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Additive Manufacturing Services

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Additive Manufacturing Services

Fathom’s industry-leading Additive Manufacturing (AM) and 3D printing services are ideal for accelerating product development and production processes. Fathom can accelerate your product development process from design to prototyping to manufacturing at a highly efficient and rapid pace. Companies from all industry categories have utilized Fathom’s team for low- to high-volume 3D printing and additive manufacturing. Our award-winning expertise, speed and quality make us one of the most trusted and innovative experts in the manufacturing industry.

Why Should You Work with Fathom on Your Additive Manufacturing Project?

Using Fathom for your AM project is easy. Fathom utilizes, SmartQuote, a state-of-the-art on-demand online quoting platform that provides unlimited access to quotes and orders for prototyping and production parts. Our production team is ready to meet your needs with a wide range of processes and materials. Companies of all sizes trust Fathom from medical to consumer products, electronics, automotive, aerospace and more.

Receive instant quotes and quick turnaround times through Fathom’s SmartQuote platform.

Receive an Instant Quote for Fathom’s Additive Manufacturing Services

Using Fathom’s additive manufacturing quote platform, receive a rapid quote for your 3D printing or additive manufacturing job in just 3 easy steps.

  1. Upload Your CAD Design in the Proper Format
  2. Select Technology, Materials, Finishes & Quantity
  3. Review Your Quote & Make Any Modifications

To receive a complimentary quote, upload your CAD design file and provide us with details about your project. Fathom accepts uploads in the following formats (max files size up to 100 MB – utilize the manual quote form for larger files) //

STL OBJ STEP IGES SLDPRT 3DM SAT X_T

For additional guidance on STL files, please refer to our STL guide.

Need additional help? We will connect you with an engineer who specializes in rapid manufacturing for complex projects. Fathom will help you choose technology and materials, improve functionality, drive part speed and more. Contact us today to get started.

How Quickly Will I Receive My 3D Quote and Additive Manufacturing Part? Most additive quotes are instant, but more complex files may need additional review. The lead time for parts depends on the complexity, quantity and technology used. Given the scale of our operations, Fathom does require a minimum order.  Please refer to the chart below for approximate lead times.


/ / / / / / SAME-DAY / / / / / / NEXT-DAY / / / / / / TWO-DAY / / / / / / THREE+ DAYS
PolyJet PolyJet
FDM
SLA
PolyJet
FDM
SLA
SLS
MJF
PolyJet
FDM
SLA
SLS
MJF
DMLS

What is Additive Manufacturing?

Additive Manufacturing (AM) or additive layer manufacturing uses Computer-Aided Design (CAD) or a 3D model to direct machinery to build an object layer-by-layer. The CAD drawing acts as a set of instructions or blueprints, illustrating all the intricacies of the product being made. These blueprints instruct the machine where and when to place the material. Complex objects can be produced in this manner without the need to join together separate parts. This type of design freedom allows an engineer or industrial designer to improve functionality through increased complexity, which is often not the case with traditional manufacturing methods. The result is an intricate, unique and lightweight product with a high level of strength.

In this process, there are fewer errors as well as the opportunity to pinpoint and resolve problems before printing. To achieve a similar result using a traditional method, additional steps would be required such as carving, milling, machining or shaping. In other words, additive technologies enable the ability to fabricate geometries that were previously not manufacturable.

While additive technologies have mostly been used for prototyping, software and hardware materials have steadily matured to produce production-quality end-use parts—a process termed Direct Digital Manufacturing (DDM). This is driven by engineers and designers engaged in both day-to-day and big-picture design vision. Those with more knowledge and comfort with how to Design for Additive Manufacturing (DFAM) will be better able to leverage the value of this technology.

More than ever before, development can be front-loaded with a faster iteration of high-quality physical prototypes. Additive manufacturing can be applied to products from vastly different industries, including medical, dental, biotech, aerospace, automotive, construction, industrial design, education, fashion, food and more. Subsets of AM include 3D printing and metal 3D printing, Rapid Prototyping (RP), DFAM, layered manufacturing and additive fabrication.

History of Additive Manufacturing

While AM may seem like a new process, its origin goes back to the 1980s. Hideo Kodama of the Nagoya Municipal Industrial Research Institute was the first to publish an account of a functional rapid-prototyping system that used photopolymers. Using this RP system, a printed model was built in layers, each layer corresponding to a cross-sectional slice within the model. This was the birth of additive manufacturing. Since its invention, additive manufacturing has evolved rapidly and has found its use for thousands of applications.

How Does Additive Manufacturing Work?

The additive manufacturing process begins with design. First, a designer creates a blueprint using CAD or Computer-Aided Design software. Alternatively, a scan of an object may be taken. The software then builds the design layer-by-layer, making instructions for the additive manufacturing machine to follow. The design is then fed to the device and the product is produced. Additive manufacturing may use various materials including polymers, metals, glass, ceramics, foams, gels and even food and human organs.

Advantages of Additive Manufacturing

Additive manufacturing will provide your project with the freedom of a lightweight, inexpensive and strong product while still meeting the demands of an intricate design. Some of the additional advantages of additive manufacturing include //

  • Allow for the creation of unique parts
  • Enable clients to make rapid prototyping alterations during the production run to allow for a dynamic and design-driven manufacturing process
  • Reduce lead times since a single component can be produced without the need for additional assembly steps
  • Produce finished components through advancements in both methods and materials
  • Produce less waste than traditional subtractive processes 
  • Allow for low-volume production runs reducing time and money investments
  • Provide limitless applications that are appropriate for numerous industries

Additive Manufacturing Challenges

While additive manufacturing has many advantages, there are some disadvantages as well. These include //

  • Machines may cost hundreds of thousands of dollars if you choose to do additive manufacturing yourself
  • Objects produced by additive manufacturing typically require some post-process cleaning or smoothing
  • New materials are constantly being developed & technology processes continue to be refined

Additive Manufacturing Technologies Overview

There are three broad categories of additive manufacturing.

Sintering // Material is heated but not liquified, which results in a complex and high-resolution object. Direct Metal Laser Sintering uses metal powder. Selective Laser Sintering uses lasers on thermoplastic powders, which causes the particles to stick together.

Melting // The material is fully melted. This technology includes DMLM which directs a laser to melt layers of metal powder and electron beam melting that uses an electron beam to melt the powder.

Stereolithography // Using photopolymerization, ultraviolet lasers are fired into photopolymer resin. The result is torque-resistant ceramic parts that can withstand extreme temperatures.

Fathom Additive Manufacturing Materials and Processes

PolyJet (PJ)

PolyJet technology can create smooth surfaces, thin walls and complex geometries with accuracy as high as 0.1 mm—the only technology that supports a wide selection of materials with properties that range from rubber to rigid and transparent to opaque. It is also possible to 3D print with multiple materials in a single build to achieve combinations of colors and characteristics (e.g., parts made of rigid and flexible materials).

How does the PJ technology work? PJ is a photopolymer-based jetting process that distributes material droplets layer-by-layer onto a build platform (immediately cured by a flash of UV light). At the end of the build process, the object is fully cured and can be handled immediately without post-curing. This technology includes using a gel-like support material, designed to enable complicated geometries (removed by soaking and/or water jetting). Learn more about PolyJet.

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

PolyJet 3D Printed Parts & Images

PolyJet

PolyJet

PolyJet

PolyJet

PolyJet

PolyJet

PolyJet

Metal

Stereolithography

Stereolithography technology is ideal for high-resolution finishes regarding medium- to large-sized parts. It is an extremely cost-effective solution for creating durable, aesthetically pleasing parts of considerable size on a tight deadline. SLA resins with extremely high heat deflection are available and are great candidates for molds or inserts.

How does the Stereolithography technology work? SLA cures photopolymer resin with an ultraviolet laser. The laser traces a shape dictated by the original file across the surface of the resin bath. The resin is touched by the laser hardens, then the build platform descends in the resin bath and the process is repeated until the entire part is complete. Learn more about Stereolithography.

SLA Parts In As Soon As Next-Day //Get A Quote

Fused Deposition Modeling

Fused Deposition Modeling (FDM) is ideal when you need to build concept models, functional prototypes and end-use parts using standard, engineering-grade and high-performance thermoplastics. As you consider the many material options available for FDM versus other additive manufacturing technologies, remember that this process uses the same types of raw materials used in the injection molding process.

How does FDM technology work? FDM is a filament-based additive technology distributed by a moving print head that extrudes a heated thermoplastic material onto a build platform in a pattern layer-by-layer. This technology includes the use of additional material to create supportive structures removed by force or solution. Learn more about Fused Deposition Molding.

FDM Parts In As Soon As Next-Day //Get A Quote

FDM 3D Printed Parts & Images

  • Fused

    Fused

    Fused

    Fused

Selective Laser Sintering

Selective Laser Sintering (SLS) technology is a commonly used powder-based additive technology to create models, prototypes and end-use parts in durable, engineering-grade thermoplastics. Consider SLS technology for applications that involve high-complexity and organic geometries, as well as parts requiring durability. SLS nests in the z-direction, which allows for short-run production and efficient builds. The technology is also capable of producing parts with more delicate details than most processes that use high-strength plastics. The composition is one of the more isotropic available from additive manufacturing.

SLS uses a blade to spread a thin layer of powder over the build volume. A laser sinters the cross-section of the part, fusing the powder together. The z-stage then drops one layer and the process begins again until the build is finished. Pieces are then excavated from the build powder-cake and bead blasted. The unused powder in the build envelope acts as the support structures, so no support removal is necessary. Learn more about Selective Laser Sintering.

SLS Parts In As Soon As Two-Days //Get A Quote

SLS 3D Printed Parts & Images

Selective

Selective

Selective

Selective

Multi Jet Fusion

Multi Jet Fusion (MJF) technology is quickly becoming a popular choice for 3D printing prototypes and production parts. Ideal uses for MJF are enclosures, electronics housings, complex ducts, lattice structures and functional assemblies. This technology is capable of 3D printing parts with great detail. It is also suitable for applications that require durability (e.g. snap fits). It is common for designers and engineers to choose this material for short production runs. Offering this technology further expands Fathom’s already comprehensive 3D printing and additive manufacturing services. To learn more about MJF, read a featured FAQ blog post by a Fathom Applications Engineer.

How does MJF technology work? MJF technology builds parts by laying down a thin layer of powder on a print bed layer-by-layer. The inkjet array in the print carriage sweeps over the print bed, jetting two agents downward—a fusing agent, printed where the powder will fuse together and a detailing agent that is used to reduce fusing at the part boundary in order to achieve greater detail. Learn more about Multi Jet Fusion.

MJF Parts In As Soon As Two Days //Get A Quote

MJF 3D Printed Parts & Images

Multi

Direct Metal Laser Sintering

Metal 3D printing technology, also known as Direct Metal Laser Sintering (DMLS) and Direct Metal Laser Melting (DMLM), is an additive layer technology. A metal 3D printer utilizes a laser beam to melt 20-60 micron layers of metal powder on top of each other. Powdered metal is spread across the entire build platform and selectively melted to previous layers. This additive process allows metal parts to be grown out of a bed of powdered metal. The process is like other polymer-based 3D printers that use powder bed fusion. Learn more about Direct Metal Laser Sintering.

Just as materials characterize manufacturing processes, manufacturing processes influence material properties. Additive technologies are also identified by the materials used and the quality of the output by the processing method. Don’t hesitate to talk with a Fathom expert directly if you need help with technology and material selection.

DMLS Parts In As Soon As Three-Days //Get A Quote

How Long Does Additive Manufacturing Take?

Depending on the complexities of your project, the size of the part, materials used, quality desired and selected finishing, your part can be produced within a matter of minutes tor several days. Explore the charts below to get a better estimate of your project’s timeline.


/ / / / / / SAME-DAY
PolyJet First Available Rigid Material** / / Technician’s Choice* Order Must Be Submitted by 10 AM PST. Pick-Up Available at 5 PM or Ships as Instructed
/ / / / / / NEXT-DAY
PolyJet Choose Any Standard Material** / / Ask Specialist About Color / / VeroWhite+, VeroBlack+, VeroClear, Digital ABS, TangoBlack+/VeroWhite+, Digital ABS/TangoBlack+, Digital ABS/Agilus30, VeroWhite+/Agilus30. Order Must Be Submitted by 4 PM PST. Pick-Up Available Next-Day at Noon or Ships as Instructed
SLA Accura 25** Order Must Be Submitted by 4 PM PST. Pick-Up Available Next-Day at Noon or Ships as Instructed
FDM First Available Thermoplastic Material**    / / Technician’s Choice* Order Must Be Submitted by 4 PM PST. Pick-Up Available Next-Day at 4 PM PST or Ships as Instructed
/ / / / / / TWO-DAY
PolyJet Choose Standard Material / / Some Restrictions Apply** / / Ask Specialist About Color Options VeroWhite+, VeroBlack+, VeroClear, Digital ABS, TangoBlack+/VeroWhite+, Digital ABS/TangoBlack+, Digital ABS/Agilus30. Order Must Be Submitted by 4 PM PST / / Pick-Up Available at 4 PM PST per Given Lead-Time or Ships as Instructed
SLA Accura 25, Accura ClearVue (clear) / / Some Restrictions Apply** Order Must Be Submitted by 10 AM PST. Pick-Up Available at 4 PM PST per Given Lead-Time or Ships as Instructed
FDM Choose Standard Material / / Some Restrictions Apply** / / Ask Specialist About Color Options. ABS-M30, ASA, Nylon12, PC, Ultem 9085. Order Must Be Submitted by 4 PM PST. Pick-Up Available at 4 PM PST per Given Lead-Time or Ships as Instructed
MJF Nylon 12 (Gray Only) and Nylon 11 / / Some Restrictions Apply** Order Must Be Submitted by 10 AM PST. Pick-Up Available at 4 PM PST per Given Lead-Time or Ships as Instructed
SLS Nylon 12 and Nylon 12 GF / / Choose to Dye Black, Red, Blue, Green, Orange, Yellow or Pink. Pick-Up Available per Given Lead-Time or Ships as Instructed
/ / / / / / THREE+ DAYS
PolyJet Choose Any Available Material / / Widest Range of Options To Choose From Pick-Up Available per Given Lead-Time or Ships as Instructed
SLA Choose From Accura 25, Accura ClearVue (clear), Accura Black Pick-Up Available per Given Lead-Time or Ships as Instructed
FDM Choose Any Available Material / / Widest Range of Options To Choose From. Pick-Up Available per Given Lead-Time or Ships as Instructed
MJF Nylon 12 and Nylon 11 in Gray or Choose to Dye Black. Pick-Up Available per Given Lead-Time or Ships as Instructed
SLS Nylon 12 and Nylon 12 GF Any Available Material / / Choose to Dye Black, Red, Blue, Green, Orange, Yellow or Pink. Pick-Up Available per Given Lead-Time or Ships as Instructed
DMLS Choose From Steel, Stainless Steel, Aluminum, Titanium & More Pick-Up Available per Given Lead-Time or Ships as Instructed

*Color and finish per discretion of the technician—this option does not allow you to choose because speed is the priority.
**Geometry, build-time, quantity, post-processing and other factors can affect lead-time (always consult a specialist before placing an order).

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Top Industries Using Additive Manufacturing

Small and large companies are using additive manufacturing and machine shops that offer such services to meet their standards and innovate their products where possible. Some of the top industries using additive manufacturing include //

  • Consumer Products // The quick turnaround of additive manufacturing has proved a significant advantage for consumer product companies. For example, complex prototypes that simulate the look and feel of the final product can be produced and tested to prove ideas to investors.
  • Aerospace // Commercial and military aerospace companies require flight-worthy parts from high-performance materials. As 3D printing can deliver intricate, durable and lightweight components with less material, aerospace companies often rely on additive manufacturing.
  • Medical // Additive manufacturing has created great possibilities for new life-saving technology. Some applications include implants, dental devices, pre-surgery models, enclosures and specialized instrumentation.
  • Transportation // Automotive companies want consolidated, lighter parts that result in more efficient vehicles. Some of these parts include elastomeric models, grilles, custom interiors, paneling and more.
  • Energy // The energy sector requires critical parts that can withstand extreme conditions. Rotors, turbine nozzles, down-hole tool components, fluid/water flow analysis, mud motor models, pressure gauge pieces, pump manifolds and control-valve components are just some of the parts produced using additive manufacturing.

Should I Use Additive Manufacturing for My Project?

If your job requires flexibility, speed and cost reduction compared to traditional manufacturing, additive manufacturing may be perfect for your project. The precision offered by additive manufacturing means that the resulting product is of a higher quality. With the added benefit of fixing issues quickly, the production time for getting a product on the shelves is significantly reduced through rapid manufacturing services. There is greater flexibility of design with additive manufacturing, which means a company can create custom molds and tooling quickly and cost-effectively.

Additive Manufacturing Questions Answered

Q // Will additive manufacturing eventually replace traditional manufacturing processes?

A // As the technology and materials continue to evolve, it is possible that additive manufacturing may eventually replace traditional methods. However, there are still some advantages to conventional manufacturing processes like injection molding, urethane casting and CNC machining, since additive manufacturing cannot yet match the rapid production at high volumes of traditional manufacturing processes.

Q // What are some of the primary applications of additive manufacturing?

A // Some common examples of additive manufacturing include intricate jewelry designs, dental and orthopedic implants, aerospace, aviation, tool repair, turbines and any low-volume job that benefits from rapid prototyping.

Q // What are the common materials used in additive manufacturing?

A // Common materials include metals, glass, ceramics, composites, graphene-embedded plastics, concrete, paper, food, yarn, bio-inks and more. Additive manufacturing and materials continue to evolve, providing for a wide range of possibilities for the future.

Q // Is additive manufacturing expensive?

A // Companies can receive significant cost savings if they utilize a process that saves them time and materials while creating high quality parts. Some of the cost analysis of AM is the type of material used in the manufacturing process. Different materials have different costs and require different technologies. Compare 3D printing and injection molding costs.

Other Additive Manufacturing Resources & References

Check out these other additive manufacturing resources, references and articles:

Additive Manufacturing Quote

Curious about Fathom’s additive manufacturing and 3D printing services? Whether your project requires sintering, melting, stereolithography, low- or high-volumes, we are ready to help. Fathom’s expertise, excellent quality, quick lead time and our online quoting tool will provide you with the best customer experience. Contact our experts directly to learn more or get started. Learn More About Additive Manufacturing Quotes.




Manufacturing Locations Across National Time Zones
Manufacturing Locations Across National Time Zones
The Fathom Advanced Manufacturing Platform
new map update 3
HEADQUARTERS

1050 Walnut Ridge Drive
Hartland, WI 53029
ISO 9001:2015
AS9100:2016
ITAR

ARIZONA

444 W. 21st St. Ste. 101
Tempe, AZ 85282
ISO 9001:2015
NIST800-171 Compliant
ITAR

FLORIDA

14000 N.W. 58th Court
Miami Lakes, FL 33014
ISO 9001:2015 Design Certified
ISO 13485:2016


 

CALIFORNIA

620 3rd Street
Oakland, CA 94607
ISO 9001:2015 Design Certified
NIST 800-171 Compliant
ITAR

ILLINOIS

1207 Adams Drive
McHenry, IL 60051

1401 Brummel Ave
Elk Grove, IL 60007
ISO 9001:2015 Design Certified

NEW YORK

401 W. Shore Blvd.
Newark, NY 14513
AS9100:2016
ISO 9001:2015
ITAR

1920 Slaterville Rd
Ithaca, NY 14850
ITAR

TEXAS

1801 Rowe Lane
Pflugerville, TX 78660
ISO 9001:2015
AS9100:2016

1513 Sam Bass Rd
Round Rock, TX 78681
ISO 9001:2015
ISO 13485:2016

COLORADO

7770 Washington St.
Denver, CO 80229
ISO 9001:2015
ITAR

MINNESOTA

13758 Johnson Street NE
Ham Lake, MN 55304