3D Printing Technologies: An Overview
- Fused deposition modeling (FDM): FDM is an additive manufacturing (AM) process in the material extrusion family that builds parts layer by layer. The Printer heats a thermoplastic filament and deposits it in a programmed path onto a build platform. As the melted filament is extruded through a nozzle, it cools and solidifies, bonding with the previous layer to form a solid object. This technology is widely used for rapid prototyping, custom jigs, fixtures, and end-use parts due to its cost-effectiveness and ease of use.
- Selective laser sintering (SLS): SLS is a type of powder bed fusion 3D Printing technology that uses a high-power laser to sinter powdered material, usually Nylon, into solid structures. In this process, a thin powder layer is spread over a printing bed platform using a levelling roller and is selectively sintered by a controlled scanning CO₂ laser beam according to the sliced CAD pattern. The fabrication bed then lowers down to the thickness of another layer, and the next layer is built in a layer-by-layer sequence.
- Stereolithography (SLA): This is an AM process that revolutionised rapid prototyping and 3D Printing with its exceptional accuracy and detail. The SLA process is a layer-by-layer 3D Printing method used to create highly accurate and detailed parts with a premium quality finish and tight tolerances. A UV laser traces each layer onto the surface of the liquid resin, curing it precisely to form a solid object. SLA is widely used for Prototypes with smooth surfaces, master patterns for moulding, and parts requiring intricate details and fine features.
- Digital light processing (DLP): It is a 3D Printing technology that makes use of a projector and a DMD (digital mirror device) to selectively cure a photopolymer one layer at a time. This technique uses a digital light source to cure liquid resin layer by layer to build a 3D object, producing parts with excellent accuracy and smooth surface finish. DLP 3D Printing is used to create solid plastic objects by selectively curing a liquid photopolymer with a UV light source one layer at a time until the part is complete.
- Polyjet Printing: Polyjet Printing is an advanced additive manufacturing technology that jets photopolymer materials in ultra-thin layers onto a build platform and immediately cures them with UV light. Polyjet achieves exceptional detail resolution with layer thicknesses as thin as 16 microns, producing smooth surfaces that require minimal post-processing. The technology is ideal for creating realistic prototypes with rubber-like textures, transparent parts, and multi-material assemblies that mimic final production components.
Benefits of Using Additive Manufacturing for Developing Production Tools
Additive manufacturing, commonly known as 3D Printing, has transformed how companies develop production tools, jigs, fixtures, and manufacturing aids. The traditional approach to tooling involves expensive moulds, lengthy lead times, and significant upfront investment, which often delays production schedules and increases costs. 3D Printing eliminates many of these constraints by enabling rapid fabrication of custom tools directly from digital designs, often within hours or days rather than weeks. One of the most significant benefits is the dramatic cost reduction achieved through 3D Printing. Traditional tooling requires CNC machining, mould making, or other subtractive processes that consume substantial material and labour resources. With AM, material is only deposited where needed, minimizing waste and reducing material costs significantly. Small to medium enterprises particularly benefit from this affordability, as they can now access advanced tooling capabilities without the prohibitive costs previously associated with custom tool development.
Customisation and design freedom represent another crucial advantage of using 3D Printers for production tools. Engineers can create complex geometries, internal channels, lattice structures, and optimized shapes that would be impossible or extremely costly to produce using conventional methods. This design flexibility enables the creation of lightweight tools that maintain structural integrity while reducing operator fatigue during extended use. Ergonomic improvements can be incorporated directly into tool designs, enhancing worker safety and productivity on the manufacturing floor.
The ability to produce tools on-demand revolutionises inventory management and supply chain logistics for manufacturing facilities. Instead of maintaining large stocks of pre-made jigs and fixtures, companies can store digital files and print tools as needed. This just-in-time approach minimises the risk of obsolescence and ensures that tools are always available when production requires them.
3D Printing enables the development of production tools with integrated features that enhance functionality and performance. Coolant channels can be embedded directly into moulds for improved temperature control during injection moulding processes. Sensors and monitoring devices can be incorporated into tool designs, enabling real-time data collection and predictive maintenance capabilities. Multi-material Printing – like with Stratasys 3D Printers – allows for the creation of tools with soft grips, rigid frames, and flexible components all in a single print, eliminating assembly steps and improving overall durability.
The environmental benefits of AM for production tools are increasingly important in today’s sustainability-conscious business landscape. Reduced material waste, lower energy consumption compared to traditional machining, and the ability to use recycled or bio-based materials all contribute to a smaller carbon footprint. Localised production of tools eliminates the need for long-distance shipping, further reducing environmental impact. The longer lifespan of optimized, custom-designed tools also means less frequent replacement and reduced overall material consumption over time.
Training and skills development become more accessible when organisations can produce their own training aids and practice tools using 3D Printers. Custom training fixtures can be developed quickly to address specific skill gaps or introduce new processes, accelerating workforce development and improving overall operational competence.
The scalability of 3D Printing allows companies to start small with simple tools and gradually expand their capabilities as they gain experience and confidence. As the technology matures and new materials become available, the range of applicable production tools continues to expand, offering ever-broader opportunities for innovation and efficiency gains.
This is why you need industry-grade, sturdy 3D Printers capable of handling demanding industrial applications with reliability and precision. And this is where Stratasys counts, as their industrial systems have set the benchmark for reliable, high-performance additive Manufacturing in production environments worldwide.
Stratasys Printers for Production Tool Development
Stratasys offers several industrial Printers ideal for developing production tools. The Fortus 450mc delivers production-grade FDM parts with exceptional dimensional accuracy and mechanical strength using engineering thermoplastics like ULTEM 9085 and PVC. The Fortus 900mc provides an enormous build volume for large jigs, fixtures, and assembly aids while maintaining tight tolerances. The Stratasys H350 combines SAF technology with high-throughput production capabilities for cost-effective tool manufacturing. The PolyJet J850 creates multi-material tools with varying hardness levels for specialised gripping and handling applications. The Stratasys F770 is another industrial FDM Printer designed for large-scale production of robust end-use parts and tooling, featuring a massive build volume and the ability to process high-performance engineering thermoplastics. Another worthy name is Origin Two, a programmable 3D Printer that combines precision SLA with intelligent, software-driven process control to deliver repeatable, production-grade parts with exceptional surface quality and dimensional accuracy.
Importance for Indian Companies
For Indian companies, 3D Printing represents a strategic advantage in the global manufacturing landscape. India’s growing manufacturing sector, driven by initiatives like ‘Make in India’, can leverage AM to reduce dependency on imported tooling and accelerate product development cycles. Small and medium enterprises, which form the backbone of Indian manufacturing, can compete with larger organisations by accessing affordable, custom tooling previously beyond their financial reach. The technology supports India’s ambition to become a global manufacturing hub by enabling rapid prototyping, reduced time-to-market, and cost-effective production solutions tailored to local needs and constraints.
