The Ultimate Guide to 3D Printing

Introduction to 3D Printing

3D printing, also known as additive manufacturing, is one of the most versatile and cost-effective ways to produce plastic and metal parts. 

Unlike traditional manufacturing methods that remove material from a solid block (subtractive manufacturing) or use molds to shape parts (formative manufacturing), 3D printing builds objects layer by layer from a digital file. This approach eliminates the need for expensive tooling, allows for intricate geometries that are difficult or impossible to achieve with other methods, and accelerates product development cycles.

Because of its flexibility and efficiency, 3D printing is used across a wide range of industries—from aerospace and automotive to medical and consumer goods. Whether you’re developing prototypes, creating custom components, or producing small-to-medium production runs, 3D printing offers unparalleled advantages in speed, design freedom, and cost savings.

How 3D Printing Works

At its core, 3D printing is an additive manufacturing process that builds objects layer by layer using digital designs. Unlike traditional methods like CNC machining—which removes material to create a part—3D printing deposits material only where it’s needed, reducing waste and expanding design possibilities.

For a more in-depth look at the history and evolution of 3D printing, check out MIT’s research on additive manufacturing.

Steps in the 3D Printing Process:

1. Design: A 3D model is created using CAD software.
2. Slicing: The model is converted into a series of layers using slicing software.
3. Printing: A 3D printer builds the part layer by layer through various processes like powder bed, fused filament, etc… with the selected material.
4. Post-Processing: The printed part may require additional steps such as support removal, dyeing, and/or assembly. 

Types of 3D Printing Technologies

Several different 3D printing technologies exist, each with its own strengths, material compatibility, and applications. Understanding these methods will help you choose the best process for your project.

Fused Deposition Modeling (FDM)

FDM is an extrusion-based process that uses a heated nozzle to deposit thermoplastic filament layer by layer onto a build platform. It is one of the most accessible and widely used 3D printing technologies due to its affordability and ease of use. 

• Materials: PLA, ABS, PETG, ULTEM, PEEK
• Applications: Prototyping, functional parts, low-cost manufacturing
• Post-processing: Support removal, sanding, vapor smoothing, painting

The two most well-known FDM companies are Stratasys and Markforged. Stratasys is a great option for industrial printing, with a build unit of 36” x 28” x 36” for larger parts. Markforged has continuous fiber material options which add extra strength to the parts, great for demanding environments. 

UPTIVE has an in-house fleet of Stratasys and Markforged printers to get your parts fast. 

Stereolithography (SLA)

SLA is a vat photopolymerization process that uses a UV laser to cure liquid resin layer by layer. Known for high-resolution prints and smooth surface finishes, it excels at producing intricate details.

• Materials: Standard resins, engineering resins, castable resins, biocompatible resins
• Applications: Dental models, jewelry casting, product design, medical devices
• Post-processing: IPA wash, UV curing, sanding, painting

Selective Laser Sintering (SLS)

SLS is a powder bed fusion process that employs a laser to selectively fuse powdered materials, typically nylon or other thermoplastics. The unfused powder naturally supports the object, enabling complex geometries.

• Materials: Nylon, TPU, PA11, PA12
• Applications: Aerospace, automotive, medical devices, functional prototypes
• Post-processing: Bead blasting, dyeing, coating, polishing

Multi Jet Fusion (MJF)

MJF is another powder bed fusion technology that uses an inkjet array to apply a fusing agent to a bed of nylon powder, which is then heated to create strong, detailed parts.

• Materials: Nylon PA11, PA12, PA12 Glass Bead, TPU
• Applications: Production-grade parts, functional prototypes, enclosures, brackets
• Post-processing: Sanding, dyeing, vapor smoothing, bead blasting

UPTIVE is the 2nd largest HP MJF service provider in the nation, with plenty of capacity for your parts. 

Digital Light Processing (DLP)

DLP is similar to SLA but uses a digital light projector to cure entire layers of liquid resin at once, resulting in faster print times while maintaining high accuracy.

• Materials: Standard resins, engineering resins, castable resins
• Applications: Dental models, jewelry, detailed prototypes
• Post-processing: IPA wash, UV curing, sanding, painting

Direct Metal Laser Sintering (DMLS) & Selective Laser Melting (SLM)

These powder bed fusion processes are designed for metal 3D printing, using a high-powered laser to melt or sinter metal powder into fully dense parts.

• Materials: Stainless steel, titanium, aluminum, cobalt chrome, Inconel
• Applications: Aerospace, medical implants, high-performance industrial components
• Post-processing: Heat treatment, CNC machining, polishing, anodizing, shot peening

Binder Jetting

Binder jetting uses a liquid binding agent to adhere layers of powder material—such as sand, metal, or ceramic. Post-printing, parts typically undergo sintering or infiltration to gain strength.

• Materials: Sand, metal, ceramics, full-color composites
• Applications: Casting molds, full-color prototypes, metal parts
• Post-processing: Sintering, infiltration, machining, polishing

Material Jetting

Material jetting works similarly to an inkjet printer by depositing tiny droplets of photopolymer material that are cured with UV light. It allows for full-color printing and multi-material capabilities.

• Materials: Photopolymer resins, wax
• Applications: Realistic prototypes, medical models, artistic applications
• Post-processing: Support removal, sanding, painting, polishing

Each of these 3D printing technologies has unique strengths and applications. The right method depends on factors such as material requirements, desired surface finish, mechanical properties, and production volume.

By understanding these different technologies, businesses and engineers can harness 3D printing to streamline manufacturing processes, reduce costs, and drive innovation.

3D Printing Materials

Choosing the right material is critical to the success of your 3D printed part. Here are the main categories:

Plastics:

• PLA (Polylactic Acid)
  • Characteristics/Benefits: Biodegradable, easy to print, low warping
  • Applications: Concept models, low-wear prototypes, hobbyist projects
  • Considerations: Brittle and low heat resistance
• ABS (Acrylonitrile Butadiene Styrene)
  • Characteristics/Benefits: Strong, impact-resistant, higher heat resistance than PLA
  • Applications: Functional prototypes, automotive parts, enclosures
  • Considerations: Requires a heated bed and controlled environment to prevent warping
• Nylon (PA12, PA11)
  • Characteristics/Benefits: High impact resistance, flexible, durable
  • Applications: Gears, hinges, durable consumer products, industrial applications
  • Considerations: Absorbs moisture and requires dry storage
• TPU (Thermoplastic Polyurethane)
  • Characteristics/Benefits: Elastic, impact-resistant, abrasion-resistant
  • Applications: Seals, gaskets, protective casings, flexible grips
  • Considerations: Challenging to print due to flexibility

Resins:

• Standard Resin
  • Characteristics/Benefits: High detail, smooth surface finish, affordable
  • Applications: Detailed prototypes, display models, concept verification
  • Considerations: Brittle compared to other plastics
• Tough Resin
  • Characteristics/Benefits: High strength, impact-resistant, slightly flexible
  • Applications: Functional parts, snap-fit assemblies, engineering applications
  • Considerations: Requires post-curing for full strength
• Castable Resin
  • Characteristics/Benefits: Burns out cleanly for casting, high detail resolution
  • Applications: Jewelry, dental crowns, investment casting
  • Considerations: Requires precise handling and post-processing

Metals:

• Aluminum
  • Characteristics/Benefits: Lightweight, corrosion-resistant, strong
  • Applications: Aerospace components, lightweight structural parts, automotive brackets
  • Considerations: Requires post-processing for optimal mechanical properties
• Titanium
  • Characteristics/Benefits: High strength-to-weight ratio, biocompatible, corrosion-resistant
  • Applications: Medical implants, aerospace parts, high-performance industrial components
  • Considerations: Expensive and challenging to machine post-printing
• Stainless Steel
  • Characteristics/Benefits: Corrosion-resistant, high strength, durable
  • Applications: Industrial tools, medical instruments, consumer products
  • Considerations: Heavy compared to aluminum and titanium

Composites:

• Onyx (Nylon with carbon fiber)
  • Characteristics/Benefits: Stiff, durable, lightweight, heat-resistant
  • Applications: Industrial tooling, jigs, fixtures, lightweight yet strong mechanical parts
  • Considerations: Requires specialized printers
• Continuous Carbon Fiber
  • Characteristics/Benefits: Ultra-strong, lightweight, high stiffness
  • Applications: Aerospace components, high-performance sporting equipment, metal replacement parts
  • Considerations: Requires specific reinforcement techniques during printing

For more information on advanced composite materials, refer to Oak Ridge National Laboratory.

Learn more about UPTIVE material options here >

Industries That Use 3D Printing

• Aerospace & Defense: Lightweight parts, custom components, rapid prototyping
• Automotive: Functional prototypes, custom parts, low-volume production
• Medical: Prosthetics, implants, surgical tools, anatomical models
• Consumer Goods: Customized products, electronics enclosures, fashion
• Industrial Manufacturing: Jigs, fixtures, tooling, machine components

Make it Simple to 3D Print Parts

3D printing is revolutionizing manufacturing by offering cost-effective, efficient, and highly customizable production solutions. Whether you’re developing prototypes or producing end-use parts, additive manufacturing can help you innovate faster and optimize your supply chain.

However, 3D printing is a huge lift–you’ll have to purchase a potentially expensive 3D printer, learn the advanced 3D printing technology and processes, know which materials to use…and much more. 

Choosing UPTIVE means partnering with a company that understands the complexities of additive manufacturing and is dedicated to helping you achieve your goals efficiently and effectively. With their advanced technologies and experienced team, UPTIVE is well-equipped to support your journey into the future of manufacturing.

Get started with UPTIVE Advanced Manufacturing.