What Is 3D Printing - The Definitive Guide - 3D Hubs
What Is 3D Printing - The Definitive Guide - 3D Hubs
What Is 3D Printing - The Definitive Guide - 3D Hubs
Short on time? Download for free the PDF version of the 3D Hubs' De initive Guide to
3D Printing. With this 40-page long e-book, you will get a complete overview of today's
3D Printing landscape.
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Part 1
The Basics
What is 3D printing? What are its key bene its, limitations and main applications?
Begin part 1
Part 2
3D Printing Processes
A complete overview of all currently available 3D printing processes.
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Begin part 2
Part 3
3D Printing Materials
Learn more about the most popular materials used in 3D printing.
Begin part 3
Part 4
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Begin part 4
Part 5
Start 3D printing
Quick tips to start printing, from buying a 3D printer to ordering parts online.
Begin part 5
Part 6
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Useful resources
A list of useful resources for those who want to delve deeper.
Begin part 6
Part 1
The Basics
What is 3D printing? How does it work? What are its key bene its and limitations and main
industrial applications?
Here, we answer all these questions and examine how 3D printing compares to traditional
manufacturing to help you understand the current state of the technology.
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In 3D printing, no special tools are required (for example, a cutting tool with certain geometry or a
mold). Instead the part is manufactured directly onto the built platform layer-by-layer, which leads
to a unique set of bene its and limitations - more on this below.
The process always begins with a digital 3D model - the blueprint of the physical object. This
model is sliced by the printer's software into thin, 2-dimensional layers and then turned into a set
of instructions in machine language (G-code) for the printer to execute.
From here, the way a 3D printer works varies by process. For example, desktop FDM printers melt
plastic ilaments and lay it down onto the print platform through a nozzle (like a high-precision,
computer-controlled glue gun). Large industrial SLS machines use a laser to melt (or sinter) thin
layers of metal or plastic powders.
The available materials also vary by process. Plastics are by far the most common, but metals can
also be 3D printed. The produced parts can also have a wide range of speci ic physical properties,
ranging from optically clear to rubber-like objects.
Depending on the size of the part and the type of printer, a print usually takes about 4 to 18 hours
to complete. 3D printed parts are rarely ready-to-use out of the machine though. They often
require some post-processing to achieve the desired level of surface inish. These steps take
additional time and (usually manual) effort.
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The irst 3D printer was released in 1987 by Chuck Hull of 3D Systems and it was using the
"stereolithography" (SLA) process.
In the 90's and 00's other 3D printing technologies were released, including FDM by Stratasys and
SLS by 3D Systems. These printers were expensive and mainly used for industrial prototyping.
In 2009, the ASTM Committee F42 published a document containing the standard terminology on
Additive Manufacturing. This established 3D printing as an industrial manufacturing technology.
In the same year, the patents on FDM expired and the irst low-cost, desktop 3D printers were born
by the RepRap project. What once cost $200,000, suddenly became available for below $2,000.
According to Wohlers the adoption of 3D printing keeps growing: more than 1 million desktop 3D
printers were sold globally between 2015 and 2017 and the sales of industrial metal printers almost
doubled in 2017 compared to the previous year.
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The hype of the previous years was based on the idea of widespread consumer adoption. This was
(and still is) a misleading interpretation of where the technology actually adds value.
3D printing today has found very speci ic roles in the world of manufacturing. The in lated
expectations of the previous years have given their place to an increased productivity. Many
aspects of the technology are now mainstream and adopted by both professional and hobbyists.
Of course, 3D printing is an evolving technology. Every year new 3D printers are released that can
have a signi icant impact on the industry. For example, HP launched their irst 3D printing system
relatively late (in 2016), but it proved to be one of the most popular industrial 3D printers already
by 2017.
Here we summarize the most important bene its and limitations of 3D printing, taking into account
the pro's and con's of all 3D printing technologies currently available. Use them to understand
where 3D printing stands today and where it is headed in the near future.
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Limitations of 3D printing
Applications of 3D printing
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Here we collected some examples to show how people used 3D printing and why they chose it for
their speci ic use cases.
Aerospace
Aerospace and Space engineers use 3D printing to manufacture high-performance parts.
The ability to create topology optimized structures with high strength-to-weight ratio and
the possibility to consolidate multiple components into a single part are particularly
appealing.
When choosing between an additive (3D printing), subtractive (CNC machining) or formative
(Injection Molding) manufacturing technology, then there are a few simple guidelines that can
gudie your decision.
As a rule of thumb:
"3D printing is the best option when a single (or only a few)
parts are required at a quick turnaround time and a low-cost or
when the part geometry cannot be produced with any other
manufacturing technology."
Choosing a subtractive technology (CNC machining) makes more sense in the following scenarios:
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Medium volumes: When producing parts in the 100's, then CNC machining is typically more
economical. This is because the economies of scale start to kick in.
Relatively simple geometries: Especially for metal parts, when the design can be manufactured
easily through a subtractive process then CNC machining is the best option.
High material requirements: When excellent material properties are essential, then CNC
machining is a better option, as 3D printed parts typically have a lower strength.
High dimensional accuracy: For functional parts with tight tolerances, CNC machining is the best
option. For complex geometries, a hybrid approach (print irst, CNC machine afterwards) is also be
a viable option.
For larger production (> 1000 parts), formative technologies (like Injection molding) are more cost
effective and usually make the most inancial sense.
For a quick reference in the unit cost, use the graph below. In this simpli ication, it was assumed
that all technologies can produce the part geometry. When this is not the case, 3D printing is
generally the preferred manufacturing solution.
To summarize:
Part 2
3D Printing Processes
After reading this section, you will have a complete overview of today's 3D printing landscape.
Quickly learn about the most popular processes and materials, as well as actionable decision
making tools to help you select the optimal 3D printing process for your application.
Material Extrusion (FDM): Material is selectively dispensed through a nozzle or ori ice
Vat Polymerization (SLA & DLP): Liquid photopolymer in a vat is selectively cured by UV light
Powder Bed Fusion (SLS, DMLS & SLM): A high-energy source selectively fuses powder particles
Material Jetting (MJ): Droplets of material are selectively deposited and cured
Binder Jetting (BJ): Liquid bonding agent selectively binds regions of a powder bed
Direct Energy Deposition (LENS, LBMD): A high-energy source fuses material as it is deposited
Sheet Lamination (LOM, UAM): Sheets of material are bonded and formed layer-by-layer
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An infographic with all currently available 3D printing technologies is available for download. It
illustrates the seven 3D printing categories, the main materials each group can print with and the
most popular printer manufacturers.
Get instant access to the high-resolution PDF version of the Additive Manufacturing
Technologies poster for free.
The next sections will introduce you to the basic operating principles and pro's and con's of the six
main 3D printing processes today.
After reading this chapter, you will be able to make educated decisions about which 3D printing
technology is best suited for your particular application.
In FDM, a spool of ilament is loaded into the printer and then fed to the extrusion head, which is
equipped with a heated nozzle. Once the nozzle reaches the desired temperature, a motor drives
the ilament through it, melting it.
The printer moves the extrusion head, laying down melted material at precise locations, where it
cools and solidi ies (like a very precise hot-glue gun). When a layer is inished, the build platform
moves down and the process repeats until the part is complete.
After printing, the part is usually ready to use but it might require some post-processing, such as
removal of the support strucures or surface smoothing.
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FDM is the most cost-effective way of producing custom thermoplastic parts and prototypes. It
also has the shortest lead times - as fast as next-day-delivery - due to the high availability of the
technology. A wide range of thermoplastic materials is available for FDM, suitable for both
prototyping and some functional applications.
As of limitations, FDM has the lowest dimensional accuracy and resolution compared to the other
3D printing technologies. FDM parts are likely to have visible layer lines, so post-processing is
often required for a smooth surface inish. Additionally, the layer adhesion mechanism makes FDM
parts inherently anisotropic. This means that they will be weaker in one direction and are generally
unsuitable for critical applications.
Low-cost prototyping
Li it d di i l
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Limited dimensional accuracy
SLA and DLP are similar processes that both use a UV light source to cure (solidify) liquid resin in a
vat layer-by-layer. SLA uses a single-point laser to cure the resin, while DLP uses a digital light
projector to lash a single image of each layer all at once.
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After printing, the part needs to be cleaned from the resin and exposed to a UV source to improve
its strength. Next, the support structures are removed and, if a high quality surface inish is
required, additional post-processing steps are carried out.
SLA/DLP can produce parts with very high dimensional accuracy, intricate details and a very
smooth surface inish ideal that are ideal for visual prototypes. A large range of speciality
materials, such as clear, lexible, castable and biocompatible resins, or materials taylored for
speci ic industrial applications, are also available.
Generally, SLA/DLP parts are more brittle than FDM parts, so they are not best suited for functional
prototypes. Also, SLA parts must not be used outdoors, as their mechanical properties and color
degrades when they are exposed to UV radiation from the sun. Support structures are always
required in SLA/DLP which may leave small blemishes in the surfaces they come in contact with
that need extra post-processing to remove.
The SLS process begins with heating up a bin of polymer powder to a temperature just below the
melting point of the material. A recoating blade or roller then deposits a very thin layer of powder -
typically 0.1 mm thick - onto the build platform.
A CO2 laser scans the surface of the powder bed and selectively sinters the particles, binding
them together. When the entire cross-section is scanned, the building platform moves down one
layer and the process repeats. The result is a bin illed with parts surrounded by unsintered
powder.
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After printing, the bin needs to cool before the parts are removed from the unsintered powder and
cleaned. Some post-processing steps can then be employed to improve their visual appearance,
such as polishing or dying.
SLS parts have very good, almost-isotropic mechanical properties, so they are ideal for functional
parts and prototypes. Since no support structures are required (the unsintered powder acts as
support), designs with very complex geometries can be easily manufactured. SLS is also excellent
for small-to-medium batch production (up to 100 parts), since the bin can be illed throughout its
volume and multiple parts can be printed at a single production run.
SLS printers are usually high-end industrial systems. This limits the availability of the technology
and increases its cost and turn-around times (compared to FDM or SLA, for example). SLS parts
have a naturally grainy surface and some internal porosity. If a smooth surface or watertightness is
required, additional post-processing steps are needed. Beware that large lat surfaces and small
holes need special attention, as they are susceptible to thermal warping and oversintering.
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Material Jetting works in a similar way to standard inkjet printing. However, instead of printing a
single layer of ink on a piece of paper, multiple layers of material are deposited upon each other to
create a solid part.
Multiple print heads jet hundreds of tiny droplets of photopolymer onto the build platform, which
are then solidi ied (cured) by the UV light source. After a layer is complete, the build platform
moves down one layer and the process repeats.
Support structures are always required in Material Jetting. A water-soluble material is used as
support that can be easily dissolved during post-processing and that is printed at the same time
as the structural material.
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Material Jetting is the most precise 3D printing technology (with SLA/DLP being a close second). It
is one of the few 3D printing processes that offers multi-material and full-color printing
capabilities. Material Jetted parts have a very smooth surface - comparable to injection molding -
and very high dimensional accuracy, making them ideal for realistic prototypes and parts that
need an excellent visual appearance.
Material Jetting is one of the most expensive 3D printing processes and this high cost may make it
inancially unviable for some applications. Moreover, parts produced with Material Jetting are not
best suited for functional applications. Like SLA/DLP, the materials used with this process are
thermosets, so the produced parts tend to be brittle. They are also photosensitive and their
properties will degrade over time with exposure to sunlight.
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Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLM) produce parts in a similar
way to SLS: a laser source selectively bonds together powder particles layer-by-layer. The main
difference, of course, is that DMLS and SLM produce parts out of metal.
The difference between the DMLS and SLM processes is subtle: SLM achieves a full melt of the
powder particles, while DMLS heats the metal particles to a point that they fuse together on a
molecular level instead.
Support structures are always required in DMLS and SLM to minimize the distortion caused by the
high temperatures required to fuse the metal particles. After printing, the metal supports need to
be removed either manually or through CNC machining. Machining can also be employed to
improve the accuracy of critical features (e.g. holes). Finally, the parts are thermally treated to
eliminate any residual stresses.
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DMLS/SLM is ideal for manufacturing metal parts with complex geometries that traditional
manufacturing methods cannot produce. DMLS/SLM parts can be (and should be) topology
optimized to maximize their performance while minimizing their weight and amount of material
used. DMLS/SLM parts have excellent physical properties, often surpassing the strength of the
rough metal. Many metal alloys that are di icult to process with other technologies, such as metal
superalloys, are available in DMLS/SLM.
The costs associated with DMLS/SLM 3D printing are high: parts produced with this processes
typically cost between $5.000 and $25.000. For this reason, DMLS/SLM should only be used to
manufacture parts that cannot be produced with any other method. Moreover, the build size of
modern metal 3D printing systems is limited, as the required precise manufacturing conditions are
di icult to maintain for bigger build volumes.
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Binder Jetting
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Binder Jetting is a lexible technology with diverse applications, ranging from low-cost metal 3D
printing, to full-color prototyping and large sand casting mold production.
In Binder Jetting, a thin layer of powder particles (metal, acrylic or sandstone) is irst deposited
onto the build platform. Then droplets of adhesive are ejected by a inkjet printhead to selectively
bind the powder particles together and build a part layer-by-layer.
After the print is complete, the part is removed from the powder and cleaned. At this stage it is
very brittle and additional post-processing is required. For metal parts this involves thermal
sintering (similar to Metal Injection Molding) or in iltration with a low melting-point metal (for
example, bronze), while full-color parts are in iltrated with cyanoacrylate adhesive.
Binder Jetting can produce metal parts and full-color prototypes at a fraction of the cost of
DMLS/SLM or Material Jetting respectively. Very large sandstone parts can also be manufactured
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with Binder Jetting, as the process is not limited by thermal effects (for example, warping). Since
no support structures are needed during printing, metal Binder Jetting parts can have very
complex geometries and, like SLS, low-to-medium batch production is possible by illing up the
whole build volume.
Metal Binder Jetting parts have lower mechanical properties than the bulk material though, due to
their porosity. Due to the special post-processing requirements of Binder Jetting, special design
restrictions apply. Very small details, for example, cannot be printed, as the parts are very brittle
out of the printer and may break. Metal parts might also deform during the sintering or in iltration
step if not supported properly.
For this reason, we have prepared decision making tools and generalized guidelines to help you
select the right 3D printing process.
Generally, there are three main things you always need to consider:
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The functional & visual design requirements: smooth surface, strength, heat resistance etc.
The capabilities of the 3D printing process: accuracy, available print volume, layer height etc.
With these considerations in mind, identifying the best solution for your application should
become straightforward. We have prepared a detailed guide to help you with the technical details
or you can se this decision trees bellow for a quick reference.
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Part 3
3D Printing Materials
3D printing materials are closely connected to 3D printing processes. In this section, you will
learn more about the most popular materials that are used today in 3D printing and their key
applications.
3D Printing Materials
Each 3D printing process is compatible with different materials. Plastics both thermoplastics and
thermosets) are by far the most common followed by metals. Some composites and ceramics can
also be 3D printed.
In the tables below, the most common plastics and metals used in 3D printing are summarized. If
you are looking for a 3D Printing material with speci ic properties, you will probably ind our
Material Index useful.
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Plastics
3D printing plastics are lightweight materials with a wide range of physical properties, suitable for
both prototyping purposes and some functional applications.
Plastics are either thermoplastics (with FDM or SLS), which are generally more suited for functional
applications, or thermosets (with SLA/DLP or Material Jetting), which are generally more suited for
applications that require good visual appearance.
PLA
ABS
Resin
Nylon
PETG
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TPU
ASA
PEI (ULTEM)
Do you want to learn more about 3D printing plastics? We have prepared extensive guides for you.
Metals
3D printing metals are mainly used in applications that require high strength, high hardness or
high thermal resistance. When 3D printing in metal, topology optimization is critical to maximize
part performance and mitigate the high cost of the technology.
DMLS/SLM are compatible with the largest range of metals and produces parts for high-end
engineering applications. For less demanding use-cases, Binder Jetting is gaining popularity due
to its lower cost with Stainless steel being by far the most used material.
Extrusion based metal 3D printing systems (similar to FDM) are being released in 2018 which are
expected to drive down the costs of metal 3D printing for prototyping purposes.
Stainless steel
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Aluminum
Titanium
Cobalt-chrome
Nickel alloys
Part 4
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If 3D modeling sounds tough (or if you are simply short in time), we give you a list of the best
online model repositories to help you ind existing designs.
Think of STLs iles as the PDFs of 3D printing: they contain all the information needed to print a
model, but they are not easy to edit.
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Don't forget that despite the great design freedom offered by 3D printing, some restrictions still do
apply: anything can be "drawn" in 3D on a digital canvas, but not everything can be 3D printed.
To make your life easier, we created a poster that sums up the most important design rules for
each 3D printing process. You can print it and put it on your wall to always have it next to you
while designing.
Level-up your 3D printing design skills. Download the free 3D Hubs Design Rules for 3D
Printing poster to always get the best results from your design.
If you want to delve deeper, we've prepared multiple guides describing the key design
consideration for 3D printing, full of actionable tips and advice.
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Overhangs & support: 3D printers cannot deposit material on thin air. Walls at an angle greater
than 45° will require support, affecting the surface quality.
Level of detail: The smallest feature a printer can create depends on the size of the end effector
(nozzle or laser) it uses.
Layer height: The layer height affects the vertical resolution of a part. It's effects are visible are
areas with greater curvature (it appears as stair-stepping).
For speci ic design guidelines for each 3D printing process, follow the links:
Do you want to step up your 3D printing skills? The 3D Printing Handbook can help you
get there. If you’re a professional looking to master the key aspects of 3D printing, this
book is for you!
Here is the list with the CAD design software we recommend to use for designing parts for 3D
printing:
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Solidworks
Rhinoceros
Fusion 360
Onshape
TinkerCAD
If you are looking for the best tools you can use to modify or repair your STL iles before you send
them to print, here is a list of the best software currently available:
Netfabb
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Meshmixer
The process of converting an STL ile into machine language (G-code) is called slicing. Here are
some of the best and most popular slicing software out there today:
Cura
Simplify3D
Thingiverse → The largest online repository with thousands of free 3D printable iles for desktop
3D printing.
MyMiniFactory → A popular online repository with free 3D models that are tested for quality and
are guaranteed to be 3D printable.
Cults → An online marketplace with high quality 3D printable models by professional designers,
and curated collections connected to big-name brands.
Pinshape → An online marketplace with both free and premium 3D printable iles, focusing mainly
on hobbyists.
GrabCAD → An online repository of many 3D models that also includes some 3D printable iles,
focusing mainly on engineering professionals.
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Part 5
Start 3D printing
It is time to put your knowledge into practice. In this section, we will guide you through the
basic steps needed to start 3D printing: from choosing what printer to buy to how to use an
online service.
No matter how you decide to proceed, we give you tips on what you should do next in the
following two sections.
you need to print regularly (10 - 25+ times a you will need too few (less than 5) or too many
week) (25+) parts printed per month
you have one speci ic application in mind for you want to print using multiple processes and
the printer materials, including industrial printers
you are prepared to setup, tinker and optimize you prefer to focus your time on designing and
your machine perfecting your models
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you have the necessary space and time to you want to test and learn irst before deciding
install and operate the printer what printer to buy
To answer this question, every year we reach out to our global network of 3D printing service
providers to learn from their experiences and ind out more about the 3D printers they own.
With reviews from more than 10 thousand veri ied 3D printer owners, who have completed about
1.48 million prints on 650+ different 3D printer models, the result of our research is the most
comprehensive 3D Printer Guide available.
Find the best 3D printers. Read the full reviews of the best Prosumer, Workhorse, Plug
‘n’ Play, Budget, and Industrial 3D printers.
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At 3D Hubs we are building the smartest manufacturing solution on the planet. One of our main
offerings is our 3D Printing service.
By combining our global network of manufacturing services with our smart sourcing engine, you
can instantly access readily available 3D printing production capacity near your area with the best
possible quotes and lead times.
When you upload a part, our proprietary Design for Manufacturing (DFM) software detects any
potential design issues before production begins, minimizing cost and delays.
This way you can be certain that you always receive the best price possible at the fastest
turnaround times for your 3D printed parts.
Bene it from the low prices and fast turnaround times offered by our global network of
3D printing manufacturing parteners. Start 3D printing now.
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Part 6
Useful resources
In this guide we touched upon all you need to get you started with 3D printing, but there is
plenty more to learn.
Below we list the best and most useful resources on 3D printing and other digital manufacturing
technologies for those who want to delve deeper.
Knowledge Base
Here, we touched upon all you need to get you started with 3D printing. There is plenty more to
learn though in our Knowledge Base - a collection of technical articles on all manufacturing
technologies, written by experts from 3D Hubs and the manufacturing industry.
Quality articles for engineers and designers to learn about Digital Manufacturing.
Written by manufacturing experts, curated by 3D Hubs.
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What's Inside:
Insights into the mechanism behind all major 3D printing technologies.
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Do you want to step up your 3D printing skills? The 3D Printing Handbook can help you
get there. If you’re a professional looking to master the key aspects of 3D printing, this
book is for you!
Get a complete overview of today's metal 3D printing landscape. Learn when and how
to use the three most popular metal 3D printing technologies: DMLS/SLM, Binder
Jetting and Metal Extrusion.
Learn all you need to know about CNC machining in 25 minutes or less. Whether you
are an experienced design engineer or just getting started with manufacturing, this
guide is for you.
Master the basic principles of Injection molding and learn how to get started with the
mass-production of plastic parts.
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29/9/2019 What is 3D printing? The definitive guide | 3D Hubs
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