SOLIDWORKS users know that the popularity of 3D printing, aka additive manufacturing, is growing in both the hobby and industrial worlds as it promotes innovation and creativity. Thus, as the adage says, the best time to get into 3D printing was years ago, but the second-best time is today.
If you’re just getting started, I’m sure you have questions. We have answers. So here are ten things you need to know to get started with additive manufacturing in SOLIDWORKS.
- What is 3D printing?
It may seem obvious, but for those newly entering the 3D printing space, it’s worthwhile to put some definition to the concept. 3D printing is an additive process where objects are made by solidifying a material one layer, or slice, at a time. It stands in contrast to traditional manufacturing methods where material is subtracted from a solid block to form a geometry.
For a gross simplification, you could say that 3D printing works like your inkjet printer at home. Instead of the print head moving across the paper laying drops of ink in specific places, it moves across a print bed depositing material one drop at a time. In a printer, the location of these ink drops creates the letters or images on the page. However, the 3D printer stacks the drops of material on top of previous drops, which have now solidified, to add a third dimension to the print.
- What do I need to know about 3D printing to start my journey?
3D printing is great for prototyping. It’s even colloquially known as rapid prototyping. However, it can be so much more than a prototyping machine. The technology has become so advanced in terms of materials and quality that some production parts can be created using a relatively inexpensive home 3D printer. As a result, 3D printers have become productivity workhorses for DIYers, product development professionals and everyone in between.
This is the stuff that the engineers, designers and hobbyists could once only dream about when seeing replicators on Star Trek.
- What does it take to get started?
It’s easy to get started with your own 3D printer. All you need are:
- A 3D printer, which can be purchased, or often rented at libraries and makerspaces.
- Software to make a 3D design and then translate it into a printing toolpath.
- Basic knowledge of physics to make informed design decisions.
My 3D design software of choice is SOLIDWORKS. You can learn more about why here. However, the second software that is used to run the machine will typically come packaged with the printer hardware. For beginners, it’s recommended to use the 3D printing software that comes with the machine.
As for a basic knowledge of physics, this is helpful to reduce the number of failed prints you will encounter. When defining a tool path, the user will need to make decisions like whether to include temporary supports to hold up parts of the print that would be hard to produce without them. They will also need to make decisions about droplet size and how that might impact resolution, print quality, printing time and printability. Basically, you need to understand the technology enough to be able to make an informed decision to achieve your goals.
- What are the methods of 3D printing?
For beginners, there are two main 3D printing methods I would suggest starting out with:
- FDM (Fused Deposition Modeling) printers work by extruding drops of molten plastic to create the shapes designed in SOLIDWORKS CAD. FDM is the likely choice for SOLIDWORKS users.
- SLA (Stereolithography) printers work by hardening liquid resin with a laser. It uses the same concept of turning drops of material into solid geometry, but it uses a different approach.
Other 3D printing methods exist, such as selective laser sintering (SLS) and various processes to print metal parts. However, they are expensive and typically reserved for industry applications. This means they are an impractical starting point for those new to additive manufacturing best practices.
- What are the pros and cons of SLA and FDM printing?
| FDM Pros | SLA Pros |
| Printing is more affordable. | Offers high resolution and smooth surface finish. |
| Machines are easier to work on and maintain. | Excellent for detailed models. |
| Offers a wide variety of thermoplastic materials (PLA, ABS, Nylon, PETG). |
| FDM Cons | SLA Cons |
| Printing typically offers lower resolution and quality. | Limited to mostly resins. |
| Parts typically have a poorer surface finish with visible layer lines. | Materials may be sensitive to UV light. |
- What 3D printing method is right for me?
Each person has their own unique goals, and each 3D printing method has their advantages depending on the application. Typically, for a SOLIDWORKS user, FDM is a great place to start.
FDM is typically optimized for general use, whereas SLA excels in precision and surface quality. For most SOLIDWORKS users, surface quality and precision will not a top priority.
- What materials considerations are important?
3D printing materials have come a long way in recent years. Compared to just a decade ago, we are living in the golden age of 3D printing. PLA and ABS plastics are popular and cost-effective options for FDM. But you can also consider some more specialized materials such as carbon-fiber reinforced materials for strength or thermoplastic polyurethane (TPU) for flexible or bendable parts. You can also print high performance metals such as titanium and aluminum, but those would require specialized printers.
When choosing a material you should consider:
- Strength vs. flexibility: Does your part need to hold up to high stress applications?
- Hot or wet environments: Will your part be exposed to high temperatures or wet environments?
- Aesthetics: How important are things like the fit, finish and surface quality of your part?
- Cost: One way or another it comes down to cost.
Some materials are more expensive than others, while others take more time to print. You’ll have to find the right balance for your applications.
- How do I design my parts and what are DfAM or DF3?
In the mechanical design space, a common phrase is DFM or Design for Manufacturing. This is the concept that you need to design something that can physically be created in a machine shop. In 3D printing we call this DF3 (design for 3D printing) or DfAM (design for additive manufacturing).
These are the considerations that you need to make in your design process so you can print a part that meets your needs. It is all about optimizing your design for 3D printing. What’s great is that most of these best practices are addressed in the 3D printing software that comes with most machines. SOLIDWORKS CAD can help as well, as it has features to help optimize a part based on layer thickness, print bed size and temporary supports.
For instance, you’ll have to make the right choice when designing your part to account for the 3D printed material’s performance as well as the printing operation. Sometimes a wall thickness is too thin and it’s too flexible, or it’s too thin and the material (subsequent layers) can’t be stacked leading to a print failure.
You’ll also need to use supports to make sure your machine can physically print the material. For instance, when the design has an overhang, the printer will need to build temporary supports to have something underneath upon which it can lay the material that will remain in the final part. Similarly, you typically won’t be printing solid materials. To save time and material you’ll be able to fill in the internal volumes with an infill grid, like a honeycomb. This infill will affect the quality of the final print in a similar way to the temporary supports.
Finally, layer orientation and thickness also play a role in both the aesthetic and the strength of a part. You’ll have to make a choice in how the overall quality and printing speed are related.
- What are the file types I need to create from SOLIDWORKS?
Your 3D printing journey will typically start in SOLIDWORKS, where you’ll create the 3D geometry. From there you’ll be exporting one of two file types: 3mf or STL. In SOLIDWORKS, it’s easy to export these files.
- How do I get started?
Once you have a machine to work on, and software to set everything up, you’ll be ready to go. The machine can be procured via professional vendors, distributors, as well as online retailers like Amazon. Many libraries and maker spaces also offer people the ability to rent time on the machines and software needed to make a 3D print.
After playing around with the machine and software you might want to explore what other options are available. For software that controls the printer, open tools like Ultimaker Cura or PrusaSlicer are popular options.
If you’re reading this, you likely already have SOLIDWORKS to create your designs. So now you’re ready to get started and see how 3D printing can be a gateway to innovation and creativity.