Imagine a world where the boundaries between the digital and physical realms blur. A world where your wildest designs can materialise before your eyes, layer by layer, seemingly out of thin air.

This is the world of 3D printing—a technology that’s not only changing how we create but also challenging everything we thought we knew about manufacturing. From intricate medical implants to bespoke car parts and even entire houses, 3D printing is taking industries by storm, reshaping the way we create, manufacture, and consume.

In this article, we’re not just covering the basics of 3D printing. We’re diving into its surprising origins, how it truly works, and the extraordinary ways it’s impacting lives today. So, if you’re ready to uncover the magic and the mechanics of this ground-breaking technology, let’s get started.

What is 3D Printing?

Also known as additive manufacturing, 3D printing is a transformative technology that has redefined the way we design and manufacture various products. Surprisingly, it dates back to the mid-1940s and has since evolved into various types of printing processes, such as vat photopolymerisation, sheet lamination, and directed energy deposition.

3D printing allows us to create three-dimensional objects from digital 3D or CAD models. Unlike traditional subtractive manufacturing, which involves cutting away material from a solid block, 3D printing builds objects by adding material layer by layer until the final shape is achieved.

This process offers incredible flexibility and precision, enabling the creation of complex geometries that would be difficult or impossible to produce using conventional techniques.

Key Terminology

A few terms often come up in 3D printing and need explanation here. Additive manufacturing is a fancy term for creating objects by adding material bit by bit, as opposed to traditional subtractive methods that carve away from a larger block.

Another term you’ll encounter is rapid prototyping. This refers to the ability of 3D printers to help designers quickly test new ideas before moving into full-scale production. This speed and flexibility are part of what makes 3D printing such an exciting innovation in manufacturing.

A Brief History of 3D Printing

While the concept of 3D printing might seem recent, its roots trace back to the mid-1940s, when people first had the idea of 3D printing. Murray Leinster was the first one to describe it in his short story Things Pass By, in which he envisioned a machine that could take his drawings and use melted plastic to form 3D objects.

The Birth of Modern 3D Printing (1980s)

In 1981, the fiction became a reality. The real action started when Dr. Hideo Kodama, a Japanese researcher, made the first-ever 3D printer that used ultraviolet light to harden polymers layer by layer, a method known today as photopolymerisation.

A few years later, Chuck Hull, an American engineer, took another big step forward. In the late 1980s, he invented stereolithography (SLA), a process that uses a laser to cure liquid resin, solidifying it layer by layer. His breakthrough paved the way for modern 3D printing, and Hull went on to co-found 3D Systems, one of the first 3D printing companies.

The Rise of 3D Printing Technologies (1990s)

The 1990s saw the rapid development of new 3D printing technologies. Selective laser sintering (SLS), developed by Carl Deckard at the University of Texas, used lasers to fuse powder materials. Simultaneously, fused deposition modelling (FDM), created by Scott Crump, extruded melted materials layer by layer to create a three-dimensional object. FDM, in particular, became a popular technology due to its simplicity and affordability, especially for hobbyists.

Commercialisation and Industrial Use (2000s)

As patents began to expire in the early 2000s, the cost of 3D printers dropped, and companies started adopting the technology for specialised applications. 3D printing began to be used to produce high-precision parts in industries like aerospace and automotive, where custom and complex parts are essential.

The Consumer 3D Printing Boom (2010s)

With patents for FDM and SLA technologies expiring, the 2010s saw a boom in consumer-grade 3D printers. Companies introduced affordable printers, making 3D printing accessible to hobbyists, educators, and small businesses. The versatility of these machines spurred innovation in customisable consumer products, fashion, art, and more.

Expanding Applications and New Frontiers (2020s and Beyond)

Today, 3D printing is moving into even more ambitious applications, from creating human organs and custom prosthetics to printing entire houses. Advances in bioprinting allow scientists to produce cells, tissues, and even organ structures, showing promise for personalised medicine. In aerospace, companies like SpaceX are experimenting with 3D-printed rocket parts to reduce costs and increase durability.

As 3D printing technologies continue to advance, we are likely to see even greater adoption across industries, alongside improvements in speed, cost, and material diversity. These developments suggest that the future of manufacturing may be decentralised and more sustainable, with 3D printing continuing to play a central role.

10 Types of 3D Printing Processes

3D printing encompasses various techniques, each with unique methods and materials suited to different applications. Below are the primary types of 3D printing processes that shape this diverse industry:

1. Vat Photopolymerisation

Vat photopolymerisation is a cool way to make 3D objects. First, it uses a liquid called a photopolymer resin as the primary material. That is why it is also known as resin-based 3D printing. This resin gets solidified when exposed to light. The used light source is often ultraviolet (UV) light or a digital light projector (DLP).

The magic happens layer by layer until the object is done. Some of the types of vat photopolymerisation are Digital Light Processing (DLP), Continuous Digital Light Processing (CDLP), and Stereolithography (SLA). The choice between SLA and DLP largely depends on factors like speed, resolution, and cost, with SLA offering high resolution but slower printing speeds compared to DLP.

1. Stereolithography (SLA)
   • Stereolithography is the original 3D printing process. It uses a UV laser to cure and harden layers of liquid resin. The laser traces each layer’s cross-section, hardening it layer by layer until the full object forms. SLA is known for high accuracy and smooth finish, making it popular in industries like jewellery, dental models, and prototyping.
2. Digital Light Processing (DLP)
   • Similar to SLA, DLP uses a digital light projector to cure liquid resin. The difference lies in the light source—DLP uses a digital projector screen to flash each layer in one go, making the process faster. DLP is known for its accuracy and speed and is commonly used in the dental models, jewellery, and consumer goods industries.
3. LCD-Based 3D Printing
   • LCD-Based 3D Printing utilises an LCD screen with UV backlighting to display and cure each layer in one go. It’s similar to DLP but is typically less expensive, making it a popular choice for desktop 3D printing.

2. Fused Deposition Modelling (FDM)

Also known as Fused Filament Fabrication (FFF), FDM is one of the most common 3D printing methods, especially among hobbyists. This technique works by heating a thermoplastic filament to its melting point, which is extruded through a heated nozzle onto a build platform. The heated nozzle moves in the X, Y, and Z axes, depositing material layer by layer to create the final object. As each layer cools and solidifies, it fuses with the previous one.

FDM is widely used due to its affordability, ease of use, and versatility, making it suitable for various applications, including custom part manufacturing, rapid prototyping, and educational purposes. It is particularly favoured in the DIY crafts and maker communities. Industries like automotive, aerospace, and consumer goods use FDM for concept modelling and low-volume production.

3. Selective Laser Sintering (SLS)

SLS is another 3D printing process that utilises a high-powered laser to fuse powdered materials, like nylon or polyamide, layer by layer. The laser selectively sinters the powder, binding the particles without fully melting them, resulting in strong and durable parts. This method is commonly employed in the aerospace, automotive, and medical industries to produce functional parts with intricate geometries.

4. Multi Jet Fusion (MJF)

MJF also uses a powder bed fusion 3D printing technology, but it differs from SLS in that it applies a binding agent across the powder before fusing it with heat. It utilises two key agents to create 3D objects:  

1. Fusing Agent: This agent is jetted onto specific areas of the powder bed, acting as a bonding agent that fuses the powder particles together.  
2. Detailing Agent: This agent is applied around the edges of the part to improve its surface finish and dimensional accuracy.  

MJF offers high accuracy, good detail, and consistency, making it ideal for functional prototypes and production-ready parts in industries such as automotive and electronics.

5. Binder Jetting

Binder jetting involves selectively depositing a liquid binding agent onto a powder bed, bonding the powder particles layer by layer. The unbound powder serves as a support structure for complex shapes and hollow parts. This process is commonly used in applications such as sand casting, full-colour models, and low-cost metal parts that are subsequently sintered for enhanced durability.

6. PolyJet Printing

PolyJet printing works similarly to inkjet printing, spraying liquid photopolymers onto a build tray and curing them with UV light. It can print in multiple colours and materials simultaneously, producing parts with different textures, colours, and levels of softness. This process is used in applications requiring high-detail models, like medical devices, product design, and realistic prototypes.

7. Sheet Lamination

Sheet lamination is another 3D printing type that lets us make complex shapes using various materials. Unlike other processes that use liquid resins, powders, or filaments, sheet lamination relies on flat, thin sheets of material like paper, plastic, or metal foil. This method offers several advantages, including the use of non-toxic, recyclable materials and the ability to incorporate colours and textures into objects.

Sheet lamination works by stacking layers of sheets on top of each other and then bonding these layers together using heat, pressure, or adhesive. There are two ways to do this: either by ultrasonic additive manufacturing (UAM) or laminated object manufacturing (LOM). This method is known for its speed, cost-effectiveness, and safety.

Sheet lamination is particularly useful for creating large-scale models, packaging prototypes, and objects where appearance and texture are important factors. Therefore, it is used in various industries, including architecture, packaging design, and educational settings. However, it may not provide the same level of detail and precision as some other 3D printing processes.

8. Directed Energy Deposition (DED)

DED is a 3D printing process that utilises a high-powered laser or electron beam to melt powdered or wire feedstock material as it is deposited, typically through a nozzle. This technique allows for the use of a wide range of materials, including metals, alloys, and hybrid materials. Due to its primary focus on metal materials, DED is often referred to as “metal 3D printing”, although it can also use ceramics and some polymers.

DED functions by melting material layer by layer, guided by CAD geometry, a tool that makes 3D shapes on a computer. This process enables rapid prototyping of metal components, making it invaluable in engineering and design for iterative testing and design refinement.

Additionally, DED’s versatility allows for the repair, fabrication, or modification of complex, large-scale components you have already made with a 3D printer. That is why it is beneficial in many industries, including aerospace, defence, and automotive; replacing or manufacturing certain parts can be costly or challenging.

9. Electron Beam Melting (EBM)

EBM is another metal 3D printing technology that uses an electron beam to melt metal powder within a vacuum environment. This process is ideal for producing high-strength metal components, particularly in aerospace and medical implants. It offers exceptional material properties and reduced residual stresses compared to other metal 3D printing processes.

10. Direct Metal Laser Sintering (DMLS) / Selective Laser Melting (SLM)

DMLS and SLM are metal 3D printing processes where a laser fuses metal powder layer by layer. The primary distinction between the two lies in the degree of material fusion: DMLS sinters the metal powder, while SLM fully melts it, resulting in denser parts. Both are widely used for high-strength, complex metal parts in the aerospace, automotive, and healthcare sectors.

Process Name	Material	Method	Applications
Vat Photopolymerisation	Photopolymer resin	Layer-by-layer curing of liquid resin with UV light	Jewellery, dental models, prototypes
Fused Deposition Modeling (FDM)	Thermoplastic filament	Extrusion of molten filament layer by layer	Prototyping, education, consumer products
Selective Laser Sintering (SLS)	Powdered materials (nylon, metal)	Laser sintering of powdered material layer by layer	Aerospace, automotive, medical
Multi Jet Fusion (MJF)	Powdered material and two binding agents	Jetting of fusing and detailing agents, followed by heat fusion	Automotive, electronics, functional prototypes
Binder Jetting	Powdered material and one binding agent	Selective depositing of a binding agent onto a powder bed	Sand casting, full-color models, metal parts
PolyJet Printing	Liquid photopolymers	Jetting of liquid photopolymer and UV curing	High-detail models, medical devices, product design
Sheet Lamination	Paper, plastic, metal sheets	Layering and bonding of sheet materials	Large-scale models, packaging, education
Directed Energy Deposition (DED)	Metal powders or wire	Laser or electron beam melting and depositing material	Aerospace, automotive, defence, repair and modification
Electron Beam Melting (EBM)	Metal powder	Electron beam melting metal powder in vacuum	Aerospace, medical implants, high-strength metal parts
Direct Metal Laser Sintering (DMLS) / Selective Laser Melting (SLM)	Metal powder	Laser sintering or melting metal powder	Aerospace, automotive, medical, high-strength metal parts

Each of these 3D printing processes brings distinct advantages, materials, and capabilities, allowing them to serve a wide range of applications across industries. Whether it’s precision, speed, or material strength that’s needed, these technologies offer options to meet diverse manufacturing needs.

Applications of 3D Printing

3D printing has various applications across different industries due to its versatility and capability to create customised, intricate, and complex objects. From the medical industry to consumer products, here are some of its key applications:

Medical Industry

In the world of medicine, 3D printing is making big changes. It helps doctors and nurses do their jobs better. With a 3D printer, they can make body parts like teeth or bones, and this is what is called customised patient care. This technology also allows them to do the following:

• Personalised Medicine: Creating customised prosthetics, implants, and surgical tools tailored to individual patient needs.
• Bioprinting: Potential for bioprinting organs and tissues for transplants.
• Medical Research: Producing complex 3D-printed anatomical models for surgical planning and education.
• Drug Discovery: Accelerating drug development by creating intricate drug delivery systems.
• Dentistry: Producing customised dental crowns, bridges, dentures, and orthodontic devices, like braces and clear aligners.
• Dental Research: Creating dental models for diagnosis and treatment planning.

The money people spend on 3D printing in medicine is getting bigger. In 2023, it was worth around $700 million. However, not all of this goes to healthcare, only about 1.6%. But by the year 2032, people are expected to be spending $11 billion on it, which is a lot more than now.

Education Sector

In the education sector, 3D printing is revolutionising the way we teach and learn. It allows students to bring their ideas to life and explore complex concepts in a hands-on and engaging manner. This technology can help in the following:

• Customisation: Producing personalised learning aids and tools by creating visual models that help students understand things better.
• Prototyping: Creating prototypes for science and engineering projects.
• STEM Education: Creating tangible models for STEM (Science, Technology, Engineering, and Mathematics) subjects, like molecules or architectural structures.
• Improving Skills: Promoting problem-solving skills, creativity, and innovation through the design and fabrication of their own objects.
• Inclusiveness: Providing visually impaired students with tactile learning resources.

The integration of 3D printing in classrooms allows for a more engaging learning experience. In some schools in Austria, especially vocational schools, it’s quite common to have a 3D printer in a classroom. There is also a subject for drawing objects and then printing them using a 3D printer.

Consumer Products

3D printing is also making a big splash in the world of consumer products. You can now find things made by 3D printers in many sectors, including fashion, beauty, sports, music, and cars.

• Rapid Prototyping: Accelerating the development of new products.
• Manufacturing: Producing complex consumer products with intricate designs in a unique and innovative way.
• Customised Consumer Goods: Customised products include fashion accessories, jewellery, customised footwear, home decor elements, household items, sports equipment, phone cases, and personalised gifts.
• Appliances and Gadgets: Efficient production of replacement parts for appliances and gadgets.
• Mass Customisation: Potential for mass customisation leading to more unique and sustainable products than ever before. This brings better designs while also cutting costs down.

This shows that 3D printing is not just about cool tech, but it is also about smoke-free manufacturing and Earth safety.

Food Industry

In the food industry, big companies are already using 3D printing to show how food production can be changed for the better. There are even special 3D printers made just for food.

• Culinary Presentation: Allowing for customised and creatively presented food items.
• Personalisation: Potential applications in personalised nutrition and special dietary needs.
• Customisation: Customising chocolates, candies, and pastries.
• Transforming Food Production: Promoting resource efficiency and sustainability.

3D-printing food items has the potential to transform how we make our meals and help us use resources wisely. It is exciting to see how quickly this technology is growing and what it means for our future meals.

Automotive Industry

Thanks to 3D printing, cars are better and safer now. This new way of making things is changing how we build cars. It lets people who make cars easily make parts that could be too hard with using old ways.

• Prototyping: Rapidly producing prototypes of car parts for testing and faster design iterations.
• Manufacturing: Creating complex components with intricate geometries.
• Customisation: Creation of customised and lightweight car parts for improved fuel efficiency and performance.
• On-demand Manufacturing: Changing car parts and accessories according to each person’s needs in the future.

The best part is that soon, every part in a car might come from a 3D printer. This way, cars will become lighter but remain strong, so they take less fuel and go faster.

Aerospace Industry

The aerospace industry, renowned for its stringent demands for precision, efficiency, and performance, has found a powerful ally in 3D printing technology. This innovative manufacturing process has revolutionised various aspects of aerospace engineering, from the design and prototyping stages to the production of critical components.

• Lightweight Components: Producing lightweight and strong components for aircraft and spacecraft.
• Rapid Prototyping: Accelerating the design and development of aerospace components.
• Tooling: Creating custom tooling for manufacturing processes.

Prototyping and Product Development

3D printing can also be used in rapid prototyping and product development.

• Design Iteration and Product Testing: Enabling faster design validation and functional testing.
• Prototyping: Reducing development costs and accelerating the product development cycle.

Architecture and Construction

The architecture and construction industry has also embraced 3D printing as a powerful tool for innovation and efficiency. This technology offers new possibilities for designing, prototyping, and constructing buildings and structures, transforming the way we approach architectural and engineering projects.

• Architectural Modelling: Creating detailed physical models of buildings and structures.
• Construction Components: Printing concrete structures and building components.
• Interior Design: Designing and producing custom furniture and decor items.

Art and Design

3D printing has revolutionised the intersection of art, design, and technology. This innovative technology empowers artists and designers to push the boundaries of creativity, enabling them to bring their imaginative concepts to life with stunning precision and detail.

• Sculpture and Art: Creating unique and intricate sculptures.
• Product Design: Designing and prototyping new products.
• Fashion: Designing and producing custom fashion accessories.

Private Sector

Some people all over the world have their own 3D printer at home, which has many advantages. For example, if you live in a big house and you need to repair something, you just draw the part and then print it.

The costs are not as expensive as you might think. The drawing software and the slicer, Cura, for example, are free. Most of the time, you do not even need drawing software because you can download nearly everything from the internet. You just need a 3D printer, which starts at about £200.

As 3D printing technology continues to advance, its applications are expanding into new and exciting areas, promising to reshape industries and create innovative solutions.

Benefits of 3D Printing

3D printing has the potential to revolutionise various industries. By building objects layer by layer, it offers a flexible and efficient approach to manufacturing. Let’s explore some of the key benefits of this technology:

1. Increased Customisation and Personalisation:
   • 3D printing allows for the creation of highly customised products tailored to individual needs and preferences.
   • This is particularly valuable in industries like healthcare, where patient-specific implants and prosthetics can be produced.
2. Optimised Supply Chains:
   • 3D printing can streamline supply chains by enabling decentralised and local production.
   • This reduces the need for long-distance transportation, leading to lower carbon emissions and improved sustainability.
   • It also allows for faster production and reduced inventory costs.
3. Enhanced Product Design and Development:
   • 3D printing enables rapid prototyping, allowing designers to quickly iterate on designs and test new ideas.
   • This accelerates the product development process and reduces time to market.
4. Sustainable Manufacturing:
   • 3D printing can reduce material waste by using only the necessary amount of material to create a product.
   • The technology also allows for the use of eco-friendly, recyclable materials and energy-efficient production processes.

As 3D printing technology continues to advance, we can expect to see even more innovative applications and benefits in the years to come. The possibilities with 3D printing are endless—who knows what incredible things we will be able to create in the future?

Future of 3D Printing

The future of 3D printing holds immense potential for innovation and transformation across various industries. Here’s a glimpse into what we can expect:

1. Advanced Materials and Multi-Material Printing: The development of new materials and the ability to print with multiple materials simultaneously will expand the possibilities of 3D printing, enabling the creation of complex objects with varying properties and functionalities.
2. Increased Speed and Scale: 3D printing technology will continue to evolve, leading to faster printing speeds and larger build volumes, making it more efficient for large-scale production.
3. Integration with Artificial Intelligence and Automation: AI-powered design optimisation and automated manufacturing processes will streamline production and improve efficiency.

As 3D printing becomes more widespread, regulatory bodies will likely develop guidelines and standards to ensure product safety and quality.

Conclusion

3D printing has come a long way since its invention in the last century. With various types of technologies and processes, it has different applications in diverse industries like medicine, automotive, consumer products, education, and even food. The future of 3D printing looks promising as it continues to revolutionise manufacturing and create endless possibilities for tangible objects.

FAQs

Have you ever wondered how 3D printing works? Or maybe you’re curious about its potential applications. In this section, we’ll answer some of the most common questions about 3D printing.