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3d printing

What is 3D printing? This article goes over the basics of 3D printing, otherwise known as additive manufacturing, covering its engineering principles and applications.


What is 3D Printing: A Comprehensive Guide to its Engineering Principles and Applications

Researchers can now observe the phonon dynamics and wave propagation in self-assembly of nanomaterials with unusual properties that rarely exist in nature. This advance will enable researchers to incorporate desired mechanical properties into reconfigurable, solution-processible metamaterials, which have wide-ranging applications — from shock absorption to devices that guide acoustic and optical energy in high-powered computer applications.Phonons are natural phenomena that can be thought of as discrete packets of energy waves that move through the building blocks of materials, whether they are atoms, particles or 3D-printed hinges, causing them to vibrate and transfer energy. This is a quantum mechanical description of common properties observed in various contexts, including the transfer of heat, the flow of sound and even seismic waves formed by earthquakes. Some materials, both artificial and natural, are designed to move phonons along specific paths, imparting specific mechanical attributes. Two real-life examples of this include materials used in structures to resist seismic waves during earthquakes and the evolution of the rugged yet lightweight skeletons of deep-sea sponges, which enable them to withstand the extreme pressures of deep-water environments.“Using the <a href="https://news.illinois.edu/view/6367/803885">liquid-phase electron microscopy technique</a> developed in our lab at Illinois, the new study marks the first time we’ve been able to observe phonon dynamics in nanoparticle self-assemblies, acting as a new type of mechanical metamaterials,” said <a href="https://chenlab.matse.illinois.edu/">Qian Chen</a>, a professor of <a href="https://matse.illinois.edu/">material science and engineering</a> at the University of Illinois Urbana-Champaign.The multi-institutional, multi-discipline study is the result of a four-year collaboration between Chen, who led the materials science and experimental portion; professor Xiaoming Mao at the University of Michigan, who led the mechanical metamaterials and theory portion of the study; and professor Wenxiao Pan, who led the simulation portion of the study at University of Wisconsin-Madison. Published in the journal Nature Materials, the study combines nanoparticle assembly with mechanical metamaterial principles, enabling the engineering of mechanical properties through structural design.“Some refer to metamaterials development as mechano-logic,” Chen said. “Metamaterials design is a very active field, and most research has focused on the macroscale realm, where it is easier to control the geometry and structure, as well as measure and model the phonon properties.”But Chen and her collaborators work in the nanoscale world, where both engineering and theoretical approaches to phonon control are tough. To address this problem, the team employed precise theoretical modeling in conjunction with experimental and observational techniques, as well as machine learning-accelerated simulations, to develop a new framework for metamaterials design.   In the lab, using liquid-phase electron microscopy, the team examined the vibrational trajectories of gold nanoparticles to determine the phonon band structures, and then matched these structures to a discrete mechanical model to extract nanoscale springs.<a href="https://youtu.be/MyEz3-rewNU">Click here to view a video explaining the liquid-phase electron microscopy workload process.</a>“We feel we are at a great intersection between disciplines, collaboration and the need for advancement in materials science,” Chen said. “With nanoparticle assembly, we can design structures with very controlled geometry, and then with mechanical metamaterials, adapt the theoretical framework in material design.”“This opens a new research area where nanoscale building blocks — along with their intrinsic optical, electromagnetic, and chemical properties — can be incorporated into mechanical metamaterials,” Mao said, “Enabling emerging technologies in multiple fields from robotics and mechanical engineering to information technology.”“This work also demonstrates the potential of machine learning to advance the study of complex particle systems, making it possible to observe their self-assembly pathways governed by complex dynamics,” Pan said. “It opens new avenues for data-driven inverse design of reconfigurable colloidal metamaterials using machine learning and artificial intelligence.”The Office of Naval Research, the National Science Foundation, the Defense Established Program to Stimulate Competitive Research and the Army Research Office supported this research.

Remarkable materials, such as the rugged yet lightweight skeletons of deep-sea sponges, have inspired engineers to develop highly advanced metamaterials that can adapt to extreme environments. A new study is taking this concept to the next level by bridging the knowledge gap between macro- and nanoscale self-assembling materials to advance technologies in multiple fields, including robotics, mechanical engineering and information technology. Photo courtesy NOAA Okeanos Explorer Program

Researchers can now observe the phonon dynamics and wave propagation in self-assembly of nanomaterials with unusual properties that rarely exist in nature.

Researchers capture nanoparticle movements to forge new materials

In defense, every decision counts. From logistics and supply chains to maintenance and repair operations, there’s little room for error - especially when operating in remote or high-pressure environments. That’s why reliability is non-negotiable. As 3D printing becomes more embedded in defense applications, its reliability is being tested in new and critical ways.Whether it's producing replacement parts in the field, prototyping critical components, or supporting MRO, 3D printing must deliver consistent results, time after time. In demanding environments - from naval vessels and aircraft hangars to remote operating bases and repair stations - this means the printer needs to function flawlessly despite external challenges like dust, heat, or vibration. This level of reliability is equally essential for maintenance crews working on tight schedules or MRO teams operating in makeshift workshops, where downtime or print failures can delay essential repairs.<h2>The cost of downtime in defense</h2>When failure isn’t an option, the true cost of downtime becomes clear. A printer issue in a research lab or helicopter maintenance hall can stall innovation, delay essential repairs, or disrupt logistics planning. Beyond reactive repairs, reliable additive manufacturing enables predictive maintenance workflows - producing parts before failure occurs, keeping fleets operational and avoiding delays.In many defense MRO settings, aging equipment and parts often requires parts that are no longer in production or only available from a single supplier - a reliable 3D printer allows teams to manufacture those components on demand, avoiding costly delays and dependence on limited supply chains.On deployment, those same issues can compromise operations or ground critical equipment. Whether in the field or on base, military operations demand dependable tools that perform under pressure.That’s why reliability in defense-focused additive manufacturing goes far beyond rugged hardware. It includes stable software, intuitive workflows for technicians and engineers, broad material compatibility, and predictable maintenance. In every military setting - from R&amp;D facilities to forward operating bases - the entire 3D printing ecosystem must deliver consistent, repeatable results when it matters most.<h2>UltiMaker: Built for rugged reliability</h2><a href="https://ultimaker.com/3d-printers/s-series/">UltiMaker’s 3D printers</a> are designed and tested to perform in real-world conditions - conditions that reflect the challenges military operations face. With a European engineering heritage and a reputation for delivering professional-grade systems, UltiMaker printers have been deployed across industries where reliability is key for success.For defense teams, this translates into a dependable manufacturing tool - whether it's integrated into a logistics hub, supporting rapid prototyping in an R&amp;D lab, or deployed with mobile repair units. UltiMaker printers are known for:<ul><li>High print success rates, even in long, complex builds.</li><li>Compatibility with a wide range of engineering materials, including wear-resistant and high-strength polymers.</li><li>Compact, modular designs make them easy to transport and gives the team the flexibility to replace parts when needed.</li></ul>UltiMaker’s NATO-compliant printers and European manufacturing standards ensure consistent quality and supply chain transparency - important factors for defense procurement processes.<h2>Additive manufacturing with defense in mind</h2>In defense operations, reliability also means predictability. Knowing your equipment will work exactly as expected - without needing constant recalibration or specialist oversight - enables faster response times and greater self-sufficiency in the field.UltiMaker’s user-friendly interface, reliable firmware updates, and open-material platform help operators stay productive, even when support is limited.As 3D printing becomes a critical enabler across the entire defense lifecycle, choosing a system built for reliability is a strategic decision.We believe it’s about more than just printing - it’s about accelerating innovation, ensuring readiness, and staying agile in the face of the unknown.

In defense, every decision counts. From logistics and supply chains to maintenance and repair operations, there's little room for error - especially when operating in remote or high-pressure environments. That's why reliability is non-negotiable.

3D printing in defense: Why reliability matters

Vacuum casting (urethane casting/vacuum duplication) produces prototypes or small-series plastic parts (typically 5 to 50 pieces) with a quality comparable to injection molding. It’s a cost-effective alternative to injection molding, as it does not require expensive steel tooling.This method allows the production of aesthetic parts with good mechanical properties and high dimensional accuracy. It is commonly used in industries such as automotive (intake manifolds, exhaust systems, body panels), consumer products (toys, sports equipment), and electronics, particularly for the production of housings, battery casings, and cell holders.<iframe width="640" height="360" src="https://www.youtube.com/embed/0uB9dQu-kTw?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0">     </iframe><h2 id="isPasted">What is Vacuum Casting?</h2>Vacuum casting involves pouring liquid plastic into a silicone mold, then curing it in an oven. A vacuum chamber removes trapped air, ensuring complete cavity filling and bubble-free parts.The process supports complex shapes, undercuts, and insert overmolding, offering excellent design flexibility. It’s ideal for pre-series parts with appearance and performance close to injection-molded components—a valuable step before mass production.However, vacuum casting has limits. Manual operation reduces dimensional accuracy, throughput, and repeatability, making it less scalable than automated methods (see how it compares with other manufacturing processes).<table>&lt;thead&gt;&lt;tr&gt;&lt;th&gt;Advantages&lt;/th&gt;&lt;th&gt;Limitations&lt;/th&gt;&lt;/tr&gt;&lt;/thead&gt;<tbody><tr><td>High design flexibility: supports complex shapes, undercuts, overmolding</td><td>Manual process: not suited for large-scale production</td></tr><tr><td>Injection-like quality: good aesthetics, fine details, and mechanical strength</td><td>Slower than CNC machining or 3D printing</td></tr><tr><td>Low cost for short runs: no steel tooling required</td><td>Lower dimensional precision and stability compared to CNC or injection molding</td></tr><tr><td>Wide material range: rigid/flexible, transparent, RAL-colorable resins</td><td>Possible visual flaws (e.g., gate marks, release gloss)</td></tr><tr><td>Multiple finishes available: polishing, painting, metallization</td></tr></tbody></table><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1755775437103-Vacuum-cast-part-next-to-its-silicone-mould.webp" style="width:100%px" class="fr-fic fr-dib" />Vacuum cast part next to its silicone mould<h2 id="isPasted">Technical Specifications of Vacuum Casting</h2>Vacuum casting uses a vacuum to evacuate air from the mold, resulting in smooth surface finishes and minimal defects.Below are general specifications for the process:<table>&lt;thead&gt;&lt;tr&gt;&lt;th&gt;Specification&lt;/th&gt;&lt;th&gt;Details&lt;/th&gt;&lt;/tr&gt;&lt;/thead&gt;<tbody><tr><td>Materials</td><td>Select materials based on final use case: rigid (for enclosures), flexible (for seals), or transparent (for visual inspection parts). Pigment resins using RAL shades for visual prototypes.</td></tr><tr><td>Lead time</td><td>10–20 days</td></tr><tr><td>Design flexibility</td><td>Take advantage of vacuum casting’s design freedom to test non-uniform wall thicknesses, soft curves, and aesthetic detailing without tooling constraints.</td></tr><tr><td>Minimum wall thickness</td><td>Maintain a wall thickness of at least 1.5 mm to ensure full cavity filling and avoid deformation. You can reduce to 0.75 mm in non-load-bearing areas, but expect a higher risk of warping.</td></tr><tr><td>Undercuts</td><td>Design undercuts with care. Vacuum casting can demold simple undercuts, but complex ones increase mold wear and risk tearing. Add inserts or use parting lines to simplify.</td></tr><tr><td>Quantity per mold</td><td>Typically 1 to 20 parts</td></tr><tr><td>Surface finish</td><td>Choose a glossy finish to highlight geometry or a matte texture to reduce reflections—both are achievable without post-processing.</td></tr><tr><td>Additional options</td><td>Use insert overmolding to simulate final assemblies or test part fit before investing in injection tooling.</td></tr></tbody></table>Tolerance values in vacuum casting depend on part dimensions and design complexity. The table below provides example tolerances based on various dimension ranges (the values provided are illustrative):<table>&lt;thead&gt;&lt;tr&gt;&lt;th&gt;Dimensions (mm)&lt;/th&gt;&lt;th&gt;0 — 25&lt;/th&gt;&lt;th&gt;25 — 50&lt;/th&gt;&lt;th&gt;50 — 75&lt;/th&gt;&lt;th&gt;75 — 100&lt;/th&gt;&lt;th&gt;100 — 125&lt;/th&gt;&lt;th&gt;125 — 150&lt;/th&gt;&lt;/tr&gt;&lt;/thead&gt;<tbody><tr><td>Tolerance (mm)</td><td>±0.3</td><td>±0.35</td><td>±0.4</td><td>±0.45</td><td>±0.5</td><td>±0.55</td></tr></tbody></table>&lt;section&gt;&lt;p&gt;&lt;strong&gt;Pro Tip&lt;/strong&gt;: For tight-fitting parts, keep tolerances below ±0.35 mm. Use vacuum casting for functional pre-series, then switch to CNC or injection molding for higher precision.&lt;/p&gt;&lt;/section&gt;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1755775512456-lunii-new-shells.webp" style="width:100%px" class="fr-fic fr-dib" />The prototypes of the silicone shell were manufactured with vacuum casting<h2 id="isPasted">Vacuum Casting Compared to Other Manufacturing Processes</h2>The table below compares vacuum casting with other common manufacturing processes—injection molding, 3D printing, and CNC machining—to help you choose the most suitable option based on production needs, materials, lead time, and cost-efficiency.<table>&lt;thead&gt;&lt;tr&gt;&lt;th&gt;&lt;br /&gt;&lt;/th&gt;&lt;th&gt;Vacuum Casting&lt;/th&gt;&lt;th&gt;Injection Moulding&lt;/th&gt;&lt;th&gt;3D Printing&lt;/th&gt;&lt;th&gt;CNC Machining&lt;/th&gt;&lt;/tr&gt;&lt;/thead&gt;<tbody><tr><td>Description</td><td>Small batches of detailed parts resembling production quality</td><td>Mass production of highly detailed plastic parts</td><td>Rapid prototyping and complex geometries with minimal tooling</td><td>High-precision parts from metal or plastic, suitable for both prototyping and production</td></tr><tr><td>Optimal Quantity Range</td><td>1 – 100</td><td>50 – 1,000,000</td><td>1 – 100</td><td>1 – 100</td></tr><tr><td>Lead Time (available at Xometry)</td><td>20 days</td><td>38 days</td><td>3 days</td><td>7 days</td></tr><tr><td>Maximum Part Size (available at Xometry)</td><td>2500 × 2200 × 1800 mm</td><td>1289 × 1910 × 1006 mm</td><td>900 x 900 x 600 mm</td><td>2000 x 750 x 600 mm</td></tr><tr><td>Mould Life</td><td>1 – 20 shots</td><td>10,000 – 1,000,000 shots</td><td>–</td><td>–</td></tr><tr><td>Material Selection</td><td>Rigid plastics (ABS-like, PMMA-like, PP-like, PC-like), rubber-like plastics</td><td>Any thermosets/ thermoplastics</td><td>Plastics (PLA, ABS, PETG, Nylon, PC, etc.), resins, metals (aluminium, steel, titanium), and composites (carbon-fibre reinforced)</td><td>Metals (aluminium, steel, titanium, brass), plastics (POM, PTFE, ABS, PC, PMMA, Nylon), and composites</td></tr><tr><td>Prototyping</td><td>⭐⭐</td><td>⭐</td><td>⭐⭐⭐</td><td>⭐⭐⭐</td></tr><tr><td>High-Volume Production</td><td>⭐</td><td>⭐⭐⭐</td><td>⭐</td><td>⭐⭐</td></tr><tr><td>Part Design Complexity</td><td>⭐⭐</td><td>⭐⭐⭐</td><td>⭐⭐⭐</td><td>⭐⭐⭐</td></tr><tr><td>Standard Surface Finish</td><td>⭐⭐⭐</td><td>⭐⭐⭐</td><td>⭐⭐</td><td>⭐⭐⭐</td></tr><tr><td>Post-Processing</td><td>No</td><td>No</td><td>Yes</td><td>Yes</td></tr><tr><td>Cost of Design Mistakes</td><td>Low</td><td>High</td><td>Low</td><td>Medium</td></tr><tr><td>Advantages</td><td>• Excellent for short production runs and detailed prototypes with fast lead times • Ideal for creating high-quality surface prototypes, such as robotic components or lenses, making it perfect for professional product demonstrations or exhibition samples where aesthetics are crucial</td><td>• High repeatability for consistent part quality • Ideal for large production volumes • Extensive material options to suit diverse applications • Ability to meet custom colour requirements, ensuring precise tones</td><td>• No tooling costs • Fast iteration • Great for custom geometries</td><td>• High precision • Excellent surface finishes • Supports diverse materials</td></tr><tr><td>Disadvantages</td><td>• Limited mould lifespan, typically up to 20 parts</td><td>• High upfront investment in mould tooling • High costs for mould modifications or improvements, particularly if the design is not frozen before mould production • Limited flexibility for highly complex or intricate designs</td><td>• Slower production for large batches • Limited material properties</td><td>• High cost per part for large volumes • Slower for intricate designs</td></tr></tbody></table><h2>Vacuum Casting vs. Injection Molding</h2>Use vacuum casting when you need 5–100 parts with production-like quality but want to avoid the cost and delay of steel tooling. Injection molds can cost €5,000–€50,000+, while vacuum casting only needs a master pattern and silicone mold. It’s ideal for validation, marketing, or pilot runs where fast iteration and low upfront costs matter more than tight tolerances.Switch to injection molding once your design is final and you’re producing hundreds to millions of parts. It offers high repeatability, precise tolerances, and low part costs at scale—but demands more time, money, and commitment upfront.&lt;section&gt;&lt;p&gt;&lt;strong&gt;Tip for designers&lt;/strong&gt;: Start with vacuum casting to test form, fit, and finish. Switch to injection molding once your geometry, materials, and tolerances are locked in.&lt;/p&gt;&lt;/section&gt;<h2>Vacuum Casting vs. 3D Printing</h2>3D printing is your go-to for rapid iterations, complex internal features, and single-unit prototyping. It’s fast, tool-free, and works well early in development—especially when functional performance isn’t critical yet.Vacuum casting comes into play when you need multiple units with production-grade appearance and mechanical properties. It offers better surface finish, material consistency, and can simulate injection-molded parts more closely.&lt;section&gt;&lt;p&gt;&lt;strong&gt;Tip for designers&lt;/strong&gt;: Use 3D printing to explore ideas and refine geometry. Move to vacuum casting to produce realistic samples for user testing, mechanical validation, or customer demos.&lt;/p&gt;&lt;/section&gt;<h2>How Vacuum Casting Works</h2>Vacuum casting uses a silicone mold and a vacuum chamber to create detailed plastic or rubber parts with smooth surfaces and minimal defects.<iframe width="640" height="360" src="https://www.youtube.com/embed/0uB9dQu-kTw?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0">  </iframe>Here’s a step-by-step breakdown of the process:<h3>1. Create a 3D Model</h3>As with most modern manufacturing processes, the first step is to design a 3D model of the part.<ul><li>Use CAD software such as AutoCAD, SolidWorks, or CATIA.</li><li>To get optimal results, follow injection molding design rules, including draft angles, uniform wall thickness, and allowances for undercuts.</li></ul><h3>2. Build the Master Pattern</h3>Produce a master pattern from the 3D model using SLA 3D printing or CNC machining.<ul><li>While CNC was traditionally used, it still offers higher dimensional accuracy, especially for pre-series parts.</li><li>3D printing speeds up prototyping and reduces cost during early design validation.</li></ul><h3>3. Create the Silicone Mold</h3>Place the master pattern in a casting box along with any cores, inserts, and gating systems.<ul><li>Pour liquid silicone over the pattern to capture its geometry and surface details.</li><li>Cure the mold in an oven at 40°C for 8 to 16 hours, depending on its size.</li><li>Once cured, cut the mold open along the parting line to reveal the negative cavity.</li><li>Apply a mold-release agent to prevent sticking and avoid surface flaws.</li></ul><h3>4. Mix and Pour the Resin</h3>Prepare a two-component polyurethane resin and add any required pigments.<ul><li>Preheat the mixture to ~40°C for better flow.</li><li>Install the mold in the vacuum chamber and connect the pouring gates.</li><li>Mix and deaerate the resin under vacuum for 50–60 seconds to remove air bubbles.</li><li>Apply vacuum to the mold so gravity fills the cavity evenly without trapped air.</li></ul><h3>5. Demold the Parts</h3>Cure the filled mold in an oven for 1 to 4 hours, depending on the material.<ul><li>After curing, remove the hardened part from the mold, then trim gates and perform any needed finishing.</li><li>A single silicone mold typically produces 10 to 20 parts, depending on the geometry and resin used.</li></ul><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1755775584684-Illustration-of-the-vacuum-casting-process.webp" style="width:100%px" class="fr-fic fr-dib" />Illustration of the vacuum casting process (Source: ProtoZone)<h2 id="isPasted">Source Your Vacuum Cast Parts at Xometry</h2><a href="https://xometry.eu/en/vacuum-casting/" target="_blank" rel="noreferrer noopener">Vacuum casting</a> is a versatile and efficient process for producing detailed plastic or rubber parts in low volumes. It’s ideal for prototypes, functional parts, and high-quality presentation models, such as exhibition pieces or customer samples.

Learn how vacuum casting helps engineers and designers produce high-quality plastic parts fast—without investing in hard tooling. This article covers the process, material options, key design rules, and how it compares to 3D printing, CNC machining, and injection molding.

Vacuum Casting: Process, Applications & How It Compares

Metal 3D printing is transforming manufacturing by allowing engineers to produce complex, high performance parts directly from digital designs.

Metal 3D Printing: A Comprehensive Guide for Engineers and Students

A comprehensive guide to 3D printing snap-fit joints, from the basics to troubleshooting common issues.

How to 3D Print Snap-Fit Joints

3D printing has revolutionized manufacturing and prototyping across industries, with two prominent technologies emerging as frontrunners: resin-based stereolithography (SLA) and fused deposition modeling (FDM).

Resin vs FDM printing: Comparing 3D printing with SLA resin vs filament

Stereolithography (SLA) and Selective Laser Sintering (SLS) are two of the most recognized 3D printing technologies, yet they work in fundamentally different ways. Despite this, confusion is common—both are professional-grade processes, involve lasers, and are often compared against more familiar FDM printing. (Not to mention both start with “SL.”) Still, SLA vs SLS comparisons quickly reveal distinct differences in materials, part characteristics, and ideal applications.SLA is part of the vat photopolymerization family, alongside Digital Light Processing (DLP) and masked stereolithography (mSLA). All use a light source to solidify photosensitive resin in a vat, producing parts with fine detail and smooth surfaces. SLA is valued for accuracy and surface quality, making it well-suited for models, patterns, and small functional components where precision matters.SLS, on the other hand, is a powder bed fusion technology that fuses layers of thermoplastic powder using a laser. It is more closely related to processes like HP’s Multi Jet Fusion (MJF) and even metal systems such as Direct Metal Laser Sintering (DMLS). By building parts in a self-supporting powder bed, SLS enables complex geometries without support structures, offering design freedom that SLA cannot match. This article will explore SLA vs SLS in more detail, including materials, costs, and performance.<h2>Fundamentals of SLA and SLS</h2><h3>Stereolithography (SLA)</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754984667047-shutterstock_1078855064.jpg" style="width:100%px" class="fr-fic fr-dib" alt="sla" />SLA 3D printers are used in fields like dentistry and jewelry makingPrinciple of OperationSLA is the oldest 3D printing technique, introduced by Chuck Hull in 1986. It belongs to the vat photopolymerization family. A build platform descends into a vat of liquid photopolymer resin. An ultraviolet (UV) laser, steered by galvo mirrors, selectively cures the resin to form the cross‑section of each layer.[1] The platform then lifts to allow fresh resin to flow beneath, and the process repeats. Multiple support structures are printed first, followed by the actual geometry. After printing, parts must be cleaned and cured further under UV light to achieve full strength.MaterialsSLA uses photopolymer resins. Standard resins produce smooth, detailed prototypes; engineering resins offer improved mechanical properties; flexible resins mimic elastomers; and biocompatible resins support medical applications. These materials are thermosetting; once cured, they cannot be remelted or reshaped.Post-ProcessingAfter printing, parts are removed from the build platform, rinsed in an isopropyl alcohol bath to remove uncured resin, and post‑cured under UV light. Support structures are snipped off and surfaces may be sanded or coated for aesthetics. Some resins require additional baking or chemical bath to improve mechanical properties.Advantages<ul><li>High resolution and surface finish: The laser can cure extremely fine features, enabling layer thicknesses around 50 µm. Parts often require little sanding or polishing, making SLA ideal for small electronic housings, connector prototypes and cosmetic models.</li><li>Dimensional accuracy: Tight tolerances are achievable because the laser precisely traces each layer.</li><li>Wide range of resins: Photopolymers can be tailored for properties like temperature resistance or elasticity.</li></ul>Limitations<ul><li>Brittle parts: Cured resins do not achieve full densification and may contain voids; they often lack high impact or fatigue resistance. Resin parts can deform under sustained load.</li><li>Support structures and post‑processing: SLA requires supports for overhangs; removing supports and washing parts adds labor and time. Final curing is necessary to reach full stiffness.</li><li>Limited build volume: Many desktop SLA machines are compact, restricting part size.</li></ul>Recommended reading: <a href="https://www.wevolver.com/article/how-do-resin-printers-work" target="_blank">How do Resin Printers Work: SLA, DLP &amp; More</a><h3>Selective Laser Sintering (SLS)</h3><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754984681709-shutterstock_2353910889.jpg" style="width:100%px" class="fr-fic fr-dib" alt="sls" />SLS is a robust prototyping and low-volume manufacturing methodPrinciple of OperationSLS is a powder bed fusion process. A recoater spreads a thin layer of thermoplastic powder (nylon, PA 11 or PA 12) across a build chamber. A high‑power laser scans the layer, locally sintering—fusing but not fully melting—the powder to form the part’s cross‑section. Unsintered powder supports overhangs and complex shapes, eliminating the need for support structures. After each layer, the chamber lowers, fresh powder is applied, and the laser continues. Once printing finishes, parts are removed from the powder bed and often bead‑blasted to remove residual powder.MaterialsSLS works primarily with thermoplastic powders. Common choices include general‑purpose nylons (PA 11 or PA 12), mineral‑ or glass‑filled variants, TPU elastomers and polypropylene. These powders deliver strong, durable parts and can withstand elevated temperatures. Material cost is higher than resin, but the resulting parts behave more like injection‑molded thermoplastics.Post-ProcessingThe build chamber cools before parts are excavated from the powder bed. Loose powder is brushed or vacuumed away and can be recycled.[2] Bead blasting or tumbling smooths the surface. For applications requiring sealed or smooth surfaces, vapor smoothing or infiltrating with epoxy can improve finish. Dyeing can add color without altering part dimensions.Advantages<ul><li>Mechanical strength: SLS parts have better durability and heat resistance than SLA parts because they use engineering‑grade thermoplastics. They can handle functional loads and repeated use.</li><li>No support structures: The surrounding unsintered powder naturally supports overhangs, allowing freeform geometry, internal channels and nested parts.</li><li>Efficient batch printing: Multiple components can be nested in a single build volume, improving throughput and reducing cost per part. Powder can also be reused partially after sieving.</li></ul>Limitations<ul><li>Rough surface finish: SLS parts typically have grainy surfaces due to powder particles, requiring sanding or post‑processing for smoothness.</li><li>Lower resolution: Layer thickness is generally 100–300 µm, limiting fine details compared to SLA.</li><li>Expensive equipment and materials: Industrial SLS printers cost significantly more than desktop SLA machines. Material handling requires sealed chambers and safety precautions (powder is combustible).</li></ul><h3>Comparing Printing Parameters</h3><div><table><tbody><tr><td> </td><td>SLA (Stereolithography)</td><td>SLS (Selective Laser Sintering)</td></tr><tr><td>Laser type</td><td>UV laser cures liquid resin</td><td>Infrared or CO₂ laser sinters thermoplastic powder</td></tr><tr><td>Material form</td><td>Photopolymer resin (thermosetting)</td><td>Thermoplastic powders (nylon, TPU, PP)</td></tr><tr><td>Layer thickness</td><td>50 µm or less (high resolution)</td><td>100–300 µm (lower precision)</td></tr><tr><td>Support structures</td><td>Required; removed after printing</td><td>Not required; powder supports geometry</td></tr><tr><td>Surface finish</td><td>Smooth to near‑polished; minimal post‑processing</td><td>Grainy texture; requires sanding or smoothing</td></tr><tr><td>Mechanical strength</td><td>Lower strength, brittle resins</td><td>High durability and heat resistance</td></tr><tr><td>Equipment cost</td><td>~$5k for desktop printers</td><td>$20k–$650k for industrial machines</td></tr><tr><td>Post‑processing effort</td><td>Wash, remove supports, UV cure</td><td>Bead blast, depowder parts</td></tr><tr><td>Ideal applications</td><td>Detailed prototypes, casings, fluidic channels</td><td>Functional parts, clips, jigs, enclosures</td></tr></tbody></table></div><h2>Materials Comparison</h2><h3>Photopolymer Resins for SLA</h3>Photopolymer resins vary widely in composition. Standard resins (often acrylic‑based) provide moderate strength and high detail, perfect for visual prototypes. Engineering resins contain fillers or modified backbones to enhance stiffness, heat resistance or impact strength; they are useful for functional prototypes and jigs. Flexible resins incorporate elastomeric segments for applications like seals or gaskets. Biocompatible resins meet ISO 10993 standards and are used for dental guides or hearing aid shells.Resins generally degrade under UV light and may absorb moisture over time. Cured parts can crack when exposed to solvents or mechanical stress. Engineering teams should consider the service environment; SLA parts may be unsuitable for high‑temperature or chemically aggressive settings.<h3>Thermoplastic Powders for SLS</h3>The PA 12 family dominates SLS due to its balanced mechanical properties and processability. PA 12 powder offers high sphericity and flowability, promoting uniform layer deposition. Its relatively low melting point (~175 °C) reduces energy consumption. PA 12 exhibits excellent impact strength, tensile strength and bending strength, making it suitable for functional prototypes and small‑batch production. Glass‑filled or mineral‑filled variants increase stiffness but may cause faster wear on machine components.PA 11 powders, derived from renewable castor oil, provide improved toughness and environmental resistance. TPU powders yield elastomeric parts for seals and flexible hinges. Polypropylene (PP) powders offer chemical resistance and low density. SLS powders can be partially recycled; however, each reuse cycle reduces mechanical properties, so a mix of virgin and recycled powder is typically used.Recommended reading: <a href="https://www.wevolver.com/article/fdm-vs-sla-comparing-extrusion-and-photopolymerization-3d-printers" target="_blank">FDM vs SLA: Comparing Extrusion and Photopolymerization 3D Printers</a><h2>Cost and Scalability</h2><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzU0OTQ2MTcwMjk1LVNVWlktZnJvbS1TaW50ZXJpdC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width:100%px" class="fr-fic fr-dib" alt="sinterit" />SLS printers are more expensive than SLA, though companies like Sinterit have introduced affordable models (image: <a href="https://sinterit.com/" target="_blank" rel="noopener noreferrer">Sinterit</a>)<h3>Printer and Material Costs</h3>Cost remains a key differentiator when selecting a 3D printing technology. Desktop SLA printers suitable for labs or design studios typically cost around $5,000, more than less precise vat photopolymerization technologies like mSLA (where some machines are available for well under $1,000). For many years, Formlabs has offered the best value desktop SLA machines, though its new Form 4 model actually uses a form of mSLA instead of traditional, laser-based SLA.[3] Consumable resin prices range from $50 to $200 per liter, and many resins have limited shelf life.SLS systems, on the other hand, range from $20,000 for entry‑level professional units to $650,000 or more for industrial machines. In 2025, the most budget-friendly machine is probably the Sinterit Suzy, priced around the $20,000 mark. The higher cost of SLS arises from high‑powered lasers, powder handling systems and inert gas chambers. Thermoplastic powders cost $60–$150 per kilogram, but some portion can be recycled. Post‑processing equipment like bead blasters or powder sieves adds to the investment.<h3>Labor and Post‑Processing Costs</h3>While SLA requires washing and curing, SLS demands depowdering and bead blasting. Labor costs vary depending on part complexity and quantity. SLS may be more efficient for batch production because multiple parts can be printed simultaneously. SLA offers fast setup and quick turnaround for single prototypes but may become slower when printing many parts due to support removal.<h3>Lead Times and Throughput</h3>For prototypes requiring fine detail, SLA can deliver parts in as little as 2–3 days because no tool fabrication is needed. SLS lead times are comparable, typically 3–4 days for polymer parts. However, SLS’s ability to nest multiple parts in a single build gives it an advantage for small‑batch production.[4] Engineers should also consider machine uptime; SLS cycles are longer due to powder heating and cooling.<h2>Practical Implementation Guidance</h2><h3>Selecting the Right Technology for Specific Applications</h3><ul><li>Common SLA applications: Dental models, jewelry casting patterns, prototypes with fine detail, custom molds, small-scale functional parts</li><li>Common SLS applications: Functional end-use parts, tooling and jigs, snap-fit components, housings and enclosures, short-run manufacturing</li></ul><h3>Optimizing Designs for SLA</h3><ul><li>Orient parts to minimize supports: Angle parts so that large flat surfaces are slightly tilted, reducing suction and peel forces. Use sacrificial structures like tree supports to minimize scars.</li><li>Consider resin shrinkage: Account for ~1–2 % dimensional shrinkage; test a sample and adjust CAD models accordingly.</li><li>Design robust features: Avoid extremely thin walls (&lt;0.4 mm) that may warp or break during support removal. Add fillets to edges to distribute stress.</li></ul><h3>Optimizing Designs for SLS</h3><ul><li>Powder removal access: Include holes or channels to remove unsintered powder from cavities. Avoid closed internal volumes.</li><li>Uniform wall thickness: Maintain consistent wall thickness to minimize warping; avoid large solid volumes that cool unevenly.</li><li>Part packing: Arrange multiple parts in the build chamber to maximize space utilization. Use software to nest parts with appropriate clearance.</li><li>Orientation for strength: Align critical features along the XY plane to take advantage of better in‑plane strength. Minimize vertical overhangs to reduce stair-stepping.</li></ul><h2>Conclusion</h2>Comparing SLA vs SLS reveals that these laser-based 3D printing methods excel at different tasks. SLA 3D printing is the go-to printing process for high-resolution, aesthetically refined prototypes. It produces a smooth surface finish and intricate features from a wide array of photopolymer resins, making it invaluable for electronics enclosures, sensor housings, fluidic devices, and medical models. However, SLA parts are generally less robust and require careful post-processing.SLS 3D printing, sometimes referred to as SLS printing, is the workhorse for functional prototypes and small-scale production. Using thermoplastic powders such as PA 12 or ABS, and a high-powered laser, it generates durable parts with good thermal and chemical resistance. The absence of support structures enables complex geometries and efficient batch production but yields rougher surfaces and requires a higher initial investment.When choosing between SLA and SLS, engineers should weigh factors such as resolution, mechanical strength, material compatibility, cost, and production volume. There is no universal winner—only the best fit for a specific design and business context. By understanding the underlying physics and practical trade-offs, hardware designers and engineers can harness the power of additive manufacturing to accelerate innovation.<h2>Frequently Asked Questions (FAQ)</h2>What is the core difference between SLA and SLS in terms of process?SLA uses a UV laser to cure liquid photopolymer resin, building parts layer by layer and requiring support structures. SLS employs a high‑power laser to sinter thermoplastic powder, with unsintered powder acting as support, enabling more complex geometries.Which technology provides better surface finish and detail?SLA typically offers superior surface finish and fine detail thanks to thin layer thicknesses (~50 µm). SLS parts have a grainy texture due to powder particles and may require sanding or vapor smoothing.Are SLS parts stronger than SLA parts?Yes. SLS parts made from nylon or PA 12 powders exhibit higher mechanical strength and heat resistance than SLA resin parts. SLA resins are prone to brittleness and should not be used for high‑load applications.How do equipment costs compare between SLA and SLS printers?Desktop SLA printers cost roughly $3,750–$5,000, making them accessible to labs and small businesses. Industrial SLS machines range from $20,000 to $650,000 due to their more complex laser systems and powder handling.Can both SLA and SLS be used for medical or bio‑compatible applications?Yes, but material choice matters. SLA offers biocompatible resins suitable for dental guides and hearing aids. SLS can produce sterilizable parts from medical‑grade nylon powders. Always verify regulatory compliance for the intended application.What about SLM?Selective Laser Melting (SLM) is a name trademarked by Nikon SLM Solutions for a metal powder bed fusion process otherwise known as Direct Metal Laser Sintering (DMLS). <h2>References</h2>[1] Çerlek Ö, KESERCİOĞLU MA, Han K.<a href="https://www.researchgate.net/publication/385620327_StereolithographySLA_An_Innovative_Additive_Manufacturing_Process" target="_blank"> Stereolithography (SLA): An Innovative Additive Manufacturing Process</a>. New trends and frontiers in engineering. 2024:399-412.[2] Uddin M, Williams D, Blencowe A. <a href="https://www.mdpi.com/2073-4360/13/13/2046" target="_blank">Recycling of selective laser sintering waste nylon powders into fused filament fabrication parts reinforced with Mg particles</a>. Polymers. 2021 Jun 22;13(13):2046.[3] Formlabs. Form 4 [Internet]. Formlabs; 2025 [cited 2025 Aug 11]. Available from: <a href="https://formlabs.com/3d-printers/form-4/?srsltid=AfmBOorHaJLyloRbGTpLWfd7ea1gOn-pyn2fJF3ijFmCaImFbcGULTyp" target="_blank">https://formlabs.com/3d-printers/form-4</a>[4] Butler J. <a href="https://www.emerald.com/ria/article-abstract/31/3/212/5311/Using-selective-laser-sintering-for-manufacturing?redirectedFrom=fulltext" target="_blank">Using selective laser sintering for manufacturing</a>. Assembly Automation. 2011 Aug 2;31(3):212-9.

3D printer novices might assume that SLA and SLS are closely related, but the technologies are used for quite different purposes.

SLA vs SLS: Choosing the Right Laser 3D Printing Technology

3D printing has revolutionized manufacturing processes, offering versatile solutions that enhance efficiency and precision. Among these advancements, 3D printed jigs and fixtures stand out as transformative tools.These custom-designed components are rapidly replacing traditional manufacturing methods, providing significant improvements in production speed, cost-effectiveness, and overall quality. As industries increasingly adopt additive manufacturing, understanding the capabilities and benefits of 3D printing jigs and fixtures becomes crucial for staying competitive and optimizing manufacturing workflows.This article explores the applications, materials, design considerations, and future trends of 3D printed jigs and fixtures, illustrating their profound impact on modern manufacturing.<h2>Understanding 3D printed jigs and fixtures</h2>3D printed jigs and fixtures are changing manufacturing by providing a quicker, more economical alternative to traditional methods. These custom tools improve production efficiency, accuracy, and safety across industries.Jigs are tools that guide cutting or machining tools during manufacturing. They ensure accurate operations, such as drilling holes or shaping components, with high repeatability. Fixtures hold workpieces in place for tasks like welding, assembly, or inspection.Key advantages include reduced lead times, lower costs, rapid prototyping, customization, and the ability to create complex geometries. These benefits have led to adoption in industries such as automotive, electronics, and construction.For instance, automakers have reported significant savings in cost and time by using 3D printed assembly tools. As the technology advances, the potential for jigs and fixtures expands, moving beyond prototyping to become an integral part of manufacturing. The next section will discuss in detail the benefits of using 3D printed jigs and fixtures in manufacturing.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754637961865-dsads.webp" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Benefits of 3D printed jigs and fixtures in manufacturing</h2>Using 3D printing for jigs and fixtures offers many advantages for manufacturers aiming to improve their production. One significant benefit is the reduction in lead times. Tools can go from CAD file to finished product in hours or days, which greatly shortens production timelines.Cost savings are another major advantage. With no minimum order quantities or expensive tooling needed, even single prototypes become affordable. Printing on demand also removes inventory costs, further cutting expenses for manufacturers.The ability to quickly prototype and change designs is a key advantage. Design changes are simple file edits and reprints, allowing for quick improvements. This flexibility extends to customization, as jigs can be tailored for unique components or processes. It's also useful to produce tools for rare, obsolete, or one-of-a-kind parts.Complex geometries that are hard to achieve with traditional machining become feasible. This enables good part alignment and faster integration in manufacturing.Beyond cost and time savings, 3D printed jigs and fixtures can improve ergonomics for workers. Lightweight designs reduce fatigue, and customized tools can be optimized for specific tasks and body mechanics, enhancing comfort and productivity. The versatility of these tools leads to their wide use in several applications, as the next section will show.<h2>Applications of 3D printed jigs and fixtures</h2>3D printed jigs and fixtures are transforming manufacturing processes across various industries. The automotive industry has been particularly quick to adopt this technology, with major manufacturers reporting significant improvements in efficiency and cost savings.Volkswagen Autoeuropa, Portugal's largest automotive plant, revolutionized their manufacturing process by bringing jig and fixture production in-house using Ultimaker 3D printers. The results were remarkable: <a href="https://ultimaker.com/learn/real-world-roi-top-success-stories-with-3d-printing/">time savings of 89% and cost reductions of 98%</a>. Within the first two years of implementation, Volkswagen Autoeuropa saved approximately €475,000 ($525,000) by replacing externally manufactured tools with in-house 3D printed alternatives. One specific example is a liftgate badge positioning tool that previously cost €400 with a 35-day lead time from external suppliers but now costs just €10 and can be produced in only four days.Ford's pilot plant in Cologne, Germany has established a dedicated 3D printing workshop to manufacture custom tools, jigs, and fixtures. After initially experimenting with SLS technology, Ford engineers <a href="https://additive-x.com/blog/3d-printing-tools-jigs-and-fixtures-with-ford-and-ultimaker">switched to Ultimaker FFF printers</a>for their faster turnaround times and lower post-processing requirements. Their team now saves more than 50% on manufacturing costs while cutting lead times by more than half. An innovative example is their custom hook-on jig for the rear of vehicles, printed in Tough PLA (as strong as ABS but soft enough to prevent bodywork scratches), which enables quick and precise positioning of badges and emblems, resulting in fewer deviations.In electronics manufacturing, 3D printed jigs offer particular advantages for PCB production. Custom fixtures can securely hold components during soldering processes, ensure alignment of stencils for precise solder paste application, and create standardized testing setups. These applications are especially valuable for small-scale production and prototyping, where traditional metal fixtures would be prohibitively expensive.Industrial service providers like ERIKS have integrated Ultimaker 3D printers to improve their production processes. One notable <a href="https://ultimaker.com/learn/application-deep-dive-maximizing-production-efficiency-with-custom-jigs-at-eriks/">application at ERIKS</a> is a box drilling jig with press-fit metal tube inserts that enables precise, repeatable hole drilling. This jig includes magnetic inserts that snap onto a metal vice, providing stability during the drilling process. Another example is their motor assembly jig, which perfectly supports a motor during the addition of electronic components, reducing assembly time from 2-3 minutes to just 1 minute.Jabil, a global manufacturing services company, implemented Ultimaker 3D printers at their Auburn Hills facility and reported an <a href="https://www.tctmagazine.com/additive-manufacturing-3d-printing-news/jabil-ultimaker-3d-printing-technology-jigs-fixtures/">80% reduction in delivery time and 30-40% cost reduction</a> for tooling components. The company found immediate success with the technology, receiving an order to print spare parts just three hours after installing their first Ultimaker machine. For Jabil, the elimination of minimum quantity requirements and ability to produce one-off items without cost constraints has been transformative.Even Ultimaker itself practices what it preaches, using their own 3D printers to create tools, jigs, and fixtures for their manufacturing facility. One example is a <a href="https://ultimaker.com/learn/application-focus-jigs-and-fixtures/">custom-designed pressure fixture</a> that assists in the assembly of sliding blocks for their 3D printers. This fixture is printed using XSTRAND™ GF30 PA6 (nylon with 30% glass fiber) for extreme strength, combined with Ultimaker TPU 95A (a flexible material) to prevent damage to the sliding blocks during assembly.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754637978798-dsadasd.webp" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Materials for 3D printing jigs and fixtures</h2>Selecting the right materials is important for creating effective 3D printed jigs and fixtures that can withstand manufacturing environments. Several materials are excellent options for producing durable, functional tooling.For general-purpose jigs and fixtures, Tough PLA offers an excellent balance of strength and usability. This material is <a href="https://ultimaker.com/learn/application-focus-jigs-and-fixtures/">as strong as ABS but soft enough to prevent scratches</a> on finished parts, making it ideal for applications like Ford's badge positioning tools where contact with finished surfaces is necessary.When higher strength is required, composite materials like XSTRAND™ GF30 PA6 (nylon with 30% glass fiber) provide excellent rigidity and durability. Ultimaker uses this material for their own <a href="https://ultimaker.com/learn/application-focus-jigs-and-fixtures/">manufacturing fixtures</a> that need to withstand repeated use and mechanical stress. For fixtures requiring compliance or cushioning, this can be combined with flexible materials like Ultimaker TPU 95A to create multi-material tools that protect workpieces.For applications requiring chemical resistance or higher temperature tolerance, engineering-grade materials such as Ultimaker ABS, CPE, or nylon variants are recommended. These materials can withstand exposure to common industrial chemicals and maintain their structural integrity in warmer environments.Specialized tools often benefit from material combinations. Volkswagen Autoeuropa's wheelgun jig, which guides their wheelgun into wheel nuts without scratching the rim, demonstrates how material properties can be optimized for specific applications. This approach prevents damage to finished products while ensuring precise tool positioning.<h2>Design considerations for 3D printed jigs and fixtures</h2>When designing 3D printed jigs and fixtures, several factors must be considered to ensure performance and functionality. Material selection is important, with options ranging from ABS for strength in low-heat applications to PEEK for high-temperature environments.Structural integrity is needed to ensure the fixture can withstand forces. Design with wall thicknesses, reinforcement ribs for added strength, and consider the part orientation during printing to optimize strength.Ergonomics and user interface design are essential for worker comfort and efficiency. Design handles for comfortable use, optimize weight distribution to reduce fatigue, and use visual cues for ease of use.Modularity and adaptability in design allow for flexibility. Create interchangeable components for different product variants, adjustable features to accommodate size variations, and parts that can be modified and reprinted as needed.Integration with existing systems is important for implementation. Design jigs to fit machinery or workstations, consider interface points with other tools, and incorporate mounting features.Post-processing should also be considered in the design. Minimize support material, plan for surface finish treatments, and incorporate features to aid in assembly if the jig consists of multiple printed parts. As technology evolves, several future trends are set to shape the landscape of 3D printed jigs and fixtures.**<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754637994375-csd.webp" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Future trends in 3D printing jigs and fixtures</h2>The future of 3D printed jigs and fixtures is being shaped by several emerging trends that promise to further enhance their utility in manufacturing environments.Integration with Industry 4.0 concepts is creating more connected manufacturing environments. Luis Rodriguez, Application Engineer at UltiMaker, notes that while there has been <a href="https://www.tctmagazine.com/additive-manufacturing-3d-printing-industry-insights/latest-additive-manufacturing-3d-printing-industry-insights/the-jig-is-up-jigs-fixtures-how-to-3d-printing-success/">"tremendous progress towards printing tooling, jigs and fixtures,"</a> there remains "a huge opportunity" for companies to discover 3D printing as "a viable alternative to traditional manufacturing."User-friendly design tools are making jig and fixture creation more accessible. Trinckle's generative software solution, used by Ford and ERIKS, allows workers without 3D printing experience to generate custom jigs. This democratization of design capabilities enables production staff to develop and refine their own tools, improving aspects like ergonomics and functionality based on direct experience.The data from Jabil suggests a clear trend: in 2021, 57% of companies reported using 3D printing for tooling, jigs, and fixtures, up from just 30% in 2017. This growing adoption indicates that 3D printed manufacturing aids are becoming mainstream, with industry leaders predicting that eventually "all fixtures and jigs will be 3D printed."Sustainability considerations are also driving innovation in this space. Companies are increasingly viewing 3D printed jigs and fixtures as environmentally friendly alternatives to traditional metal tooling. By producing only what is needed when it's needed, and by extending the lifespan of existing equipment through custom accessories, manufacturers can reduce material waste and energy consumption.<h2>Evolving manufacturing with 3D printed jigs and fixtures</h2>The integration of 3D printing into manufacturing through jigs and fixtures signifies a shift towards more agile and efficient production processes. This adaptability not only reduces costs and lead times but also enhances the overall quality and precision of manufacturing operations. Companies like Volkswagen Autoeuropa, Ford, Jabil, and ERIKS have demonstrated the transformative impact of Ultimaker's 3D printing solutions, achieving remarkable cost savings (up to 98%) and time reductions (up to 89%) compared to traditional methods.As UltiMaker's Application Engineer Luis Rodriguez observes, successful implementation requires organizational commitment: "If a company doesn't commit a person to focus on this a few hours a week then adoption will never happen." However, for those who make this commitment, the rewards are substantial. The ability to produce custom tools on-demand, iterate designs quickly, and optimize for specific production challenges provides a competitive advantage in today's fast-paced manufacturing environment.By embracing these advancements, manufacturers can stay competitive, optimize workflows, and meet the dynamic demands of modern industries, ensuring a future where production is both streamlined and sustainable. The growing adoption of 3D printed jigs and fixtures, from 30% of companies in 2017 to 57% in 2021, suggests that this approach is increasingly becoming standard practice rather than just an innovative exception.

3D printing has revolutionized manufacturing processes, offering versatile solutions that enhance efficiency and precision. Among these advancements, 3D printed jigs and fixtures stand out as transformative tools.

3D printing jigs and fixtures: Revolutionizing manufacturing efficiency

This article was discussed in our <a href="https://www.wevolver.com/profile/the.next.byte" rel="noopener noreferrer" target="_blank">Next Byte podcast</a>. <iframe height="200px" width="100%" frameborder="no" scrolling="no" src="https://player.simplecast.com/31667843-cd8b-4bae-bcde-8a37ddd81eab?dark=false"></iframe> The full article will continue below.<hr />Following a heart attack, blood flow to the heart is interrupted and the resulting lack of oxygen can cause heart damage. The heart wall can rupture in severe cases, requiring immediate surgical intervention. Today, bovine pericardial patches are used to repair such heart defects owing to their stability, permeability and ease of implantation.An interdisciplinary research team from ETH Zurich and the University Hospital of Zurich, led by Professor Robert Katzschmann and Professor Omer Dzemali, have developed a novel three-dimensional heart patch for intraventricular implantation. The team has just presented it in the scientific journal Advanced Materials.<h2>Not only to seal but also to heal</h2>The bovine pericardial patches currently used, BPPs for short, have significant disadvantages. Not only are they biologically inert, meaning they remain foreign bodies in the heart and cannot be broken down, but they can also cause unwanted reactions such as calcification, thrombosis, or inflammation. “Traditional heart patches do not integrate into the heart tissue and remain permanently in the body. We wanted to solve this problem with our patch, which integrates into the existing heart tissue,” explains Lewis Jones, lead author of the study.The “RCPatch” (Reinforced Cardiac Patch) could become a long-term alternative to conventional patches made from bovine pericardium: “Our goal was to develop a patch that not only closes a defect but also helps to repair it completely,” explains Katzschmann.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzU0NDkwMjkwNzc5LTE3NTQ0OTAyOTA3NzkucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib" /><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzU0NDkwMzA4MTc1LTE3NTQ0OTAzMDgxNzUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dib" /> <h2 id="isPasted">One patch, three components</h2>The new RCPatch has significant advantages over bovine pericardium because it consists of three parts: a fine mesh that seals the damage, a 3D-printed scaffold for stability and a hydrogel populated with heart muscle cells. The scaffold has a lattice structure composed of a degradable polymer, which the researchers produce in a 3D printer. “The scaffold is stable enough and can be filled with a hydrogel containing living cells,” explains Jones.The ETH researchers combined the lattice structure with a thin mesh so that it could be easily attached to the heart. Katzschmann and his team enriched this mesh with the same hydrogel. This allows the RCPatch to integrate into the surrounding tissue and grow together with the heart muscle cells. “The big advantage is that the scaffold is completely degraded after the cells have combined with the tissue. This means that no foreign body remains,” explains Jones. The combination of the three components results in a dense, easy-to-use heart patch that is partly made of living cells.<iframe width="640" height="360" src="https://www.youtube.com/embed/JWBZC-mtN9g?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0"> </iframe><h2 id="isPasted">Initial tests on the heart</h2>An initial animal experiment demonstrated the ability of the patch to be successfully implanted and withstand the high pressure in the heart. The researchers succeeded in preventing bleeding and restoring cardiac function. In preclinical tests on pig models, the RCPatch was used to close an artificial defect in the left ventricle. “We were able to show that the patch retains its structural integrity even under real blood pressure,” says Katzschmann.The research group has thus created a promising foundation for the development of a mechanically reinforced and tissue-engineered heart patch suitable for implantation in humans. In the long term, the RCPatch is intended not to only repair but also to regenerate myocardial damage, ultimately healing the heart. In the next step, the researchers aim to develop the material further and investigate its stability in long-term animal studies.<hr /><h2 id="isPasted">References</h2>Lewis S. Jones et al. Volumetric 3D Printing and Melt-Electrowriting to Fabricate Implantable Reinforced Cardiac Tissue Patches, Advanced Materials. DOI: <a href="https://doi.org/10.1002/adma.202504765">external page10.1002/adma.202504765</a>

Illustration of the 3D-printed scaffold, which contracts in heart tissue  (Image: Soft Robotics Laboratory / ETH Zurich)

A new type of tissue-engineered cardiac patch could not only seal defective areas of the heart, as has been the case up to now, but also heal them. An interdisciplinary team led by ETH Zurich has successfully implanted the patch in animals.

A Patch for the Heart

3D printing is a simple way to create custom tools, replacement pieces and other helpful objects, but it is also being used to create untraceable firearms, such as ghost guns, like the one implicated in the late 2024 killing of UnitedHealthcare CEO Brian Thompson.Netanel Raviv, assistant professor of computer science &amp; engineering in the McKelvey School of Engineering at Washington University in St. Louis, led a team from the departments of Computer Science &amp; Engineering and Biomedical Engineering that has developed a way to create an embedded fingerprint in 3D-printed parts that would withstand the item being broken, allowing authorities to gain information for forensic investigation, such as the identity of the printer or the person who owns it and the time and place of printing. The research will be presented at the USENIX Security Symposium Aug. 13-15, 2025, in Seattle. First authors of the paper are Canran Wang and Jinweng Wang, who earned doctorates in computer science in 2024 and 2025, respectively. Fingerprinting in 3D printing embeds unique, traceable data, such as timestamps, geolocations and printer identification, into each item and allow items to be traced to the creator. While there are multiple ways to create fingerprints, none have looked at how these fingerprints may stand up to someone who tampers with or breaks the item into pieces.Raviv’s team developed mathematical techniques to embed information into 3D printed objects in a robust way and coupled them with security mechanisms to enforce 3D-printers to embed those codes in the objects they print. The team’s framework, Secure Information Embedding and Extraction, or SIDE, uses break-resilient, loss-tolerant embedding techniques that stand up against adversaries and acts as a security mechanism.The technique is built on <a href="https://arxiv.org/abs/2310.03897">research</a> Raviv and his student presented in July 2024 at the IEEE International Symposium on Information Theory. That research focused on creating a mathematical framework for an encoder that would recover original information bits from fragments of broken 3D printed objects resulting from adversarial tampering.“This work opens up new venues for protecting the public from the harmful aspects of 3D printing via a combination of mathematical contributions and new security mechanisms,” Raviv said. “While SIDE has limitations in defending against resourceful attackers with strong expertise in 3D printing, it significantly raises the level of sophistication, prior knowledge and expertise required from the adversary to remain undetected after committing the crime.” <hr />Wang C, Wang J, Zhou M, Pham V, Hao S, Zhou C, Zhang N, Raviv N. Secure Information Embedding in Forensic 3D Fingerprinting. Presented at the USENIX Security Symposium Aug. 13–15, 2025. <a href="https://arxiv.org/abs/2403.04918">https://arxiv.org/abs/2403.04918</a>Funding for this research was provided by the National Science Foundation (CNS-2223032, CNS-2038995, CNS-223863) and the Army Research Office (W911NF-24-1-0155).

Netanel Raviv and members of his lab have developed a way to create an embedded fingerprint in 3D-printed parts that would withstand the item being broken, allowing authorities to gain information for forensic investigation. (Credit: Raviv lab)

3D printing is a simple way to create custom tools, replacement pieces and other helpful objects, but it is also being used to create untraceable firearms, such as ghost guns, like the one implicated in the late 2024 killing of UnitedHealthcare CEO Brian Thompson.

Unique fingerprints in 3D printing may foil adversaries

Electronic devices have evolved tremendously in recent years, moving beyond standard-sized rigid, silicone chips to include increasingly versatile sensors and circuits, including flexible electronics, miniaturized electronics, and large-area electronics (LAE).These new frontiers in the electronics industry are in large part enabled by emerging prototyping technologies, like <a href="https://www.voltera.io/blog/introduction-direct-ink-writing-printing-technology?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=large-area-electronics&amp;utm_content=direct-ink-writing">Direct Ink Writing</a> (DIW), which make it possible to print electronics directly—without the need for tools—and to use a broad array of materials, including flexible substrates and stretchable conductive inks. As we’ll see in this article, DIW solutions, such as Voltera’s <a href="https://www.voltera.io/products/nova?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=large-area-electronics&amp;utm_content=nova-materials-dispensing-system">NOVA materials dispensing system</a>, are facilitating the development of novel large-area electronics applications, which could change the game for electronic devices in the healthcare, consumer, and automotive segments, among others.<iframe src="https://www.youtube.com/embed/erRY7sHCaP8??si=bxUiFB9l63gKYrA7&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" style="width:640px;height:460px">       </iframe><h2 id="isPasted">What are Large-Area Electronics?</h2>If you haven’t heard the term before, LAE is a cutting-edge field in the broader electronics industry that is focused on the development of ultra-thin, flexible electronics that can cover a wide area and, in many cases, conform to non-planar surfaces. LAE is thus closely tied to <a href="https://www.wevolver.com/article/electronics-that-bend-the-rules-the-benefit-of-flexible-multilayer-designs">flexible electronics</a>, with the added element of scale.Among the most common application areas for LAE are displays (i.e. liquid crystal displays) and photovoltaics (i.e. solar cells). As technologies that enable LAE continue to advance, however, more and more applications are being explored in a variety of sectors, including healthcare, consumer goods, automotive, packaging, and more. For example, the study “Materials and Applications for Large Area Electronics: Solution-Based Approaches”, published in the journal Chemical Reviews, highlights a number of LAE applications, including medical imaging arrays, flexible active matrix displays, printed radio frequency identification (RFID), and light-emissive flexible displays.[1]These LAE applications and others like <a href="https://www.voltera.io/use-cases/applications/wearable-flexible-electronics?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=large-area-electronics&amp;utm_content=smart-textiles">wearable sensors and smart textiles</a> are largely made possible thanks to material advances and innovative printing technologies, which have unbound electronics from their original rigid state and are making it possible to create large-scale conductive patterns on thin, flexible substrates. Production technologies like inkjet printing, screen printing, and roll-to-roll printing use varying approaches to apply conductive traces onto a large-scale flexible substrate.<h3>Challenges for LAE</h3>The biggest challenges still facing LAE—despite the technical ability to print conductive patterns onto large swaths of substrate—are related to functionality and cost. LAE developers and research groups are working to establish a balance between the production of large-area electronics with a high level of functionality (at a microelectronic level) over a large area without dramatically driving up the cost of creating the required conductive patterns. That’s where Direct Ink Writing (DIW) is making an impact.<h2>DIW’s central role in LAE prototyping</h2>Direct Ink Writing is becoming a key technology in the development and advancement of LAE devices. DIW is a printing method that selectively dispenses a viscous material or ink onto a substrate. The dispensed material is then solidified using UV curing, air drying, or a chemical reaction, resulting in a stable printed pattern. DIW is an incredibly versatile technology thanks to the broad range of materials it can process. For example, dispensing feedstocks can include conductive or dielectric inks—even those with flexible properties—while compatible substrates include anything from TPU and thin-film PET to paper and fabric. This material versatility is central to why LAE developers are increasingly turning to DIW in order to prototype new devices. The ability to test new conductive materials on unconventional substrates, including thin and flexible substrates, is a must in LAE development.Not only does DIW enable LAE developers to rapidly test the compatibility of print materials and substrates, it also facilitates rapid design iteration and validation. With DIW solutions in house, R&amp;D groups can print and immediately test components (including sensors, interconnects, etc.), performing mechanical stress tests to understand how the device’s functionality is influenced by stretching or bending as well as implementing other quality checks. This capability enables LAE developers to not only dramatically accelerate prototyping cycles but to maintain greater control over the development process and design iterations.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754385971850-Volteras+Applications+team+testing+the+quality+of+force+sensitive+resistors+printed+on+Beyolex.jpg" style="width:100%px" class="fr-fic fr-dib" />Voltera's Applications team testing the quality of force sensitive resistors printed on BeyolexTMWhile DIW itself is not a full-scale production solution, the prototyping technology does facilitate the transition from development to manufacturing. This is because the DIW process is compatible with most screen printing materials, enabling developers to test their LAE devices on a smaller scale using the same conductive inks and substrates before moving into mass production. Finally, compared to more conventional electronic prototyping workflows—which in the case of screen printing requires the production of a mask—Direct Ink Writing does not require any tooling. By directly printing conductive patterns onto a substrate, DIW eliminates the need for tooling, which has multiple knock-on benefits, including less material usage, faster lead times, and lower prototyping costs. In summary, DIW offers several benefits to LAE developers:<ul><li>Versatile material compatibility </li><li>Rapid design iteration and validation</li><li>Seamless transition to scalable production</li><li>Reduced prototyping costs</li></ul><h2>LAE innovators leverage Voltera solutions</h2>Canadian company <a href="https://www.voltera.io/about/about-us?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=large-area-electronics&amp;utm_content=voltera">Voltera</a> is a leading provider of DIW solutions and the company’s technologies have supported many electronics R&amp;D and product development efforts in recent years. Voltera’s flagship product is <a href="https://www.voltera.io/products/nova?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=large-area-electronics&amp;utm_content=nova">NOVA</a>, a DIW-based materials dispensing platform capable of dispensing screen-printable materials into a wide range of substrates. The intuitive system has been used to develop myriad applications, from <a href="https://www.voltera.io/use-cases/white-papers/printing-ecg-electrodes-biocompatible-gold-ink-tpu?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=large-area-electronics&amp;utm_content=wearable-sensors">electrocardiogram (ECG) electrodes</a> to <a href="https://www.voltera.io/use-cases/white-papers/printing-magnesium-zinc-battery-saral-inks-pet?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=large-area-electronics&amp;utm_content=printed-batteries">printed batteries</a>. Because of its compatibility with a wide range of materials, NOVA is particularly well suited to LAE development and prototyping, enabling researchers to experiment with new material combinations and iterate designs quickly. In his 2023 thesis at the University of Surrey’s Advanced Technology Institute, for example, Georgios Bairaktaris leveraged one of Voltera’s printing platforms in the exploration of unconventional user interfaces. His work, which involved printing an augmented paper platform—the “Magic Bookmark”—using a combination of off-the-shelf parts and flexible printed conductors, demonstrated how simple fabrication processes and low-cost materials could be used to create large-area electronics.[2]<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754385473280-NOVA+dispensing+conductive+polymer+ink+on+paper+for+an+electroluminescent+display.webp" style="width:100%px" class="fr-fic fr-dib" />NOVA dispensing conductive polymer ink on paper for an electroluminescent display.In another use case relevant to LAE, Voltera used its NOVA platform to print <a href="https://www.voltera.io/use-cases/white-papers/printing-electroluminescent-ink-paper-pet?utm_campaign=Wevolver&amp;utm_source=website&amp;utm_medium=large-area-electronics&amp;utm_content=electroluminescent-displays">electroluminescent displays</a> on paper and PET substrates. This application, which resulted in a blue-light emitting pattern in the shape of Voltera’s logo, is a good example of NOVA’s ability to print multilayer electronics. In this case, the electroluminescent display consisted of four layers: a base conductive layer, a dielectric layer, a phosphor layer, and a top conductive layer. According to the company this approach could also be applied to larger electronic displays, like billboards, control panels, and branded merchandise.<h2>The future outlook of LAE </h2>While large-area electronics is still very much an emerging field, and many potential use cases are still limited to the research realm, it has huge potential for healthcare, consumer, and industrial applications in terms of advancing the functionality of large-scale electronic displays and sensors, while also reducing costs.With DIW platforms like Voltera’s NOVA empowering LAE developers, like those associated with the <a href="https://innolae.org/">INNOLAE</a>, to test out new materials and designs, we can expect to see many more LAE devices coming to market at competitive costs. Devices like large-scale venue displays; conformable solar skins, which could be designed to fit seamlessly onto buildings; wearable batteries or energy storage devices; smart bandages that monitor wound healing; textiles with thermal regulation built in; augmented e-paper; and much more. Overall, technologies like DIW are paving the way to LAE devices that are more functional, flexible, and lower cost.<h2>References</h2>[1] Arias AC, MacKenzie JD, McCulloch I, Rivnay J, Salleo A. Materials and applications for large area electronics: solution-based approaches. Chemical reviews. 2010 Jan 13;110(1):3-24.[2] Bairaktaris G. Flexible electronic technologies for new user interfaces (Doctoral dissertation, University of Surrey).

Voltera’s NOVA dispensing conductive silver ink for a flexible capacitive touch sensor.

Explore how Direct Ink Writing (DIW) and Voltera's NOVA system are revolutionizing electronics prototyping—enabling flexible, stretchable, and large-area electronics for next-gen applications in healthcare, consumer tech, and automotive industries.

Unlocking Large-Area Electronics with Direct Ink Writing

Carbon fiber-reinforced nylon is widely used in aerospace, automotive, and tooling industries for applications requiring strength, stiffness, and thermal resistance while maintaining a lightweight profile. However, many filaments come with limitations like proprietary ecosystems, high costs, and restricted compatibility with open-source platforms or newer printer models. These constraints make it difficult for teams working with diverse printer fleets or limited budgets to take full advantage of carbon-reinforced composites. This article discusses how <a href="https://www.3dxtech.com/">3DXTech</a> developed <a href="https://www.3dxtech.com/pages/obsidian-v2">Obsidian CF v2</a> in response to these constraints, and examines its performance characteristics in more detail, including platform compatibility, mechanical behavior, and filament handling practices for consistent results.<h2>From V1 to V2: Reengineering Based on Real-World Feedback</h2>Filaments designed for engineering use often struggle to balance printability with mechanical performance, especially on open-source hardware. The original Obsidian CF (V1) material was positioned as an alternative to Markforged’s Onyx, but over time, feedback from the user community revealed some areas of improvement. For example, one area highlighted by the users was the difficulty in achieving reliable print results under Turbo settings. This feedback prompted 3DXTech to re-examine the base polymer blend, carbon fiber content, and the engineering validation pipeline. The objective was to develop a material that matches or exceeds Onyx on both printability and mechanical output regardless of whether users were locked into proprietary systems or using open hardware. The new Obsidian CF v2, was rebuilt from the ground up to provide better flow characteristics, improved compatibility with high-speed settings, and better surface finish. It was tested in controlled lab conditions as well as in real-world printing environments.<iframe width="640" height="360" src="https://www.youtube.com/embed/085jpfr4eoE?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0"></iframe><h2 id="isPasted">Performance in Print: Test Results and Material Behavior</h2><h3>Printability and Flow Characteristics</h3>Printability is one of the most critical factors in evaluating a high-performance filament. One of the main bottlenecks in adopting carbon fiber-reinforced filaments at scale is inconsistent extrusion behavior, especially at high speeds. To address this, 3DXTech reformulated Obsidian CF v2 and validated its printability using the Orca Slicer’s volumetric flow rate test, which gradually increases the material feed rate to identify the threshold beyond which consistent extrusion can no longer be maintained. Obsidian v2 Turbo achieved a max volumetric speed of 35 mm³/s, nearly identical to Onyx Turbo’s 33 mm³/s. This result places Obsidian CF v2 Turbo among the highest-performing filaments in its category, particularly for high-speed printing scenarios. For applications such as drone housings, aerospace tooling, or automotive brackets, where dimensional accuracy must be preserved even under rapid prototyping conditions, Obsidian CF v2's high flow stability helps reduce print errors during high-speed runs.In terms of flow ratio, Obsidian CF v2 achieved a value of 1.00, which is considered ideal and matches that of Onyx. This indicates that the filament exhibits reliable dimensional accuracy and layer consistency across various speeds.<h3>Surface Quality and Visual Comparison</h3>The visual characteristics of a print can heavily influence its suitability for end-use applications. Surface finish is a persistent concern when shifting filaments, especially for client-facing prototypes or end-use components. Visual inspection and comparative prints conducted across the Markforged X7, Bambu Lab X1E, and H2D platforms show that Obsidian CF v2's surface appearance is nearly indistinguishable from Onyx. When examining layer lines and top-layer fill, the differences between Obsidian CF v2 and Onyx were minimal. In side-by-side prints using a standard gripper jaw model, v2’s top layers were filled with similar density and alignment as Onyx, showing consistent fusion and minimal gaps. Moreover, v2 mimics Onyx’s subtle matte texture, resulting in a more uniform appearance. This improves aesthetics and reduces visual distractions in printed parts used for functional prototypes or end-use applications. This is valuable in customer-facing prototypes or production components in the automotive interior and aerospace cabin systems, where surface finish impacts both perception and functionality.<h3>Mechanical Testing</h3>The performance of any engineering-grade filament ultimately comes down to its mechanical properties. To evaluate strength and interlayer adhesion of v2 tensile tests (ASTM D638, Type V) were conducted across three printer platforms including Markforged X7, Bambu Lab X1E, and H2D in both XY and ZX orientations.In the XY orientation, Obsidian CF v2 consistently outperformed Onyx in tensile stress at break. On the X7, v2 measured 80.63 MPa, which is roughly 12% higher than Onyx’s 71.98 MPa. On the X1E, the difference grew even larger, with v2 reaching 80.62 MPa versus Onyx’s 55.63 MPa, which is a 45% improvement. Similar trends were observed on the H2D, where v2 reached 75.71 MPa, compared to Onyx’s 55.00 MPa. Elongation results showed a tradeoff, with v2 showing slightly lower ductility compared to Onyx, indicative of a stiffer, slightly more brittle material. However, the differences were within acceptable bounds, and the mechanical strength gains more than compensated for the minor loss in elongation.In the ZX orientation, which tests interlayer adhesion, Obsidian CF v2 again outperformed its predecessor and closely matched Onyx. On the X1E and H2D, v2 demonstrated Tensile Stress at Break values of 35.54 MPa and 56.08 MPa respectively, outpacing Onyx in both cases. The inclusion of a heated chamber, available on the Bambu Lab platforms but not on the X7, further improved v2’s layer bonding.<h3>Cross-Platform Consistency</h3>One frequent concern with third-party filaments is performance drift across different hardware ecosystems. However, Obsidian v2 achieves consistent results, regardless of whether it is used on a closed-source Markforged X7 or open printers like the Bambu Lab X1E and H2D. It maintains relatively stable tensile strength values, with a recorded standard deviation of ±4.38 MPa. This consistency speaks to 3DXTech’s success in optimizing crystallization behavior and thermal stability. This results in fewer failed prints, more predictable part quality, and easier scaling.<h3>Field Validation: Trusted by High-Use Customers</h3>Along with lab testing, Obsidian CF v2 has already been validated by professional users in production environments. These customers operate under demanding conditions that test not just mechanical strength but also long-term reliability and require print consistency across batches. Their feedback reinforces the lab-based results, confirming that v2 performs reliably in high-throughput, real-use scenarios. The positive feedback from these users reinforces the material’s practical value and confirms that the improvements in formulation have translated into tangible real-world improvements.<h2>Compatibility Beyond Markforged: Open-Source Advantages</h2>A defining characteristic of Obsidian v2 is its smooth operation in open-source 3D printer ecosystems. Unlike Onyx, which is paired tightly with Markforged's proprietary systems, Obsidian CF v2 is engineered for broad compatibility, with notable success on Bambu Lab printers featuring AMS (Automatic Material System) and heated chambers. Test results from platforms like the X1E and H2D demonstrate that users can achieve performance comparable to Onyx, without being restricted to proprietary materials or software ecosystems. Organizations running mixed fleets or aiming to scale production across diverse equipment can use this material to standardize part quality and performance across platforms.<h2>Cost Considerations: A Practical Onyx Alternative</h2>When selecting materials for functional parts or production-grade components, cost efficiency becomes critical. Markforged’s Onyx is widely used for its reliability in high-performance environments, but its pricing and proprietary ecosystem can make it a less viable option for many users, especially those outside enterprise settings or those operating on open hardware.In this regard, Obsidian CF v2 offers a practical alternative by significantly reducing material costs while still serving the same functional use cases. It allows teams to produce strong, stiff nylon-carbon fiber parts without committing to the higher price tags or vendor-specific constraints that often accompany closed systems. This is relevant in settings such as small-batch production, iterative prototyping, or large-format printing, where material usage can scale quickly and begin to dominate operational costs.Engineering teams operating under budget constraints, whether in startups, academic settings, or lean R&amp;D environments, can experiment, iterate, and manufacture with Obsidian CF v2 while maintaining financial sustainability. Similarly, companies scaling up production can benefit from switching to a more cost-accessible filament like Obsidian CF v2, as the savings compound across multiple printers and manufacturing cycles, improving overall project economics.Moreover, its availability for a wide range of open-platform machines provides further cost relief by allowing users to avoid licensing fees, service contracts, and platform-specific accessories. Overall, Obsidian CF v2 shifts the pricing dynamics as it retains professional-grade material characteristics while freeing users from vendor lock-in and high recurring costs. This positioning makes it an economical substitute for Onyx, and a strategic material choice for organizations aiming to scale without overextending their budgets.<h2>Filament Handling and Maintenance </h2>Along with material properties and print performance, proper handling and storage practices are very important in achieving consistent results with carbon fiber-reinforced filaments. <h3>Why Moisture Matters for CF Filaments</h3>Carbon fiber-reinforced nylons are hygroscopic as they naturally absorb moisture from the air, even at relatively low humidity levels. When these materials are exposed to ambient conditions for extended periods, absorbed water can lead to several undesirable outcomes during printing. The most immediate symptoms include stringing, oozing, and inconsistent extrusion, but the consequences go beyond surface defects. Moisture in the filament can disrupt the polymer matrix during melting, creating microvoids and weakening the overall integrity of the print. Poor layer bonding and surface finish caused by moisture-laden filament can lead to part failure, particularly in end-use components or mechanically loaded prints. Keeping the material dry is therefore imperative for maintaining reliable performance.<h3>Best Practices for Users</h3>Users should adopt consistent filament handling routines to mitigate the effects of moisture. Carbon fiber nylons should be stored in a controlled-humidity environment when not in use. Dry-boxes and automatic material systems (AMS) with sealed enclosures and desiccants are suitable for this purpose. These help prevent the material from absorbing moisture between prints, especially in humid climates or uncontrolled workshops.If a spool has been exposed to room air for more than a few hours, it is better to dry it before the next print. Standard drying conditions for PA6-based composites typically involve heating the filament to 80–90°C for several hours, using a purpose-built filament dryer or a low-temperature oven with precise control. Users should avoid makeshift or unregulated methods, as excessive heat can degrade the polymer or cause uneven drying. Users can maintain consistent extrusion behavior and reduce waste caused by failed or low-quality prints by implementing these storage and drying habits.<h3>3DXTech’s Drying and Storage Solutions</h3>3DXTech provides several tools to help users manage moisture exposure effectively. Each spool of Obsidian CF v2 is shipped vacuum-sealed with desiccant packs, ensuring it arrives in optimal condition. This packaging is designed to limit humidity ingress during storage and transit, but it is only effective until the seal is broken. Once opened, proactive moisture management becomes the user’s responsibility.3DXTech offers two key accessories, including the <a href="https://www.3dxtech.com/pages/fm1-filament-maintainer">FM1 Filament Maintainer</a> and the <a href="https://www.3dxtech.com/pages/fd1-filamentdryer">FD1 Filament Dryer</a>, to support users in managing moisture. The FM1 is intended for dry storage of multiple spools, keeping them at low humidity levels for long durations between prints. This is useful for workshops that keep several materials on hand or rotate spools frequently.The FD1, on the other hand, is designed for in-line filament drying. It actively removes moisture from filament as it feeds into the printer, making it suited for high-humidity environments or long-duration prints where moisture uptake could occur mid-job. These tools by 3DXTech give users control over keeping the material consistently dry.<h2>Conclusion</h2>Obsidian CF v2 stands out not only because it performs well in technical benchmarks, but because it addresses a broader challenge faced by many professional users to find a material that balances strength, consistency, and open-platform compatibility without introducing unnecessary tradeoffs. Users can incorporate Obsidian CF v2 into existing workflows without needing to overhaul equipment or commit to a locked ecosystem. Its consistent behavior across machines, compatibility with high-speed settings, and cost-effectiveness make it a preferred choice for professional users in demanding applications.For teams seeking high-performance filament without vendor constraints, <a href="https://www.3dxtech.com/products/obsidian-nylon-6-cf-v2">Obsidian CF v2</a> is a practical, validated option worth considering in professional print environments. To find out more, visit <a href="https://www.3dxtech.com/">3DXTech Website</a>.<hr /><h1 id="isPasted">References</h1><ol><li>3DXTech. [Online] Available at: <a href="https://www.3dxtech.com/">https://www.3dxtech.com/</a> (Accessed on July 20, 2025)</li><li>OBSIDIAN CF v2 [Online] 3DXTech. Available at: <a href="https://www.3dxtech.com/pages/obsidian-v2">https://www.3dxtech.com/pages/obsidian-v2</a> (Accessed on July 20, 2025)</li><li>Onyx [Online] Markforged. Available at: <a href="https://markforged.com/materials/plastics/onyx?_gl=1*pbezl3*_up*MQ..*_gs*MQ..&amp;gclid=CjwKCAjwyb3DBhBlEiwAqZLe5GPqQrfNN9IFsBopMxFuLh2YW-VDVKcGUYC-BdIu2mixR6yRRAz09xoCqscQAvD_BwE&amp;gbraid=0AAAAADoxHCZ3vpnX7WLYMlz7c7aena3Vy">https://markforged.com/materials/plastics/onyx?_gl=1*pbezl3*_up*MQ..*_gs*MQ..&amp;gclid=CjwKCAjwyb3DBhBlEiwAqZLe5GPqQrfNN9IFsBopMxFuLh2YW-VDVKcGUYC-BdIu2mixR6yRRAz09xoCqscQAvD_BwE&amp;gbraid=0AAAAADoxHCZ3vpnX7WLYMlz7c7aena3Vy</a> (Accessed on July 20, 2025)</li><li>FM1 - Filament Maintainer [Online] 3DXTech. Available at: <a href="https://www.3dxtech.com/pages/fm1-filament-maintainer">https://www.3dxtech.com/pages/fm1-filament-maintainer</a> (Accessed on July 20, 2025)</li><li>FD1 - Filament Dryer [Online] 3DXTech. Available at: <a href="https://www.3dxtech.com/pages/fd1-filamentdryer">https://www.3dxtech.com/pages/fd1-filamentdryer</a> (Accessed on July 20, 2025)</li><li>OBSIDIAN™ NYLON 6+CF V2 [Online] 3DXTech. Available at: <a href="https://www.3dxtech.com/products/obsidian-nylon-6-cf-v2">https://www.3dxtech.com/products/obsidian-nylon-6-cf-v2</a> (Accessed on July 20, 2025)</li></ol>

Discover how Obsidian CF v2 simplifies high-performance printing with a reformulated blend that performs across platforms and print speeds.

Obsidian CF v2: Reformulated and Ready to Outperform

In-Person, Business ConferenceAdditive Manufacturing Strategies is a 100% in-person event, taking place from February 24-26, 2026, in New York City. This industry touchstone conference brings together AM stakeholders from all over the world. <img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754256277748-AMS-2024-photo-07.jpg" style="width:100%px" class="fr-fic fr-dib" /><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1754256298955-Conference-Opening-AMS.jpg" style="width:100%px" class="fr-fic fr-dib" />AMS includes panels and keynotes on topics most critical in the fast-growing world of additive manufacturing. Bringing together the industry’s leaders in a contained networking environment makes AMS the place for startups to access capital, for financial institutions and investors to sharpen their radars, and for the AM industry to focus on the business of AM.SPEAKERS<ul><li>Karsten Heuser, VP Additive Manufacturing, Siemens Digital Industries, Siemens AG</li><li>Scott Dunham, Executive Vice President of Research, Additive Manufacturing Research</li><li>Amy Elliott, Leading Expert, Additive Manufacturing, Oak Ridge National Laboratory (ORNL)</li><li>Felix Ewald, Co-Founder and CEO, DyeMansion</li><li>Omar Fergani, CEO &amp; Co-Founder, 1000 Kelvin GmbH</li><li>Michael Fuller, Founder &amp; CEO, Conflux Technology</li><li>Filip Geerts, Director General, CECIMO, the European Association of Manufacturing Technologies</li><li>Kimberly Gibson, Additive Manufacturing Ecosystem Director, America Makes</li><li>Jason Gorey, Executive Director, ASTRO America</li><li>Jeff Graves, President &amp; CEO, 3D Systems</li><li>John Hart, Professor of Mechanical Engineering, MIT - Massachusetts Institute of Technology</li><li>Among others...</li></ul>For registration, sponsorship, and speaking opportunities, please click the link below.<a href="https://wevlv.co/450pDZn" target="_blank" rel="noopener noreferrer" class="button-main-action">CLICK HERE</a>

9th Annual. February 24-26, 2026. New York City

Event: Additive Manufacturing Strategies 2026

The ability to combine different materials in a single print unlocks new possibilities for functional and aesthetic design.<a href="https://ultimaker.com/learn/technical-guide-multi-material-3d-printing-with-ultimaker/">Multi-material 3D printing</a> allows for the creation of parts with varying properties, such as flexible hinges integrated into a rigid structure. This capability streamlines manufacturing processes and enhances product performance.<h2>Understanding multi-material 3D prints</h2>Multi-material 3D printing marks a notable step forward in additive manufacturing, enabling the creation of parts with diverse functional, mechanical, or visual characteristics. It achieves this by combining two or more distinct materials within a single print. The introduction of dependable dual material printing on UltiMaker 3D printers has broadened the accessibility of this technique to professionals and hobbyists alike.The advantages of multi-material 3D prints are substantial. By integrating different material properties, such as flexibility and rigidity, intricate parts can be created that were previously difficult to manufacture. Support structures can be printed using dissolvable materials like <a href="https://ultimaker.com/materials/pva">UltiMaker PVA</a>, which simplifies post-processing and facilitates complex geometries. Multi-color parts enhance visual appeal and can also serve functional purposes by highlighting particular areas. Furthermore, mechanical properties can be enhanced by reinforcing critical sections with stronger materials.When using multi-material 3D printing, consider material compatibility, printing temperatures, and adhesion properties. Because not all materials bond well, careful selection and testing are needed to achieve good results. UltiMaker's <a href="https://ultimaker.com/materials">material compatibility guide</a> provides valuable insights on which materials work well together.UltiMaker Cura slicing software allows users to assign different materials to specific parts of a model, enabling the creation of complex parts with varying properties or the use of soluble support materials for intricate geometries. A breakthrough feature introduced in <a href="https://ultimaker.com/learn/unlock-true-multi-material-printing-with-ultimaker-cura-5-3/">UltiMaker Cura 5.3</a> is material interlocking, which allows for printing with traditionally incompatible materials by automatically generating an interlocking structure between different materials. The next section explores the different types of systems that facilitate this process.<h2>Types of multiple filament 3D printer systems</h2>Several types of multiple filament 3D printer systems exist, each offering its own advantages and considerations. A clear understanding of these different approaches helps users select the solution that best fits their needs.Dual extruder systems are a common and reliable option for multi-material printing. UltiMaker's S-series printers, including the <a href="https://ultimaker.com/3d-printers/s7">UltiMaker S7</a>, <a href="https://ultimaker.com/3d-printers/s5">S5</a>, and the newest <a href="https://ultimaker.com/3d-printers/s6">S6</a>, feature dual extrusion with two independent nozzles.This design allows for quick print times by eliminating the need for filament switching during the printing process. These systems excel at combining different materials or colors and are particularly suited for printing support structures with dissolvable materials like PVA. The ability to use two materials with vastly different properties makes UltiMaker dual extruder systems efficient for a wide range of applications.Single nozzle multi-material filament system feeders are a more affordable alternative to dual extruder systems. These printers use a single nozzle with a filament changing system, enabling multiple materials or colors to be printed through one nozzle.This approach may lead to longer print times because of filament switching and can produce more waste material. However, it provides a cost-effective way to start with multi-material printing. These systems are often limited to materials with similar printing temperatures.Tool-changing systems are an advanced approach to multi-material printing. These printers swap tool heads with different nozzles mid-print, offering flexibility with independent material setups. This allows for the use of different nozzle sizes for various materials, which can be useful for specialized applications. However, tool-changing systems can involve more complex setup and maintenance and may have slower print times. They are generally better for research than industrial workflows.Some printers include filament mixing systems, which combine multiple filaments before extrusion. This allows for color blending and gradients, mixing of different material properties, and the creation of unique visual and functional effects. These systems are typically limited to materials with compatible melting temperatures.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1753859055183-dsada-1.jpg" style="width:100%px" class="fr-fic fr-dib" /><h3 id="isPasted">Comparison of multi-material printing systems</h3><table><tbody><tr><td>System Type</td><td>Pros</td><td>Cons</td><td>Best For</td></tr><tr><td>Dual Extruder (e.g., S7)</td><td>Fast switching, material flexibility</td><td>Slightly more hardware complexity</td><td>Professional multi-material use</td></tr><tr><td>Single Nozzle Switching</td><td>Affordable, entry-level option</td><td>Slower prints, more waste</td><td>Hobbyists, budget workflows</td></tr><tr><td>Tool-Changing</td><td>Max flexibility, nozzle variety</td><td>Complex setup, slower, costly</td><td>Research, experimental setups</td></tr><tr><td>Filament Mixing</td><td>Color blending, visual effects</td><td>Limited to compatible materials</td><td>Visual prototypes, R&amp;D</td></tr></tbody></table>When selecting a multiple filament 3D printer system, consider factors such as print quality requirements, material compatibility, production speed, and budget. UltiMaker's dual extruder systems offer an excellent balance of reliability, print quality, and ease of use, making them ideal for professional environments where consistent results are crucial. The system you choose will significantly impact your ability to print in multiple colors, as discussed in the following section.<h2>How to 3D print multiple colors</h2>Printing with multiple colors opens up possibilities for creating visually appealing and functional parts. To learn how to 3D print multiple colors with UltiMaker systems, follow these steps:First, choose the right printer. UltiMaker offers several dual extruder 3D printers with two separate nozzles, including the S3, S5, and S7 models. Each printer features UltiMaker's reliable dual extrusion system, allowing for precise color separation and material combinations. Consider your printing volume needs and budget when selecting the appropriate model for your applications.Next, prepare your 3D model. Design your model with separate parts for each color, or use mesh painting tools in UltiMaker Cura to assign different colors to specific areas. For beginners, UltiMaker offers a helpful tutorial on <a href="https://ultimaker.com/learn/get-started-with-cura-printing-with-two-colors/">getting started with Cura for printing with two colors</a>, which guides you through the process of loading and merging multiple color models. This step is important for achieving the color distribution you want in your final print.Setting up your slicer software is key. When using UltiMaker Cura for multiple colors, enable multiple extruders in the printer settings, assign different colors to model parts, and configure temperature and retraction settings for each extruder. These settings ensure that your printer switches between colors correctly and produces clean color transitions.For cleaner results, use print aids such as prime towers to purge excess filament when switching colors and ooze shields to catch oozing filament before it affects the print. UltiMaker Cura automatically generates these features for dual extrusion prints, helping to improve the quality of your multi-color prints.Once you start printing, monitor the process closely. Pay attention to color transitions and adjust settings as needed for good results. With practice and the help of UltiMaker's resources, you'll be creating multi-color prints that demonstrate the potential of additive manufacturing. Mastering these techniques sets the stage for employing best practices in dual filament 3D printer use.<h2>Best practices for dual filament 3D printer use</h2>To get good results when using a dual filament 3D printer like the UltiMaker S-series, it's important to follow practices that address the challenges of multi-material printing. Proper calibration and alignment are important. UltiMaker printers feature automated bed leveling and nozzle offset calibration, but it's still good practice to verify these settings regularly, especially when switching between different material combinations.Material compatibility is another key consideration. UltiMaker provides a comprehensive <a href="https://ultimaker.com/materials">material compatibility chart</a> that helps users select materials that have similar printing temperatures and bed adhesion properties, and are known to bond well if printing parts that require material fusion. For parts requiring dissolvable supports, UltiMaker PVA works exceptionally well with PLA and is also compatible with CPE, facilitating the creation of complex geometries.One of the most exciting developments in UltiMaker's ecosystem is the material interlocking feature introduced in <a href="https://ultimaker.com/learn/unlock-true-multi-material-printing-with-ultimaker-cura-5-3/">Cura 5.3</a>. This innovation allows printing with traditionally incompatible materials by automatically generating an interlocking structure between different materials. For example, you can now combine rigid CPE with flexible TPU to create functional parts with both rigid and soft components.Optimizing slicer settings is important. UltiMaker Cura includes pre-configured settings for ooze shields and prime towers that prevent cross-contamination between materials. These features are automatically enabled for dual extrusion prints, but you may want to fine-tune the settings based on your specific print requirements. Adjusting retraction settings for each extruder can also help minimize stringing and improve overall print quality.When preparing models for multiple filament printing, take advantage of UltiMaker Cura's mesh painting tools to assign different materials to specific areas. Consider interlocking features for parts requiring strong bonds between dissimilar materials, or use the automatic material interlocking feature for incompatible materials. Design support structures with proper clearance for easy removal, particularly when using water-soluble PVA supports.Regular maintenance is important for printer performance. UltiMaker printers include maintenance tools and guides to help keep your printer in optimal condition. Clean nozzles thoroughly between color or material changes, perform regular checks on both extruders for wear or clogs, and keep filament dry and properly stored to prevent moisture absorption. These practices will help ensure consistent print quality and extend the life of your printer. The versatility offered by these methods unlocks a wide array of applications for multi-material printing.<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1753859070620-fdsafdas.webp" style="width:100%px" class="fr-fic fr-dib" /><h2 id="isPasted">Applications of multi-material printing</h2>Multi-material printing with UltiMaker systems has created a range of applications across industries, changing product design and manufacturing. One key application is the creation of complex functional parts. The University of Central Lancashire utilized UltiMaker technology to develop a prototype exoskeleton combining PLA for the internal core with Nylon and TPU for the external shell, demonstrating how <a href="https://ultimaker.com/learn/ultimaker-highlight-dual-extrusion-material-interlocking/">UltiMaker's dual extrusion capabilities</a> can create advanced medical devices.Support material for complex geometries is another important application of multi-material printing. UltiMaker's PVA support material enables the printing of intricate designs with internal cavities that would otherwise be impossible to produce. This water-soluble support dissolves completely, leaving no trace on the finished part and eliminating the need for manual support removal that could damage delicate features.In the automotive industry, Volkswagen Autoeuropa developed innovative liftgate badge jigs using TPU for the surface in contact with the car to prevent paint scratches, while using a rigid structural filament for the frame. This <a href="https://ultimaker.com/learn/ultimaker-highlight-dual-extrusion-material-interlocking/">application of dual extrusion</a> showcases how multi-material printing can solve specific manufacturing challenges by combining materials with complementary properties.Visual prototypes benefit from UltiMaker's dual extrusion capabilities through color effects. Prototypes with multiple colors, architectural models with color-coded sections, and educational models highlighting different components can all be produced quickly, enhancing communication and understanding of design concepts across fields.For end-use parts, UltiMaker's multi-material printing allows for the production of functional components with integrated features. A compelling example comes from a packaging company that redesigned a part that pushes 8-packs of cans. Using <a href="https://ultimaker.com/learn/ultimaker-highlight-dual-extrusion-material-interlocking/">material interlocking in Cura</a>, they printed the inside with red PLA for structure and the outer layer with wear-resistant Nylon. This not only improved functionality but also created a wear indicator as the red inner material became visible when the outer layer wore down.Medical applications of multi-material printing are impactful. Patient-specific anatomical models with color-coded regions aid in surgical planning and education. Prosthetics combining rigid and flexible components can be customized for individual patients, improving comfort and functionality. Dental models with soft tissue analogs provide more realistic training and fitting experiences.In tooling and manufacturing, multi-material printing enables the creation of injection mold inserts with conformal cooling channels and custom jigs and fixtures with integrated soft-touch areas. These applications can reduce lead times and costs in industrial settings while improving tool performance and ergonomics. However, these advanced techniques can present unique challenges, addressed in the following section on troubleshooting.<h2>Troubleshooting common issues in dual extrusion</h2>When working with dual extrusion systems like those found in UltiMaker S-series printers, issues can arise that may affect print quality and reliability. Understanding these common problems and their solutions is important for multi-material and multi-color 3D printing.Nozzle alignment issues often appear as misaligned layers or poor quality when switching extruders. UltiMaker printers include an automated calibration system that helps maintain proper alignment between nozzles. If misalignment occurs, running the calibration procedure through the printer's touchscreen interface can resolve most issues. For more persistent problems, consult the <a href="https://support.ultimaker.com/">UltiMaker support resources</a> for detailed calibration instructions.Oozing and stringing are common challenges in dual extrusion printing. UltiMaker Cura automatically enables ooze shields and prime towers for dual extrusion prints to help mitigate these issues. You can further refine these settings by adjusting the prime tower size and position in the "Dual Extrusion" section of Cura's print settings. Optimizing retraction settings for each material can also help reduce oozing; UltiMaker's material profiles include pre-configured retraction settings that work well for most applications.Poor adhesion between materials can occur when printing with different filaments. UltiMaker's material compatibility chart provides guidance on which materials work well together. For materials that typically don't bond well, the material interlocking feature in Cura 5.3 and later can create physical interlocking structures that hold different materials together even when they wouldn't chemically bond. This revolutionary feature expands the range of possible material combinations for UltiMaker users.Clogged nozzles can lead to inconsistent extrusion or complete filament flow stoppage. UltiMaker printers include a built-in cleaning procedure that can be accessed through the printer's maintenance menu. Regular use of UltiMaker's cleaning filament between material changes can help prevent clogs, especially when switching between materials with different properties or printing temperatures.Uneven extrusion between nozzles can result in one extruder producing better quality prints than the other. UltiMaker Cura allows for individual adjustment of flow rate settings for each extruder under the "Material" section. If persistent issues occur, check for worn nozzles or partially clogged hot ends and follow UltiMaker's maintenance guide for resolving these issues.Color contamination is a common issue when printing different colors. UltiMaker Cura's prime tower settings can be adjusted to increase purge volume when switching between colors, ensuring cleaner color transitions. While this may increase material usage, it can significantly improve color purity in your final prints.By addressing these common issues and implementing regular maintenance and calibration practices, you can improve the quality and reliability of your multi-material prints. The <a href="https://community.ultimaker.com/">UltiMaker Community forum</a> is also an excellent resource for troubleshooting specific issues and learning from other users' experiences with dual extrusion printing.<h2>Refining your approach</h2>Dual material 3D printing with UltiMaker systems significantly expands design and manufacturing possibilities, allowing for functional and visually appealing parts. To enhance your proficiency, focus on mastering UltiMaker Cura's advanced settings, understanding material compatibility, and implementing routine maintenance procedures. The material interlocking feature in Cura opens up new possibilities for combining previously incompatible materials, taking multi-material printing to new heights.Explore UltiMaker's extensive learning resources, including detailed guides on dual extrusion techniques, material selection, and troubleshooting tips. With practice and the right knowledge, you'll be creating professional-quality multi-material prints that showcase the full potential of UltiMaker's dual extrusion technology. Last but not least, <a href="https://ultimaker.com/learn/technical-guide-multi-material-3d-printing-with-ultimaker/">download our free multi-material 3D printing guide.</a>

Multi-material 3D printing allows for the creation of parts with varying properties, such as flexible hinges integrated into a rigid structure. This capability streamlines manufacturing processes and enhances product performance.

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In manufacturing, achieving a high-quality finish is just as important as the fabrication process itself. Post-processing transforms raw or freshly produced components into professional, functional, and aesthetically appealing parts. Whether a component is 3D printed, cast, or machined, post-processing ensures it meets the required surface, dimensional, and structural standards. Among the many post-processing methods available, media blasting is one of the most versatile and widely adopted techniques.Media blasting involves propelling abrasive materials—called “media”—at a surface under controlled conditions. This process removes imperfections, cleans contaminants, and alters surface textures to achieve specific functional or cosmetic outcomes. It is used across industries such as aerospace, automotive, metal fabrication, and additive manufacturing. When properly executed, media blasting can significantly improve adhesion for coatings, enhance corrosion resistance, and produce a consistent surface finish. Understanding the fundamentals of this process, as well as selecting the correct media type and parameters, is essential for maximizing both performance and quality.<h2>What is Media Blasting?</h2>Media blasting, often referred to as abrasive blasting, is a surface finishing process that uses high-pressure air or mechanical force to propel abrasive media against a substrate. The goal is to clean, smooth, roughen, or otherwise modify the surface of a part.[1] Depending on the medium and pressure applied, media blasting can range from aggressive material removal to delicate surface cleaning.The process typically involves three key elements: <ul><li>Blasting equipment</li><li>Abrasive media</li><li>Surface being treated </li></ul>In the media blasting process, compressed air or a centrifugal wheel accelerates the media, which strikes the part surface at high velocities. The impact either removes unwanted material (like rust, scale, or old paint) or modifies the surface texture for improved adhesion or appearance.Media blasting can be performed in enclosed cabinets for small parts or in open blasting rooms for larger workpieces. Automated systems are also common in production environments, offering consistent and repeatable results.The versatility of this process makes it compatible with metal surfaces, plastics, composites, ceramics, and even wood.[2] By adjusting variables—such as pressure, nozzle type, distance, and media composition—operators can precisely control the aggressiveness and finish quality of the process. This adaptability has made media blasting an indispensable tool in both industrial and artisanal applications.<h3>What is media blasting used for:</h3>Media blasting is a highly adaptable finishing process used to clean, shape, or enhance the surface of a material through the controlled impact of abrasive media. Its versatility makes it suitable for everything from heavy-duty industrial cleaning to precision finishing of delicate components. Below are some of the post-processes that media blasting is used for:Surface cleaning: Effectively removes rust, oxidation, paint, scale, grease, and other contaminants from metals, composites, and plastics. This process restores surfaces to a clean, bare state, ready for further finishing or inspection.Surface preparation: Creates a controlled texture that enhances coating, paint, or adhesive adhesion. It ensures consistent bond strength and extends the lifespan of protective coatings.Smoothing and polishing: Refines rough or uneven surfaces, eliminates tool marks, and produces smooth, uniform finishes for both functional and aesthetic purposes.Peening: Strengthens metal components by inducing compressive surface stresses, increasing fatigue resistance in parts such as springs, gears, and turbine blades.Deburring and deflashing: Removes burrs, sharp edges, or excess flash from machining, molding, or casting operations without altering part geometry.Surface blending: Harmonizes repaired or welded areas with surrounding surfaces to create a uniform, professional appearance.<h2>Different Types of Media</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761131494482-granular_material_samples_various_types_in_small_bags.jpg" style="width:100%px" class="fr-fic fr-dib" alt="Different types of media used in media blasting post-process" />There are many different types of media used in media blasting, from ceramic beads to steel shot.There are many types of blasting media, each designed for specific materials and results. Selecting the correct medium ensures efficiency, quality, and cost-effectiveness. Below is a comparison of commonly used blasting media:<div id="isPasted"><table><tbody><tr><td>Media Type</td><td>Description</td><td>Typical Applications</td><td>Material Compatibility</td></tr><tr><td>Glass Beads</td><td>Spherical glass particles used for smooth, satin finishes without material removal.</td><td>Peening, cleaning, polishing.</td><td>Aluminum, stainless steel, plastics.</td></tr><tr><td>Aluminum Oxide</td><td>Sharp, durable abrasive for aggressive cutting and surface prep.</td><td>Paint removal, etching, deburring.</td><td>Steel, iron, titanium.</td></tr><tr><td>Sodium Bicarbonate (Soda blasting)​</td><td>Gentle, non-destructive medium; dissolves in water.</td><td>Cleaning delicate surfaces, removing coatings without damage.</td><td>Soft metals, plastics, composites.</td></tr><tr><td>Walnut Shells</td><td>Organic, biodegradable media used for polishing and light cleaning.</td><td>Cleaning engines, molds, or wood.</td><td>Metals, plastics, composites.</td></tr><tr><td>Sand</td><td>Traditional abrasive for heavy-duty cleaning; less common due to health risks (silicosis).</td><td>Rust and paint removal.</td><td>Metals and masonry.</td></tr><tr><td>Plastic</td><td>Soft, non-metallic media ideal for gentle cleaning and finishing without damaging surfaces.</td><td>Removing coatings, cleaning delicate parts, paint stripping.</td><td>Aluminum, plastics, composites, sensitive metals.</td></tr><tr><td>Steel Grit/Shot​</td><td>Reusable metallic media providing aggressive cleaning or peening.</td><td>Descaling, surface hardening.</td><td>Ferrous metals.</td></tr><tr><td>Silicon Carbide</td><td>Extremely hard media for cutting and etching dense materials.</td><td>Etching, surface prep for ceramics or glass.</td><td>Hard metals, ceramics, stone.</td></tr><tr><td>Corn Cob Grit</td><td>Lightweight, biodegradable medium for gentle cleaning.</td><td>Drying, polishing, removing light contamination.</td><td>Wood, plastics, soft metals.</td></tr><tr><td>Ceramic Beads</td><td>Tough, spherical media producing consistent, smooth finishes.</td><td>Surface finishing, cleaning high-value components.</td><td>Stainless steel, titanium, alloys.</td></tr><tr><td>Garnet</td><td>Natural mineral abrasive known for high efficiency and recyclability.</td><td>Rust removal, surface prep for coatings.</td><td>Metals, concrete.</td></tr><tr><td>Wire Shot</td><td>Cut or conditioned wire particles used for cleaning, finishing, or peening. Durable and provides uniform impact energy.</td><td>Shot peening, surface cleaning, descaling, and preparation before coating.</td><td>Steel, stainless steel, aluminum, and other metals. Not ideal for soft materials.</td></tr></tbody></table></div><h3 id="isPasted">Five Tips for choosing media blasting material</h3><ol><li>Match hardness to substrate: Choose media softer than the base material to prevent damage when precision or surface integrity is important. </li><li>Define your goal: Use coarse, angular media for material removal and fine, spherical media for polishing or peening. </li><li>Consider reusability: Steel shot and ceramic beads are more durable and reusable, reducing long-term cost. </li><li>Consider environmental impact: Biodegradable media like nut shells or corn cob grit are safer for the environment since they are biodegradable. Glass blasting can also use recycled glass. </li><li>Evaluate contamination risk: Use non-ferrous media when blasting aluminum or stainless steel to avoid rust contamination.</li></ol><h2>Applications for Media Blasting</h2>Media blasting serves a wide variety of industrial and commercial purposes. One of its most common uses is surface preparation (i.e. removing rust, paint, or scale before coating or painting operations). The process ensures better adhesion and durability of subsequent finishes.In the aerospace and automotive sectors, precision blasting is used for peening components such as gears, turbine blades, and springs. Peening induces beneficial compressive stresses on the surface, improving fatigue resistance and extending component life.The maritime industry also relies heavily on media blasting for both maintenance and surface preparation. Ship hulls, propellers, and offshore structures are frequently blasted to remove marine growth, corrosion, and old coatings before repainting or anti-fouling treatment. This process helps maintain hydrodynamic efficiency, reduces fuel consumption, and prolongs vessel life. Specialized blasting techniques—such as wet blasting—are often employed to minimize dust and environmental contamination during shipyard operations.For restoration and maintenance, blasting efficiently removes corrosion, oxidation, or contaminants from tools, machinery, and historical artifacts without altering the underlying material. The process is also invaluable in tooling and mold cleaning, where buildup removal helps maintain dimensional accuracy and product quality.Finally, decorative finishing applications, such as frosting glass or creating matte metallic surfaces, rely on carefully controlled blasting to achieve consistent aesthetics.<h3>Media blasting and 3D printing</h3>Media blasting has become an essential post-processing step in additive manufacturing, helping transform freshly 3D printed parts into production-ready components. After 3D printing—especially with powder bed fusion or binder jetting—parts often have residual powder, rough surfaces, or visible layer lines. Media blasting effectively cleans, smooths, and refines these surfaces without altering fine details or dimensional accuracy.By selecting the right media type and pressure, manufacturers can achieve various finishes, from a subtle matte texture using glass beads to more aggressive smoothing with aluminum oxide. This process improves not only the appearance of printed parts but also their functional performance, enhancing coating or paint adhesion and reducing friction between mating surfaces.<h2>Health and Safety when Media Blasting </h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1761131526917-sand_blasting_worker_pipe_rust_removal.jpg" alt="Industrial media blasting using PPE" class="fr-fic fr-dii" />It is imperative to wear the proper PPE when using any media blasting systems, particularly portable, non-enclosed onesAlthough media blasting is highly effective, it poses several health and safety risks that must be carefully managed. The process generates airborne dust, noise, and high-velocity particles that can be hazardous to operators. Proper ventilation and dust collection systems are essential to prevent inhalation of fine particles, especially when using silica-based media, which can cause silicosis and other respiratory illnesses.[4]Operators should always wear personal protective equipment (PPE) such as blast suits, gloves, eye protection, and respirators rated for the material being used. Automated blasting machines or enclosed blast cabinets can further reduce exposure.Equipment safety is also critical: hoses, nozzles, and pressure vessels must be regularly inspected for wear or damage to avoid accidental ruptures. Safe handling and disposal of spent media, particularly when contaminated with coatings or hazardous residues, should comply with local environmental regulations.By following these safety guidelines and maintaining proper operational practices, media blasting can be performed efficiently, sustainably, and without compromising worker health.<h2>Conclusion</h2>Media blasting remains one of the most effective and adaptable post-processing methods in modern manufacturing. Its ability to clean, refine, and prepare a wide range of materials—from metals and plastics to composites and ceramics—makes it indispensable across industries such as aerospace, automotive, maritime, and additive manufacturing. By carefully selecting the appropriate media type, pressure, and blasting parameters, manufacturers can achieve precise control over surface finish, enhancing both functional and aesthetic qualities of components. Beyond improving adhesion and corrosion resistance, media blasting also contributes to structural integrity through processes like peening and deburring.However, the success of media blasting depends not only on process optimization but also on strict adherence to safety and environmental standards. Proper ventilation, PPE use, and responsible media disposal are critical to ensuring safe and sustainable operations. As manufacturing technologies continue to evolve—particularly in additive and precision production—media blasting will remain a cornerstone of surface finishing, bridging the gap between raw fabrication and high-performance, ready-for-use components. By understanding and applying its best practices, manufacturers can ensure consistent quality, extended component lifespan, and superior overall product performance.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzYwNzMzNTIzODUxLXN0b2NrLXBob3RvLW1hY3JvLWNsb3NlLXVwLW9mLWFicmFzaXZlLWJsYXN0aW5nLW1lZGlhLWN1dC13aXJlLXNob3QtcGVlbmluZy0yMjEwOTI5NTkzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width:100%px" class="fr-fic fr-dib" alt="Wire Shot used for media blasting" />Media blasting with wire shot is suitable for peening, surface cleaning, and descaling hard materials.<h2>Frequently Asked Questions (FAQs)</h2><h3>Q: What is the difference between sandblasting and media blasting?</h3>A: While the terms are often used interchangeably, sandblasting specifically refers to the use of sand as the abrasive material, whereas media blasting is a broader term that encompasses a variety of abrasive materials such as glass beads, aluminum oxide, steel shot, or even organic materials like nut shells and corn cob grit. Modern industry favors the term “media blasting” since it includes safer and more environmentally friendly alternatives to traditional silica sand, which can pose health risks such as silicosis when inhaled.<h3>Q: What is the difference between dry blasting and wet blasting?</h3>A: The key distinction lies in whether water is used during the process. Dry blasting propels dry media using compressed air, offering strong cutting power and fast material removal. Wet blasting, on the other hand, mixes the abrasive with water to suppress dust and produce a smoother finish. Wet blasting is ideal for applications where surface contamination, dust control, or part preservation are critical—such as in the maritime, aerospace, or restoration industries.<h3>Q: Can media blasting damage the material being processed?</h3>A: Yes, if the wrong media type, pressure, or technique is used, blasting can damage or distort the substrate. For instance, using a hard, angular medium like aluminum oxide on a soft material such as aluminum or plastic can cause pitting or erosion. Proper selection of media and process parameters is essential to achieving the desired surface finish without harming the underlying material.<h3>Q: How do I choose the right blasting media for my application?</h3>A: Start by considering the material hardness of the workpiece, the desired finish, and the goal of the process (e.g., clean surfaces, smoothing, or peening). Softer, spherical media like glass beads are ideal for polishing and cleaning delicate parts, while harder, angular media such as aluminum oxide or garnet are used for aggressive surface removal. Reusability, environmental impact, and contamination risk should also factor into your choice.<h3>Q: What safety equipment is required for abrasive blasting?</h3>A: Media blasting requires proper personal protective equipment (PPE) including: Blast helmet or hood, respiratory protection (such as an air-fed respirator or NIOSH-approved mask), protective clothing, hearing protection, and eye protection. In addition to PPE, a well-ventilated workspace or dust collection system should be in place to minimize airborne contaminants. Operators should also regularly inspect hoses, nozzles, and pressure vessels to ensure the system is in safe working condition.<h2>References</h2>[1] Rudawska A. Mechanical surface treatment of adherends for adhesive bonding. Progress in Adhesion and Adhesives. 2023 Dec 29;7:113-69.[2] Kılınç İ, Budakçı M, Korkmaz M. The Use of Environmentally Friendly Abrasive Blasting Media for Paint Removal from Wood Surfaces. BioResources. 2023 Jan 1;18(1).[3] Protecting Workers from the Hazards of Abrasive Blasting Materials [PDF]. U.S. Department of Labor OSHA. September, 2014. <a href="https://www.osha.gov/sites/default/files/publications/OSHA3697.pdf" target="_blank">https://www.osha.gov/sites/default/files/publications/OSHA3697.pdf</a> [4] Abrasive Blasting Hazards in Shipyard Employment [Internet]. U.S. Department of Labor OSHA. December, 2006. <a href="https://www.osha.gov/maritime/guidance/shipyard-guidance" target="_blank">https://www.osha.gov/maritime/guidance/shipyard-guidance</a>

Understand the fundamentals of media blasting and discover proven methods for improving surface adhesion, minimizing contamination, and achieving consistent, high-quality finishes in post-process operations.

Media Blasting: Fundamentals and Best Practices for the Post Process

Here we explore how Multi Jet Fusion (MJF) 3D printing combines powder bed fusion and ink jetting to produce strong, isotropic parts with exceptional efficiency.

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Discover the FDM printer meaning in practical terms, exploring how fused deposition modeling works and why it remains one of the most widely used technologies today.

FDM Printer Meaning Explained: Theory, Technology, Terminology

When planning a prototype or a custom fixture, digital-design and hardware engineers almost always ask, “How long does a 3D printer take to print something?” The answer isn’t simple. Depending on the part and the process, a print might be ready in under an hour or it might take a couple of days. Fast prints can keep design work moving, while long ones risk slowing projects, tying up machines, and driving up costs.That’s why it helps to understand what actually drives print time. Factors like part size, layer height, infill density, and the printer’s own hardware all play a role. Some of these choices are in the designer’s control—like orienting the part or choosing coarser layers—while others come down to the limitations of the machine or material. Knowing where time is spent makes it easier to balance speed against quality.This guide looks at the basics of how print time is determined and how different FDM machines handle the job. It also covers practical ways to estimate how long a print will take and what adjustments can make the biggest difference. With a clear view of these levers, designers can set realistic schedules, speed up iteration, and get more out of their printers.<h2>What Really Determines Print Speed?</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1757668056484-stacked_white_plates.jpg" style="width:100%px" class="fr-fic fr-dib" alt="layer height" />Layer height is one factor that affects print time3D printing builds parts layer by layer. Print time depends on how long each layer takes to deposit or cure, along with the additional movements and heating required during the process. The main influences are technology type, part geometry, print settings, material, and the machine’s hardware limits.<h3>Printing Technology and Hardware</h3>Different additive manufacturing technologies vary widely in throughput. Within the polymer 3D printing sphere, FDM (Fused Deposition Modeling) is common and inexpensive but slower, since a nozzle must trace every contour. SLA (Stereolithography) and PolyJet offer high detail but take time on large builds. By contrast, mSLA/DLP printers project entire layers at once, making them faster for individual prints. Powder-bed systems like SLS/MJF achieve efficiency by printing many parts in one batch. This article focuses mainly on FDM, the most common 3D printing technology.Hardware strongly affects printing speeds. For FDM printers, rigid frames and motion systems (CoreXY, delta) handle higher acceleration without introducing vibration. High-flow hotends and larger nozzles increase volumetric throughput, while direct-drive extruders improve control at higher speeds. Enhanced part-cooling fans allow faster deposition without defects. In practice, slicer speed settings must respect these mechanical and thermal limits: budget FDM machines often run at 30–60 mm/s, while tuned high-end printers may sustain 150–200 mm/s with advanced firmware like Klipper.<h3>Geometry, Size, and Orientation</h3>Bigger parts naturally take longer, but height matters more than overall volume. A tall column requires many more layers than a short, wide object of similar volume. Reorienting a part can drastically shorten print duration—for example, laying a model flat may cut hours compared to printing it upright.[1]Complex geometries add time in multiple ways: longer toolpaths, intricate internal channels, and overhangs that require supports. Every support adds to both print time and post-processing. Minimizing support through careful orientation is one of the most effective strategies for faster builds.<h3>Layer Height, Nozzle Size, and Print Settings</h3>Layer height sets the vertical resolution. A 60 mm part at 0.1 mm requires 600 layers, while at 0.3 mm only 200 layers are needed. Coarser layers shorten print time but reduce surface quality. Nozzle size also matters: a 0.6 mm nozzle deposits more material per pass than a 0.4 mm, supporting thicker layers, but sacrifices fine detail. As a rule of thumb, layer height should not exceed ~80% of the nozzle diameter.Other slicer settings also influence time. Infill percentage determines how dense the internal structure is: decorative parts may use 10–20% infill, while structural components require 50% or more. Each additional wall, top, or bottom layer adds strength but extends duration. Supports, printed slowly for removability, can increase time by 50% or more depending on geometry.<h3>Material and Thermal Properties</h3>Different materials tolerate different speeds. PLA prints quickly because it melts at low temperatures and cools fast. ABS, PETG, and ASA need higher temperatures and slightly slower speeds to prevent warping. Flexible TPU is among the slowest, often limited to 20–40 mm/s to avoid extrusion problems. High-performance polymers like PC, nylon, and PEEK require elevated temperatures and enclosures, restricting speed further.Recommended reading: <a href="https://www.wevolver.com/article/3d-print-speed" target="_blank">PLA Print Speed: Best Print Speed Settings and More</a><h2>How Long Does a 3D Printer Take to Print a Benchy?</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1757668069665-3d_printer_filament_spools_and_blue_printing_parts.jpg" style="width:100%px" class="fr-fic fr-dib" alt="benchy" />The famous Benchy model is a good way to compare 3D printing speedsWhen people talk about 3D printing speed, they often reference the same model: 3DBenchy. Designed in 2015 by the Swedish company Creative Tools, this small tugboat was created as a calibration benchmark—hence the nickname “Benchy.” The idea was to produce a playful, recognizable print that could quickly reveal how well a printer handles common challenges: dimensional accuracy, bridging, overhangs, circular holes, fine details, and smooth curved surfaces.The standard Benchy model measures 60 mm long, 31 mm wide, and 48 mm tall, with a hull designed to sit flat on the print bed. At this size it’s large enough to test accuracy and cooling but compact enough to serve as a speed benchmark. It has since become one of the most downloaded STL files in the world, functioning both as a stress test and an informal “speedrun” model.Because Benchy is compact and moderately complex, manufacturers often use it to showcase their machines. A simple cube is too easy; a big functional part takes too long. Benchy hits the middle ground: short enough to print in under an hour (or even minutes on high-speed systems), but tricky enough to demonstrate quality at those speeds. That makes it a natural benchmark for time comparisons across printers.<h3>Vendor Claims and Demonstrations</h3><ul><li>Prusa Research (Original Prusa MK4, 2023) publicized its MK4 launch by printing a Benchy in about 19 minutes using input shaping and pressure advance.[2] Earlier Prusa models often took closer to an hour with default profiles.</li><li>Bambu Lab (P1S, 2023) markets its CoreXY machines as capable of a Benchy in roughly 18 minutes, thanks to accelerations up to 20,000 mm/s² and high-flow hot ends.[3] Many user tests confirm results in the 18–25 minute range.</li><li>Creality (K1, 2023) advertised that its K1 can complete a Benchy in 13 minutes—compared with 1 hour 30 minutes on a typical budget FDM printer.[4]</li><li>Anycubic (Kobra 2 Pro, 2023) published an official demonstration of a 14 min 56 s Benchy, positioning it as a “speed printing” machine in the sub-$300 range.[5]</li></ul>Note: These manufacturer claims do not prove that one machine is faster than another. Unsurprisingly, Bambu Lab made its 18-minute Benchy claims after Prusa set the bar at 19 minutes, and the other two companies made their claims after Bambu Lab.<h3>Independent Benchmarks</h3>While vendor claims are eye-catching, independent tests provide context. Review sites like Tom’s Hardware and many community YouTubers often <a href="https://www.tomshardware.com/best-picks/best-3d-printers" target="_blank">report</a> “fast Benchy” times clustering between 20 and 25 minutes for modern CoreXY and tuned bedslinger printers. These results suggest that marketing numbers usually represent best-case scenarios, achieved with aggressive settings that may sacrifice some surface finish.<h3>Why These Times Matter</h3>The difference between 13 minutes and 1.5 hours for the same 60 × 31 × 48 mm model illustrates how far consumer printers have come in just a few years. Benchy times give users a practical reference point for “everyday” print speeds. They’re not perfect predictors, but they help calibrate expectations: if your printer takes 60 minutes for Benchy, something larger or more complex like a phone stand might take 3–5 hours; if it takes 20 minutes, you can expect to slice those times nearly in half.Recommended reading: <a href="https://www.wevolver.com/article/ender-3-print-speed" target="_blank">Ender 3 (V2, Pro, S1) Print Speed and How to Maximize It</a><h2>Calculating Print Time</h2><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1757668105426-researcher_working_on_3d_printer_in_lab.jpg" style="width:100%px" class="fr-fic fr-dib" alt="slicer" />A 3D print slicer can estimate print timeOne of the most common questions before starting a 3D print is, “How long does a 3D printer take to finish this part?” But print time is not fixed; it depends on geometry, slicer settings, materials, and machine performance. While real-world results may vary, engineers and hobbyists have a few practical ways to estimate duration with reasonable accuracy.<h3>Using Slicer Estimation Tools</h3>The most reliable method is to use modern slicing software such as Ultimaker Cura, PrusaSlicer, or Simplify3D. These programs analyze the 3D model, layer height, infill density, support requirements, and printer settings to generate a predicted print time. Most slicers account not only for extrusion paths but also for travel moves, acceleration limits, and cooling pauses. With well-tuned profiles, slicer predictions are typically accurate within about 10–15% of the actual duration.However, accuracy depends on the slicer settings matching the printer’s firmware limits. If acceleration or maximum flow rates are set higher in software than the hardware can actually sustain, the print will run longer than predicted. For this reason, it’s good practice to compare slicer estimates with actual print times and adjust profiles accordingly.<h3>Manual Approximation</h3>When slicer tools aren’t available, a few rules of thumb can help answer the question, “how long does a 3D printer take for a given part?”<ul><li>Volume-Based: A common heuristic is that about 1 cubic inch of material takes up to an hour to print at standard FDM settings. This is rough but provides a quick ballpark.</li><li>Layer Count: Divide the model’s height by the chosen layer height to calculate the number of layers. Multiply this by the average time per layer (30–60 seconds for typical FDM printing). For example, a 50 mm-tall object sliced at 0.2 mm layer height produces 250 layers. At 40 seconds per layer, the estimated print time is about 2.8 hours, before adding warmup and setup.</li></ul>These rules can’t replace slicer predictions, but they are useful for feasibility checks in design or quoting scenarios.<h3>Online Calculators</h3>For quick estimates, several free online calculators let you enter key parameters such as part dimensions, layer height, nozzle size, and infill percentage. Some require the upload of an STL file for automatic calculation. While convenient, these tools lack machine-specific data like acceleration tuning or cooling limits.As with manual rules, results should be cross-checked against slicer predictions or small test prints for higher confidence. In practice, combining slicer predictions with a few tried-and-true heuristics gives the best balance between accuracy and speed of estimation.<h2>10-Point Checklist for Faster 3D Printing</h2>For many users, the biggest frustration with FDM printing is the waiting time. Even small, palm-sized objects can take several hours, and larger builds often stretch overnight or longer. While speed has improved with newer machines, most printers still balance throughput against quality. The good news is that you don’t need to buy a new printer to cut hours off your jobs—many time savings come from simple setting adjustments.The key to faster printing is understanding which factors matter most. Print time is influenced by how much plastic must be laid down (volume, infill, perimeters) and how quickly the printer can handle it (layer height, nozzle size, motion, cooling). Some optimizations are as easy as changing a slicer setting, while others require hardware upgrades or firmware tuning. The list below moves from the simplest tweaks to more advanced modifications.<ol><li>Lower Infill Density – Reduce infill to the minimum needed for function (e.g., 10–15%).</li><li>Reduce Perimeter Walls – Use 2 walls instead of 3–4 when high strength isn’t required.</li><li>Increase Layer Height – Switch to 0.24–0.3 mm layers for faster prints with less detail.</li><li>Use Draft or Speed Profiles – Select faster preset profiles in your slicer to cut time.</li><li>Orient for Lower Height – Rotate parts to minimize Z-axis layers and reduce build time.</li><li>Print Multiple Parts Together – Batch small items in a single print to avoid repeated heat-up and cooldown cycles.</li><li>Use a Larger Nozzle – Swap to 0.6 mm or 0.8 mm to deposit more material per pass.</li><li>Boost Cooling – Upgrade or add stronger fans for faster solidification at higher speeds.</li><li>Enable Speed-Optimized Firmware – Install and tune features like input shaping or pressure advance (e.g., Klipper).</li><li>Upgrade to a High-Flow Hotend – Install a hotend designed for higher volumetric flow to sustain faster extrusion.</li></ol><h2>Conclusion</h2>For anyone working with FDM, the question “how long does it take?” still depends on design choices, machine setup, and printing materials. Compared with CNC machining, the 3D printing process offers more freedom of shape but also takes variable amounts of time depending on orientation, layer height, and the printer’s speed. Even simple changes—such as lowering infill or using higher infill only where strength is essential—can help balance turnaround with durability.Optimization often starts at the print head. A larger nozzle or high-flow hotend allows more material to be deposited in less time, while careful tuning ensures that print quality doesn’t suffer. Choice of filament also matters, since different plastics tolerate different speeds, cooling rates, and geometries. For beginners, experimenting with these variables builds confidence and makes it easier to plan the amount of time a job will realistically take.Looking forward, improvements in motion systems, smarter slicers, and advanced print head designs promise faster results without compromising high-quality output. As these tools spread beyond industrial labs, the question of how long 3D printing takes will shift toward ever-shorter cycles, making rapid iteration and same-day prototyping accessible to anyone, from hobbyists to engineers.<h2>Frequently Asked Questions (FAQ)</h2>How long does a 3D printer take to finish a part?Anywhere from under an hour for small models to more than a day for large, detailed prints. The exact time depends on geometry, slicer settings, and printer hardware.What settings most affect print speed in FDM?Layer height, nozzle diameter, and infill density are the biggest factors. Reducing Z-height by reorienting a model can also cut hours off a job.How accurate are slicer time estimates?Modern slicers are usually within 10–15% if profiles match the printer’s real limits. However, tall or cooling-limited parts may take longer than predicted.Can hardware upgrades really make a big difference?Yes—high-flow hotends, stronger cooling, and faster motion systems can significantly reduce print times. Firmware features like input shaping further improve speed without sacrificing quality.What simple changes save the most time without new hardware?Increase layer height, use a larger nozzle, and lower infill for non-structural parts. Draft or speed profiles in slicers are quick wins.What does the future look like for FDM print speeds?Emerging features like adaptive flow, multi-gantry printers, and smarter slicers point toward faster cycles. Waiting overnight for common prints may soon be a thing of the past.<h2>References</h2>[1] Hällgren S, Pejryd L, Ekengren J. <a href="https://www.scirp.org/reference/referencespapers?referenceid=2065252" target="_blank">Additive manufacturing and its effect on part orientation and support structures</a>. Procedia CIRP. 2016;50:164-9.[2] Prusa Research. <a href="https://blog.prusa3d.com/announcing-original-prusa-mk4_76585/" target="_blank">Announcing Original Prusa MK4</a> [Internet]. 2023 Mar 29 [cited 2025 Sep 9].[3] Bambu Lab. <a href="https://ca.store.bambulab.com/products/p1s" target="_blank">P1S Product Page</a> [Internet]. 2023 Jul 13 [cited 2025 Sep 9].[4] Creality. <a href="https://www.creality3dofficial.com/blogs/news/lightning-fast-3d-printing" target="_blank">Lightning-Fast 3D Printing: Creality K1 Blog</a> [Internet]. 2023 Jun 15 [cited 2025 Sep 9].[5] Anycubic. <a href="https://store.anycubic.com/blogs/3d-printing-guides/fastest-consumer-3d-printer" target="_blank">Fastest Consumer 3D Printer: A Comprehensive Guide</a> [Internet]. 2023 Sep 15 [cited 2025 Sep 9].

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3D Printing

Engineers Wiki.

Most Asked Questions.

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