve SVP™ can print parts with industrial grade plastics that are used to make injection-molded products. The speed and material selection of the Evolve SVP™ means 3D printing can now be used for low- to mid-volume production.

How to Utilize 3D Printing in Manufacturing?

3D printing allows companies to completely change the way they design, produce, plan, and distribute products. Our customers use 3D printing to remain competitive in their industries and to continuously innovate their products.

These companies react much quicker to market changes – taking advantage of new trends or waiting on customer demand to update stock, printing only as many parts as needed. Mass customization, faster times to market, rapid prototyping, and making adjustments early in the development cycle will provide our customers a clear edge over their competitors.

Aerospace and 3D Printing 

Since the late 1980s, the aerospace industry has been using 3D printing to create lightweight components, tooling, functional prototypes, and more. Advances in 3D metal printing now allows for parts made with specialty metals. Printing metal parts eliminates the waste associated with traditional manufacturing while opening the doors to new design possibilities. Direct Metal Laser Sintering (DMLS) can be used to build parts out of titanium, aluminum, and Inconel. Aerospace is just one of many industries that enjoys the benefits of digital manufacturing, including / / 

• Maintenance and Repair / / Metal 3D printed parts can be produced quickly to create replacement parts. 
• Part Consolidation / / 3D printing reduces the number of parts needed and eliminates the need for assembly. 
• Material Efficiency / / Additive manufacturing produces very little waste. Material is only used where needed. Traditional manufacturing like milling or lathing start with a large block of material, cutting away up to 90% during the machining process.  
• Lightweight / / 3D printed parts can be made with metal or plastic. These parts are exceedingly lightweight. Further weight reduction is possible by including internal voids.  
• Low Volume Production / / Small batches of parts can be produced quickly and cost-effectively without the need to invest in expensive tooling or molds.  

Metal 3D Parts In As Soon As 3 Days / / Get A Quote 

Automotive and 3D Printing 

The automotive and aerospace industries share many of the same engineering issues and benefit from 3D printing in similar ways. Additive manufacturing is used by the automotive industry for prototypes, tooling, and parts. There are many benefits of using 3D printing in the automotive industry, including / / 

• Complex Geometries / / Additive manufacturing facilitates the creation of complex car and truck parts. The resulting product is both lightweight and durable. 
• Customization / / Unique parts for both the interior and exterior of a vehicle can easily be made using 3D printing. 
• Flexibility of Design / / Being able to quickly produce parts allows designers to test a concept and make adjustments as needed without the time and expense associated with traditional manufacturing. 
• Rapid Product Development / / Parts can be produced quickly and tested before they are made at a larger volume without the need for expensive tooling or molds. 
• Prototypes / / Companies can produce multiple versions of one design within a short time frame. Design changes are implemented by simply manipulating the CAD file. 

Medical and 3D Printing 

Additive manufacturing has allowed the medical industry to provide patients with an unprecedented level of personalized care. 3D printing gives the medical industry the ability to work rapidly across different applications including / / 

• Implants and Implant Replicas / / Additive manufacturing is paving the way for improved, patient-specific medical care. Implants can now be tailored to a patient’s body. 
• Surgical Tools / / Specialized surgical instruments and medical devices can be quickly and cost-effectively produced with additive manufacturing. 
• Custom-Sized Screws / / 3D printing is ideal for small production runs where material and manufacturing standards must meet stringent quality requirements.  
• Dental Prototypes / / Prototypes and custom tools can be manufactured quickly and profitably. Conventional manufacturing would take weeks to return fixtures that impact quality of life. 
• Prosthetics / / Lightweight, high-strength parts can be easily manufactured out of titanium for custom prosthetic applications. 3D printing eliminates material waste, making specialty metals more affordable.  
• Medical Equipment / / Custom enclosures can be manufactured out of both metal and plastic for your next medical device project.

Mechanical Assembly of a Robotic Finger / / Read More 

Consumer Goods 

All retailers are aware of the fickle nature of consumers. Staying abreast of changing trends can mean the difference between a typical year and a successful year. Retailers and manufacturers are able to adapt to a changing marketplace quickly by leveraging the benefits of digital manufacturing. Advantages of using 3D manufacturing for consumer goods include / / 

• Faster to Market / / 3D printing allows companies to produce, test, and refine products in a fraction of the time required for traditional manufacturing.  
• Rapid Prototypes / / Multiple versions of the same design can be produced quickly and repetitive testing can be performed in a shorter timeframe. 
• Potential for Mass Customization / / Traditional manufacturing leaves very little room for changes from part to part. 3D printing presents the possibility to provide customers with a unique product. Customizing each product can be done easily by modifying the CAD file. 

Industrial Goods 

Industrial goods may include tooling, equipment, machinery, and parts used in the production of other goods. 3D printing provides the industrial goods industry the ability to respond immediately to machine breakdowns, supply chain issues, and consumer demands. Some of the benefits of using 3D printing for industrial goods include / / 

• Complex Design / / 3D printing is excellent for creating goods that are both complex and durable. 3D printing can produce parts with complex geometry that would be impossible to machine by conventional methods.  
• Short Lead Times / / 3D printing requires less labor and no tooling. Parts can go into production in a matter of hours or days. 3D printed parts are also incredibly cost effective.  
• Rapid Prototyping / / Rapid prototypes for a part can be made quickly and tested within a shorter time frame to bring products to market faster than ever before. 
• On-Demand Parts / / Waiting weeks or months for replacement parts can seriously hamper workflow and damage the bottom line. 3D printing can produce parts on demand to minimize downtime. 

Additive Manufacturing Technologies Offered by Fathom 

• Selective Thermoplastic Electrophotographic Process (STEP) / / Fathom has partnered with Evolve Additive Solutions to present the Evolve Scaled Volume Production (SVP™) system. This machine offers the speed and versatility of 3D printing with the durability and production capability of injection molding. Ability to build parts with multiple materials and colors. Learn more about the Evolve SVP™ and STEP. 
• Selective Laser Sintering (SLS) / / Great for parts that are high in complexity with medium accuracy. Can be used for low- to mid-volume production. Wide range of color options available. Learn more Selective Laser Sintering. 
• PolyJet (PJ) / / High accuracy, great surface finish, and wide selection of rigid and soft materials. Ability to build multiple materials and colors in a single part or assembly of parts. Ideal for prototyping. Learn more about PolyJet. 
• Fused Deposition Modeling (FDM) / / Wide range of engineering-grade thermoplastics. Good choice for low-volume production, prototyping, tooling, and manufacturing aides. Parts are lower resolution but have very high functionality. Learn more about Fused Deposition Modeling. 
• Stereolithography (SLA) / / Good accuracy, great surface finish. Often used for medium to large prototypes and models. Learn more about Stereolithography. 
• Multi Jet Fusion (MJF) / / Durable parts with medium-quality surface finish. Produces products with high-complexity and medium accuracy. Can be used for short production runs. Color is limited to grey or black. Learn more Multi Jet Fusion. 
• Direct Metal Laser Sintering (DMLS) / / 3D printed metal parts. Capable of complex geometry in a variety of specialty metals. Practical option to create rapid tools for injection molding. Learn more about Direct Metal Laser Sintering.

Parts In As Soon As Same Day / / Get A Quote 

Why Work with Fathom Digital Manufacturing? 

Range of Options / / We specialize in a hybrid approach to manufacturing, mixing the best of 3D printing and traditional machining to meet your needs. Parts can be made in a variety of materials, both metal and plastic, to suit your needs. 

Manufacturing Capability / / No job is too big or too small. Need one part? We can do that. Need one million parts? We can do that, too. Our wide range of manufacturing technologies, from traditional to advanced, is at your fingertips.  

Easy Quoting / / Fathom utilizes SmartQuote, a state-of-the-art on-demand online platform that provides our clients with unlimited access to additive manufacturing quotes and orders. Follow your project as it moves from design, to prototyping, to production from our online portal.  

Receive an Instant Quote for Fathom’s 3D Manufacturing Services 

Get a 3D printing quote in as soon as one hour on any 3D project today. 

Additional Resources 

• All Fathom Capabilities 
• Additive Manufacturing 
• 3D Printing Services 
• Metal 3D Printing 
• 3D Printing Quotes 
• Sheet Metal Fabrication 
• Sheet Metal Prototyping 

• CNC Machining 
• Urethane Casting 
• Injection Molding 
• 3D Printing vs. Injection Molding 
• ITAR Manufacturing 
• Medical Device Manufacturing