Online custom 3D printing service, for startups & enterprises.

Prototyping & production 3D printing, using 70+ thermoplastics, thermosets & metals.

Custom parts delivered in 2 days.

Our 3D printing & additive manufacturing capabilities

To help ensure the success of your project, we have numerous 3D printing technologies, including FDM, SLS, MJF + SLA, DLS, Polyjet + DMLS and MBJ. This range of technologies allows us to 3D print 70+ types of plastics, elastomerics and metals. Enabling engineers to target many applications, whether it is medical, industrial, or consumer.

3D printing thermoplastics capabilities

Fused Deposition Modeling (FDM)

A technology with large material selection, accuracy, and possibility to print large parts. Great for fast & low cost rapid prototyping.

Min lead time

2 days

General tolerances

± a single build layer thickness for the first mm, plus +/- 0.05mm for every mm thereafter

Max part size

609 x 914 x 914mm

Minimum feature size

0.89mm (but > 1.14mm is best)

Minimum wall thickness

• 1.19mm for parts < 356 x 406mm
• 1.52mm for parts > 356 x 406 - 914mm

Layer thickness

• 0.203mm for parts 249 x 208 x 208mm (Desktop)
• 0.254mm for parts < 356 x 406mm footprint (Industrial)
• 0.330mm for parts > 356 x 406 - 914mm footprint (Industrial)

Guaranteed tolerances

Get custom quote

Selective Laser Sintering (SLS)

A technology for industrial 3D printing that is inexpensive, hence popular. Great for functional prototyping & short-run production.

Min lead time

2 days

General tolerances

± 0.25mm for the first mm, plus +/- 0.05mm for every mm thereafter

Max part size

330 x 330 x 508mm (standard) 660 x 381 x 584mm (glass filled)

Minimum feature size

0.76mm

Minimum wall thickness

0.7mm (Nylon 12) - 2mm (Carbon filled Nylon 12)

Layer thickness

0.114mm

Guaranteed tolerances

Get custom quote

Multi Jet Fusion (MJF)

A technology that produces highly accurate and durable parts at comparitively fast speeds. Great for functional prototyping & short-run production.

Min lead time

2 days

General tolerances

±0.305mm up to 102mm, plus ±0.076mm for every mm thereafter

Max part size

381 x 279 x 381mm (but 355 x 330 x 279mm is best)

Minimum feature size

0.51mm

Minimum wall thickness

0.30mm short walls on XY plane x 0.40mm short walls on Z plane

Layer thickness

0.102mm

Guaranteed tolerances

Get custom quote

3D printing thermosets capabilities

Stereolithography (SLA)

A technology that produces extremely accurate and high-resolution parts. Great for visual prototyping.

Min lead time

2 days

Tolerance - XY plane

±0.127mm for the first mm, plus ±0.05mm for every mm thereafter

Tolerance - Z plane

±0.254mm for the first mm, plus ±0.05mm for every mm thereafter

Max part size

736 x 635 x 533mm

Minimum feature size - linear

0.51mm (but > 0.76mm is best)

Minimum feature size - radial

0.89mm

Minimum wall thickness

• 0.60mm unsupported walls
• 0.40mm supported walls (both sides)

Layer thickness

0.102mm

Guaranteed tolerances

Get custom quote

Carbon Digital Light Synthesis (DLS)

A technology that produces parts with exceptional durability, resolution & surface finish. Great for functional prototyping & short-run production.

Min lead time

4 days

General tolerances

±0.127mm for the first mm, plus ±0.05mm for every mm thereafter

Max part size

101 x 101 x 152mm (standard) 187 x 116 x 325mm (custom)

Ideal part size

< 50.8 x 25.4 x 76.2mm (best production economy of scale)

Minimum feature size

1.0mm

Minimum wall thickness

0.76mm (walls, text, lattice features)

DLP Pixel Resolution

Approx 0.127mm square

Layer thickness

0.102mm

Guaranteed tolerances

Get custom quote

PolyJet

A rigid photopolymer technology that produces high-detailed models. Great for flexible and multi material prototyping.

Min lead time

2 days

General tolerances

±0.1mm for the first mm, plus ±0.05mm for every mm thereafter

Max part size

490 x 391 x 200mm

Minimum feature size

1.3mm - for rigid 1.6mm - for rubber-like

Minimum wall thickness

1mm

Layer thickness

0.025mm

Guaranteed tolerances

Get custom quote

3D printing metals capabilities

Direct Metal Laser Sintering (DMLS)

A technology that selectively fuses a fine aluminum or stainless steel powder. Great for metal prototyping & short-run production.

Min lead time

8 days

General tolerances

±0.13mm for the first mm, plus ±0.05mm for every mm thereafter

Max part size

250 x 250 x 250mm

Minimum feature size

0.75mm - for cosmetic features 1.5mm - for structural features

Layer thickness

0.03mm - 0.04mm (depending on material)

Surface roughness

150-400 µin Ra (depending on material & build orientation)

Infill

1

Guaranteed tolerances

Get custom quote

Metal Binder Jetting (MBJ)

A technology used to make complex metal parts with excellent mechanical properties. Great for metal prototyping & short to medium run production.

Min lead time

8 days

General tolerances

0.8% – 2.5% shrinkage during cooling < 5% shrinkage of internal geometries (slots / holes)

Max part size

400 x 250 x 250mm

Minimum feature size

1.0mm

Minimum wall thickness

1.0mm

Layer thickness

0.10mm

Surface roughness

30 to 200 µin Ra (depending on material, build orientation & finish)

Density

95%+ for infiltrated, 98%+ for single alloy (density is homogeneous)

Guaranteed tolerances

Get custom quote

Custom parts delivered in 2 days.

What is 3D printing?

3D printing is an additive manufacturing process that builds 3D objects layer by layer, highly suited for prototyping and low-volume production of both plastic and metal parts. Numerous different 3D printing technologies exist, but the three primary types are fused deposition, selective laser sintering, and stereolithography.

While 3D printing has been around for decades, it has only been in the last decade that its development and use have accelerated, and this has also seen numerous technological achievements, including reduced layer heights, improved accuracy, and faster printing times.

Our cloud-3D printing manufacturing service provides engineers with the most essential 3D printing technologies to help accelerate project development times, reduce overall project costs, and provide the highest quality printed parts.

Our 3D printing materials

Whether you’re looking to create an IoT device, medical sensor, or industrial controller, our stock of over 70 3D printing materials will provide you with the perfect option. Instead of choosing a printing technology, the desired material is chosen, and this then dictates the printing technology used. For example, PLA and ABS will use FDM machinery, whereas metals will use selective laser sintering (SLS) systems.

3D printing thermoplastics materials

Fused Deposition Modeling (FDM)
MaterialColorsTensile Strength, Yield (XZ MPa-ZX MPa)Elongation at Break (XZ%-ZX%)HDT @ 66 psi (°C)
ABS-M30Black, Blue, Dark Grey, Ivory, Red, White32 MPa-28 MPa7% - 2%96 °C
ABS-ESD7Black (electrostatic dissipative properties)36 MPa0.03%96 °C
ABSiTranslucent Natural, Translucent Amber, Translucent Red37 MPa0.044%86 °C
ASABlack, Dark Blue, Dark Gray, Light Gray, Green, Ivory, Orange, Red, White, Yellow27 MPa9% - 3%98 °C
Nylon 12Black49.3 MPa-41.8 MPa30% - 6.5%91.9 °C
PC-ABSBlack41 MPa0.06%110 °C
PCWhite57 MPa-42 MPa4.8% - 2.5%138 °C
PC-ISOTranslucent Natural, White57 MPa0.04%133 °C
PPSFTan55 MPa0.03%189 °C @ 264 psi
Prototyping PLABlack, Blue, Red, White50 MPa-37 MPa2.9% - 1.9%55 °C
ULTEM 9085Black, Tan47 MPa-33 MPa5.8% - 2.2%153 °C
ULTEM 1010Amber (Natural)64 MPa-41 MPa3.3% - 2.0%216 °C
Selective Laser Sintering (SLS)
MaterialOther NamesImpact Strength, Notched (kJ/m²)Elongation at Break (%)Shore Hardness
Nylon 11 EXDuctile plastic, PA11, Rilsan® Invent NaturalNo break0.45%77D
Nylon 12Durable plastic, PA12, PA 22004.8 kJ/m²0.18%75D
Nylon 12, Glass-Filled (GF)Stiff plastic, PA12 GF, PA 3200 GF4.2 kJ/m²0.09%80D
Nylon 12, Carbon-Filled (CF)High-performance plastic, carbon-filled PA12, PA 602-CF, carbonmide5.3 kJ/m²0.04%N/A
Nylon 12, Aluminum-Filled (AF)Metallic gray plastic, aluminum-filled PA12, alumide4.6 kJ/m²0.03%76D
Nylon 12, Mineral-Filled (HST)Heat-resistant plastic, mineral fiber-reinforced PA12, PA 620-MFN/A3% - 5%75D
Nylon 12, Flame Retardant (FR)Meets FAR 25.853 60 second burn specification, PA 606-FRN/A0.24%73D
Multi Jet Fusion (MJF)
MaterialDescriptionImpact Strength (XY, ZX kJ/m²)Elongation at Break (XY, ZX %)Shore Hardness
Nylon 11HP 3D High Reusability PA 116 kJ/m², 5 kJ/m²55%, 40%80D
Nylon 12HP 3D High Reusability PA 123.6 kJ/m², 3.5 kJ/m²20%, 15%80D
Nylon 12, Glass-FilledHP 3D High Reusability PA 12 Glass Beads (40% GB)3 kJ/m²0.1%82D
Polypropylene (PP)HP 3D High Reusability PP3.5 kJ/m², 3.0 kJ/m²0.2%70D (est.)
TPU 88ABASF Ultrasint™ TPU01Partial break, No break220%, 120%88A

3D printing thermosets materials

Stereolithography (SLA)
MaterialDescriptionFlexural Strength (MPa/KSI)Elongation at Break (%)HDT@0.46 MPa (°C)
Accura 25White, PP-like58 MPa/KSI0.2%63 °C
Accura ClearVueClear/Translucent, PC-like67 MPa/KSI0.07%46 °C
Somos Watershed BlackBlack/Dark-Grey, ABS-like69 MPa/KSI0.15%50 °C
Somos WaterShed XC 11122Clear/Translucent, ABS-like69 MPa/KSI0.15%50 °C
Somos EvoLVe 128White, ABS-like70 MPa/KSI0.11%52 °C
Accura Xtreme GreyGrey, ABS-like71 MPa/KSI0.22%62 °C
Somos NeXtWhite, PP-like71 MPa/KSI0.1%57 °C
Somos ProtoGen 18420White, ABS-like71 MPa/KSI0.16%47 °C
Somos TaurusDark Gray, ABS-like74 MPa/KSI0.24%62 °C
Accura ABS Black (SL 7820)Black (painted), ABS-like78 MPa/KSI0.13%51 °C
Accura Xtreme White 200White, ABS-like79 MPa/KSI0.2%47 °C
Somos WaterClear Ultra 10122Clear/Translucent, PC-like84 MPa/KSI0.07%47 °C
Accura 60Clear/Translucent, PC-like101 MPa/KSI0.13%55 °C
Somos ProtoTherm 12120*Translucent Red, PC-like109 MPa/KSI0.04%126 °C
Accura 48HTR*Translucent Amber, PC-like118 MPa/KSI0.07%130 °C
Somos PerFORM*White, Ceramic-filled146 MPa/KSI0.01%268 °C
Accura Bluestone*Blue, Ceramic-filled154 MPa/KSI0.02%284 °C
* Requires post-thermal curing to achieve HDT.
Carbon Digital Light Synthesis (DLS)
MaterialDescriptionImpact Strength (J/m)Elongation at Break (%)Shore Hardness
RPU 70Rigid polyurethane22 J/m1%80D
UMA 90Urethane methacrylate33 J/m0.17%86D
EPX 82Impact-resistant epoxy44 J/m0.059%89D
CE 221High temp cyanate ester (HDT 230C)15 J/m0.035%92D
FPU 50Flexible polyurethane40 J/m2.8%71D
EPU 40Elastomeric polyurethaneN/A3.1%68A
SIL 30Elastomeric silicone-urethaneN/A3.3%35A
PolyJet
MaterialDescriptionNotched Impact Strength (J/m)Elongation at Break (%)Shore Hardness
Photopolymer - rigidVeroUltra™ Black (RGD865) + VeroUltra™ White (RGD825) + VeroUltraClear Component (RGD820) + VeroClear (RGD810)19 - 25 J/M7% - 12%83D - 86D
Photopolymer - rubber-like (digital rubber)Agilus30 + VeroN/A185% - 230%26-28A, 35-40A, 45-50A, 57-63A, 68-72A, 80-85A, 92-95A
Multi-material, multi-color (digital material)Combination of 2+ PolyJet materialsVariesVariesVaries

3D printing metals materials

Direct Metal Laser Sintering (DMLS)
MaterialDescription
Aluminum AlSi10MgLightweight aluminum alloy instead of machining complex geometries
Stainless steel 17-4Fully-dense metal, hardness 40 HRC, heat treatable
Stainless steel 316/LFully-dense metal, superb corrosion resistance, meets requirements of ASTM F138
Metal Binder Jetting (MBJ)
MaterialDescription
X1 Metal 420i™A 95%+ dense matrix metal composite material composed of 60% 420 stainless steel and 40% bronze infiltrant. Good mechanical properties and excellent wear resistance. Its properties behave similarly to 4140 steel.
X1 Metal 316i™A 95%+ dense matrix metal composite material composed of 60% 316L stainless steel and 40% bronze infiltrant. Good mechanical properties and excellent wear resistance. 316i is easier to tap and post-machine versus 420i.
Single alloy 316L stainless steelA 98%+ dense metal with superb corrosion resistance, and excellent feature details.
Custom parts delivered in 2 days.

How does software-accelerated manufacturing work?

The speed at which technology is advancing can make it difficult for engineers to keep up with the latest manufacturing trends while also requiring engineers to increasingly make more complex design decisions when considering how their product will be manufactured. To help engineers with this, software-accelerated manufacturing eases the burden of design and manufacturing designs by shifting this complexity to our software-driven services.

At the same time, our online quotation tools for 3D printed parts enable engineers to get prices for their designs at much faster rates compared to traditional ordering techniques. Not only does this reduce the time taken to get parts manufactured, but it allows engineers to make design iterations much faster, thereby saving money spent on R&D.

Finally, our software-driven services for 3D printed parts allow engineers to quickly scale their projects, whether it is a single part or one thousand. Thus, engineers moving from prototypes to finalized designs can use the same software platform without making any changes to their design or process.

How much do 3D printing services cost?

Because of the many different factors that can affect the price of a 3D printed part, there is no one simple answer for the price of a 3D printed part. However, what can be said is that the price of a 3D-printed plastic part is a fraction of the cost of a plastic-injected molded part when ordered in low volumes (considering that molds can cost well over ten thousand dollars).

The same applies to 3D-printed metal parts when compared to CNC and cast parts. The additive manufacturing technique used to manufacture metal parts with a 3D printer results in no waste, and the lack of a tool head reduces the running costs of a 3D metal printer, whereas a CNC requires frequent tool changes, while a metal cast requires a new mold with every cast.

As such, 3D printing remains one of the most price-competitive manufacturing techniques for prototypes and low-volume manufacturing. This is especially true for industries such as IoT where development times need to be minimized, and medical industries, where order quantities for prototypes are typically very small.

However, parts that require extreme precision will fare better with CNC machining, and those that require to be purchased in the thousands can take advantage of the fast product speed of plastic injection molding.

Custom parts delivered in 2 days.

Quality, at speed, guaranteed.

No matter if a print is being used as a prototype or as a market-ready product, every 3D printed part that we produce is made to the highest quality standards, conforming to our strict set of capabilities.

At the same time, our 3D printing services provide engineers with a rapid service that can produce parts far quicker compared to other manufacturing methods including injection molding.

Furthermore, all 3D printed parts manufactured by Ponoko come with a 365-day guarantee which not only demonstrates our confidence in our 3D printing capabilities, but also provides engineers with confidence in their designs.

What parts are good for 3D printing?

Generally speaking, most 3D parts are ideal for 3D printing, especially for low-volume production runs and prototypes. While the manufacturing time for 3D printed parts is longer than that by injection molding, the lack of molds and use of additive manufacturing means that there is minimal waste and no tooling charges, which can be extremely expensive for other production methods.

The high strength of 3D printed parts makes 3D printing ideal for mechanical fixtures such as brackets, mounts, and enclosures. If plastic parts are made thick enough, even washers and large bolts can be printed, but engineers who require stronger parts can turn to metal powder 3D printing.

3D printing is also great for printing low-volume production runs of parts that need customisation. While CNC and injection molding can be used to create custom parts, their high setup costs only make them viable for mass production, and so 3D printing offers engineers an inexpensive custom part manufacturing service. For example, a new IoT product that requires a specific type of enclosure bracket or fitting can do well to use 3D printing if only a few hundred are being produced (this is also ideal for industries where market-ready products are highly specialized and see small scale volumes).

What applications can Ponoko 3D printed parts be used in?

3D printed parts have many applications across numerous industries, including medical, automotive, aerospace, robotics, industrial and electronics, but are especially popular in the prototyping and R&D industries due to their rapid build time and ability to create complex 3D parts. For example, the electronics industry heavily relies on 3D printing for developing and testing enclosures as injection molding is far too expensive for individual prototypes. This is also true for those with aero and fluid dynamics whereby small-scale models can quickly be printed and tested in wind tunnels. Uses include:

  • Aerodynamic model testing in wind tunnels
  • Electronic enclosures
  • Mechanical fittings
  • Robotic frames
  • Visual aids
  • Injection molding tools
  • Jigs
  • Fixtures
  • Durable end use parts

A robotic arm

Fused Deposition Modeling (FDM 3D printing)

Every single day, hundreds of thousands of engineers are taking advantage of FDM printing to quickly prototype parts as well as provide engineering teams with a physical part to examine. However, some engineers are leveraging FDM 3D printing for heavily customized parts in low-volume industries. For example, numerous industrial equipment manufacturers are using 3D printing to create robotic arm attachments, which not only allows it to tailor parts to each customer's needs but also provides a low-cost replacement option that allows heads to be rapidly recycled and replaced. Thus, FDM 3D printing can be used for far more than just prototypes and could even become a critical manufacturing technology of the future.

A metal automotive part.

Direct metal laser sintering (DMLS 3D printing)

Metallic parts are essential in the field of engineering thanks to their high strength, machinability, and ability to withstand large temperatures. But for all the advantages that metal brings, it also presents some serious challenges including high costs of machining and the need for molds in castings. However, direct metal laser sintering offers engineers the ability to create metallic 3D structures using an entirely additive process which not only reduces the costs, but allows for extremely intricate and complex designs that would typically be impossible to machine using traditional methods. Now, many engineering companies involved in the automotive, industrial, and commercial industries are turning to direct metal laser sintering for both prototyping and low-volume production needs.

Close-Up Shot of CNC Lasers

Stereolithography (SLA 3D printing)

While 3D printing technologies such as FDM and SLS provide engineers with a cost-effective solution, the rough surface finishes caused by large layer heights can be problematic, especially for parts that have intricate details. For such parts, many engineers turn to SLA printing thanks to the ability to print with small layer heights, the fast-printing speeds, and the numerous material choices. One such application for SLA is prototyping miniature models before mass production via plastic injection molding. Another application for SLA printing is in high-precision industries including lasers and optics thanks to the precision offered by SLA.

Why you can trust Ponoko for 3D printed parts

When it comes to custom manufacturing services, Ponoko has many years experience, manufacturing over 2 million parts for more than 33,000 customers. Not only do we have extensive manufacturing experience, but we also work closely with numerous high-end engineering customers in fields such as medical, aerospace and automotive, where precision and reliability are essential.

Additionally, Ponoko has vast experience in manufacturing parts used during early product development stages where design confidentiality is critical. Our strong data protection practices ensure that all designs and parts are secured from unauthorized access, which helps to secure intellectual property at the most vulnerable point of a product’s development.

3D printing FAQs

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What kinds of 3D printing technologies exist?

The term “3D printing” refers to the process of manufacturing 3D objects using an additive process, but this can be done in numerous ways including fused deposition, selective sintering, and laser lithography.

The most common technology used in 3D printers is fused deposition manufacturing (FDM) which involves a material which is melted in an extruder and then placed down where it is needed. These printers build up 3D models in discrete layers and utilize support structures for areas that overhang (i.e., have no physical connection to the base of the printer). FDM printers predominantly use plastic materials such as PLA and ABS, but other materials do exist including wood and metal.

Selective laser sintering (SLS) uses a laser beam to sinter a powdered material which causes the molten material to stick to neighboring sintered material. Just like FDM, objects are made layer by layer, and each time a new layer is needed, the printer applies a thin layer of powder which effectively buries the part being manufactured. This presents a major advantage in that parts do not require support structures as the powder itself acts as the support. However, sintered parts require a heating cycle afterwards to properly fuse the powder together.

Resin printers (commonly known as SLA printers) utilize a UV-sensitive plastic liquid that submerges a tank, and either a laser beam attached to a series of rotatable mirrors or an LCD with a UV source underneath is placed at the underside of the tank (the bottom of the resin vat is transparent). With each layer, the desired pattern is exposed into the resin which causes it to harden, and then when the layer has fully cured, the printer extrudes the part out of the vat and then plunges the part back into the vat. From there, the next layer is imaged onto the part, and this cycle is repeated for each layer.

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How does 3D printing differ from other manufacturing processes?

Compared to the vast majority of other manufacturing techniques, 3D printing is unique in that it offers customized manufacturing capabilities while using an additive process.

Even though numerous additive manufacturing technologies exist, these are mainly geared towards mass production which makes them unsuitable for prototyping. For example, plastic injection molding consists of an extruder that injects molten plastic into a mold, and these can operate at extremely high speeds (some can produce parts every two seconds). But the cost of a plastic injection mold can easily be several thousand dollars with high-precision molds being in the hundreds of thousands of dollars. As such, plastic injection molding only makes sense when manufacturing a product in larger numbers.

CNC milling is a subtractive process that can be used to create 3D parts from solid blocks of material. Cutting tools (such as router bits and drills) are used to remove unneeded material, and this makes CNCs somewhat wasteful. However, if a recyclable material is chosen, the resulting waste can be recycled which minimizes waste. Additionally, CNCs are very slow to operate due to the need for slow feed rates, but this comes with the advantage that CNCs offer high levels of precision. Due to the high costs involved, CNCs are either used for prototypes or for high-quality engineered parts (such as jet engines).

Laser cutting is a subtractive manufacturing process that is extremely fast, low cost, and offers a high level of precision. The use of CNC axis controls also allows laser cutters to cut any and all 2D parts, but the use of a 2D axis system and shallow cut depth means that laser cutters are only able to create 2D shapes. At the same time, the use of a laser beam also limits what materials can be used as some materials when vaporized can release toxic gasses and smoke.

Stamping is another common manufacturing process that involves a metal stamp punching through a sheet of material (typically metal). Stamping, like plastic injection molding, is an extremely fast process and ideal for producing millions of parts. But just like plastic injection molding, stamping requires custom-made stamps which are heavy and expensive to produce. Thus, stamping is rarely seen in the prototyping industry.

Vacuum forming is a popular manufacturing method for quickly producing 3D shapes using a 2D sheet of material, and is mostly used with plastics (thanks to their ability to become soft and malleable at low temperatures). Just like injection molding, vacuum forming relies on a mold that the heated plastic wraps around which enables for high speed manufacturing. At the same time, the need for a mold can make vacuum forming very expensive, but the molds used are nowhere near as precise as those found in plastic injection molding.

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What advantages does 3D printing offer?

Compared to other manufacturing methods, 3D printing offers numerous advantages including its low cost, ability to print custom designs without the need for tooling, and high speed for individual prototypes.

The first advantage of 3D printing comes from the ability to create any custom 3D shape without the need for molds or specialized tooling. This allows 3D printers to switch between user designs instantly while also reducing the costs associated with designing molds and replacing tools. At the same time, 3D printers are also able to print complex shapes as well as internal structures to a part, and this enables them to be used in complex designs. For example, 3D printing is one of the few methods that can print a part inside another part with both parts being physically separated.

The second advantage of 3D printing is that entire structures can be printed and fused together which eliminates the need for bolts, bonding, and other fixtures. Of course, 3D-printed parts can be made to have mounting holes and other fixtures, but the ability to create an entire 3D part from a singular continuous piece of material greatly speeds up the manufacturing time of that part.

The third advantage of 3D printing is that it is entirely configurable, and this can help to increase the speed of a print or increase its quality. For example, the density of solid areas of an object can be adjusted by changing the wall fill percentage, and reducing this figure decreases the print time while also reducing the amount of material used (and therefore, reduces the cost). At the same time, the thickness of the layer can be reduced to improve the quality of the final print.

The fourth advantage of 3D printing is that it entirely eliminates the need for skilled workmanship. Instead of spending long hours trying to cut materials out by hand and then put those parts together, a single engineer with 3D CAD experience can design extraordinarily complex parts and then have them printed without needing to ever pick up a saw, screwdriver, or ruler.

Finally, 3D printing produces minimal amounts of waste as the material is only printed where it is needed. FDM printers that rely on the heating of a filament also have the added bonus that the parts they produce are fully recyclable. As such, the environmental impact of 3D printers is far better than other manufacturing methods.

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What disadvantages does 3D printing introduce?

The slow speed of 3D printing and the low resolution only makes 3D printing viable for prototyping and is rarely used, if ever, in mass production.

There is no doubt that 3D printing is an absolutely revolutionary technology as it has allowed engineers for the first time in history to be able to quickly manufacture 3D parts in a single process with no need for human intervention. However, 3D printing is excellent as a rapid prototyping technology, but is not suitable for mass production.

Compared to other prototyping methods, 3D printing is relatively fast as it can create 3D structures in a single machine cycle, but if compared to machines used in mass production, it becomes obvious that 3D printing is extremely slow.

Another challenge faced with 3D printers is resolution, precision, and accuracy. Simply put, individual layers of a 3D print are often around 0.2mm, and while this may seem small, it leads to visible defects on the 3D part. For example, printing a sphere will result in a part that has visible steps between each layer. The resolution can be increased to maximize the quality of the print, but this increases the time taken to print the part, and therefore drives up the cost.

Finally, plastic prints (such as those made using an FDM printer) will often be structurally weak, especially if the part has a low in-fill density. As such, 3D prints are great for non-load bearing parts that are being used in prototypes, but parts requiring high degrees of strength need to be careful when using 3D printed parts. In the case of sintered metal parts, the need for a final heat treatment cycle also drives up their cost, and these parts will not be as structurally strong as a part cut out from a block of metal.

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Is 3D printing cheap?

When compared to other prototyping methods for producing 3D parts, 3D printing is an excellent low-cost option.

It is important to note that while individual 3D-printed parts may seem expensive, they are in fact cheaper when taking all factors into consideration. Firstly, getting a part 3D printed entirely eliminates the engineering time needed to build the part, and this allows designers to spend their time focused on other more important tasks (instead of manually laboring over tools and equipment).

Secondly, the cost of engineering-grade 3D printers can be extremely expensive, and these also require maintenance, material refills, and at times, configuration. Unless an engineering department is planning to produce 3D-printed parts on a daily basis then it is more cost-effective to use a third-party manufacturer (such as Ponoko).

Thirdly, the vast majority of the cost of a 3D printed part comes from the material used in the print, and the machine time. The combination of long print times (in excess of 24 hours depending), the cost of the machine, the electricity used to run the machine, and the space occupied by the machine, all add up to an expensive process. Even then, if 3D printing is compared to other manufacturing processes such as CNC milling, plastic injection molding, and manual labor, 3D printing still comes out as the cheapest by a large margin.

Ponoko’s years of experience in the field of manufacturing provide the expertise needed by engineers to create professional 3D-printed parts. Combined with our other services including laser cutting, laser engraving, and finishing, Ponoko offers an entire suite of manufacturing capabilities under one roof that is geared towards all engineering projects ranging from individual prototypes to first production runs.

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How fast is 3D printing?

The speed of 3D printers highly depends on the printing technology being used, but generally speaking, FDM printers are slow and SLA printers are fast, but either way, all 3D printers are faster than trying to manually build something by hand.

FDM printers are famous for their slow printing speed, and this is because FDM printers not only print 3D objects layer by layer, but line by line as well. When a 3D object is sliced into individual 0.2mm layers, those layers are then described as a series of lines with a typical width of 0.4mm. With print speeds of around 50 mm/sec, it can take an extraordinarily long time to print even just a single layer.

SLA printers, however, are significantly faster than FDM, especially if the SLA printer uses a display instead of a laser beam. This is because display-based SLA printers are able to image an entire layer in a single exposure, and each exposure lasts for 2 to 3 seconds. Thus, the time taken by modern SLA printers is a function of the number of layers, and not the complexity of each layer.

At the end of the day, the speed of a print highly depends on the final quality of the part, the wall density of the part, and the print speed being used. But even though high-quality 3D-printed parts take time to manufacture, it is still far faster than other rapid prototyping manufacturing methods.  

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What materials can be 3D printed?

Materials that can be 3D printed depend on the 3D printing technology being used, but generally speaking, FDM printers print plastic and organics, SLA printers print resins, and DMLS typically print metal.

The most common 3D printing technology used is FDM, and these involve a heated extruder and a 3-axis system that moves the head over a heated build area. As such, only materials that can be melted down and fed into the extruder can be used, and this means that most material filaments used by 3D printers are thermoplastics such as PLA and ABS. However, it is also possible to print materials that do not melt (such as wood), and this is done by grinding down the material into a powder and then using a binder (such as PLA) that can be melted.

Furthermore, the way in which FDM printers rely on a filament means that materials being printed need to have some degree of flexibility (enough that they can be reeled and fed through a feed pipe). Additionally, materials that denature at high temperatures (such as thermosetting plastics) cannot be 3D printed.

SLA resin printers only require materials that remain in a liquid form until activated by UV light. While these materials have historically been petroleum products, new advances in material science now allow for plant-based bioplastics that help reduce the environmental impact of 3D SLA prints.

Direct Metal Laser Sintering (DMLS) printers typically rely on finely powdered metal. Due to the intense heat of the laser, it is not possible to fuse flammable materials such as wood and plastics. Furthermore, powdered metals must be able to absorb the energy of the laser, which can introduce challenges when fusing highly reflective metal powders.

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What design considerations should I take when designing 3D parts?

Even though 3D printing is by far one of the best rapid prototyping technologies, it needs to be used correctly if it is to be effective. This means that engineers need to take precautions in their designs to help reduce the price while maximizing the quality of the final print.

The first consideration that engineers need to take is that overhangs often require supports. This means that a part that has an overhang at the top will require support structures from the base. Fortunately, most 3D printing slicers will automatically add these overhangs, but the inclusion of overhangs also affects the quality of parts while also increasing the print time and thus the cost of the part.

Reducing the density of walls in a 3D print can reduce the cost of a part by using less material which also reduces the price of the final part. However, this also makes printed parts structurally weak as well as light which may not be appropriate for load-bearing parts.

Platforms are often needed to ensure adhesion between the build plate and the part being printed, but like supports, these are also added by the machine operator. However, the inclusion of platforms can affect the quality of the first layer as separating the platform from the part can be difficult (often leaving bumps of material behind).

The use of printed layers also results in a staircase appearance on curved edges. This effect can be reduced by using smaller layer sizes, but this increases the print time, and therefore increases the cost. One more unusual method to remove this stepped appearance on ABS parts is to leave the part inside a sealed container with a small open container of acetone. The vapors from the acetone partly dissolve the outer layer of the print, and this causes the print to become shiny and smooth.

Finally, engineers should pay extra attention to the fact that FDM prints are especially weak along layer lines. As such, mechanical forces acting parallel to layer lines should be avoided at all costs as this can easily separate the layers of a print. This issue is less prevalent in SLA and SLS prints.

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What 3D printing technology is best for my part?

While numerous 3D printing technologies exist, choosing the right one for your design can be challenging, but in essence the factors that matter are the quality, the price, and the environment.

FDM printers are a cost-effective solution due to the simplicity of the setup, the lack of harmful compounds, the low-cost nature of FDM filaments, and the lack of post-processing needed. As such, FDM is an excellent choice for those who require parts that are not dependent on structural strength, need to keep costs down, and want to utilize a recyclable material.

SLA printers are excellent for those looking for high-resolution prints that minimize layer lines, require mechanical strength, and need a fast print. However, the use of UV resin increases the cost of such parts, and the need for additional processing steps such as cleaning and additional UV exposure make SLA more expensive than FDM.

DMLS printers are ideal for those needing to 3D print metal parts, but the high cost of metal powders combined with the high-cost nature of DMLS printers make them the most expensive prints. Furthermore, DMLS-printed parts also require additional heat-treating stages to fully fuse the powdered structures together, but the final result is mechanically strong parts that closely resemble the final product.

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How does the 3D printing order process work?

Just like our laser cutting, 3D parts can be uploaded and ordered within minutes thanks to our software-powered services.

The first step in getting 3D printed parts from Ponoko is to design your part in your favorite 3D CAD software. For those still deciding on what software to use, there are numerous tools available including Autodesk and Alibre Design, but for those who want to start with CAD, FreeCAD makes an excellent choice too.

Once your part has been designed, the second step is to export your model in a format that we can accept. Two of the most common formats used in the 3D printing industry are STL and 3mf (which stands for 3D manufacturing format). It is important that you check your design is compatible with the 3D printing process, as well as making sure to check for overhangs and small features that may be difficult to manufacture.

Thirdly, upload your design file to our software-powered online service and choose your material as well as specifying the quality of the part. Remember that increased in-fill density and smaller layer heights will result in a more expensive part, but the final quality will be much greater. Also ensure that you have selected the right process for your part, and consider the differences between FDM, SLA, and DMLS printers.

Fourthly, pay for your part and wait until it arrives. While our engineers manufacture your 3D-printed parts, go ahead and learn a new skill, discuss new ideas with other engineers, or just take the time to enjoy life. Once your part arrives, enjoy your newly 3D printed part and get cracking with the rest of the project.

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Is buying a 3D printer worth it?

While desktop 3D printers can be an excellent addition to an engineering office, there are numerous challenges that they face which make custom 3D printing services more appropriate.

Desktop 3D printers have come extremely far since the first machines were demonstrated to the public. The quality of materials has become increasingly better, the cost of desktop printers has dramatically fallen, and their physical size has increased. However, while desktop printers have some advantages including the ability to quickly print parts in-house and operate overnight, they also face numerous challenges.

The first one is that cheaper desktop printers are good for rough work, but creating precision 3D-printed parts is very challenging. As such, those needing dimensionally accurate parts are only possible with the use of industrial 3D printers which Ponoko utilizes, and as such engineers needing high-quality parts will be better off using online 3D printing services.

It’s possible for an engineering department to purchase its own industrial printer, but the large cost involved and the need for maintenance can make them a difficult cost to justify. Furthermore, 3D printers also pose a fire risk that needs to be properly managed in a controlled industrial environment. Even though some 3D printer owners print parts overnight, any failure in the printer can see fires start, and this is especially problematic if used in office or residential environments.

Want something else? Check our other services...

3D printing is a fantastic manufacturing technology, but just like how most manufacturing technologies have both advantages and disadvantages, 3D printing is not always the best choice. For those needing large-scale volume production, our injection molding processes can be used for numerous materials, including plastic, elastomers, and metal, while our laser cutting services can provide 2D parts from a selection of 250+ curated engineered materials.

Finally, for those needing an electronic circuit (which commonly goes with 3D printed and injection molded parts), our PCBA services will not only fabricate your PCBs, but source all components and provide full automated manufacturing. Thus, our digital manufacturing services combine all engineering production technologies for an entire product under one roof.

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