Additive Manufacturing Services

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

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

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

*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).

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.