Introduction

3D printing has been around for more than 30 years, but for much of that time it would have been inconceivable for anyone without corporate backing to even think of taking advantage of this technology. Recently, however, the core technology for 3D printers has developed to the point where it is now available at prices many individuals and smaller companies can afford.

Three key things make 3D printing stand out from almost any other manufacturing process:

• Printed parts are “grown” in layers. Many complex objects that have internal structures or are comprised of interlocking sub-assemblies can be manufactured in a single run, with no further intervention, whereas previously they would be made from many separate parts, some of which could not be made by fully automated machining processes or more traditional means. Multiple materials can be used together to improve the performance or overall integration of the finished part. For example a simple referee's whistle needs to have a hollow inside with a slot and pea inserted that will not fall out. All traditional methods for manual or automated manufacture would require at least three separate parts to be connected together. With 3D printing, the hollow shell of the whistle can be made as a seamless object and the pea inside can be printed and designed to release and form the rattle all in a single operation where the finished whistle is ready to use directly after 3D printing.
• Material is added rather than subtracted. This method of manufacturing adds raw materials to build an object rather than removing material. Machining away 90 percent of a metal block to make a cooling system for a race car is far less efficient than adding the 10 percent or so of metal powder needed to make a more compact and efficient design that couldn’t have been machined in the first place.
• 3D printing often eliminates the need for complex or expensive production tooling. This benefit is becoming significant as 3D printers are being used for mass manufacturing runs in which individual tooling or hand-crafting would make customized products far too expensive (such as solid gold jewelry).

In short, 3D printing turns a digital model in a computer data file into a physical representation of the object or product. The term 3D printing is now widely used by media and communities to help communicate the idea that an object is being produced in a similar way as a paper printer, but as a physical three-dimensional part. The term 3D printing is often disliked in the wider industry, as it’s a poor representation of what this technology can achieve. A more professional name is additive manufacturing, which covers a vast array of sectors, materials, and processes used to produce physical objects from data.

Since the first edition of this book was released in 2013, desktop 3D printing and various forms of industrial additive manufacturing have been through the rise and fall of a technology hype cycle. Reports about 3D printing applied to biomedical research anticipated the leap from lab to patient too soon, rather than focusing on the possibility of printing tissue samples for medical research. Researchers and individuals are still working out appropriate uses of 3D-printing technology. Often, they come to the conclusion that there are still vastly better ways to produce many things without 3D printing.

Much of the media hype surrounding 3D printing was exactly that: hype. But we are now approaching the end of that hype cycle, and 3D printing is stronger than ever. Most 3D-printing equipment vendors realize that not everyone needs or wants a home 3D printer. The desktop 3D-printing market has returned its focus to people who need and want to explore this technology.

About This Book

3D Printing For Dummies, 3rd Edition, was written with the average reader in mind. It’s a survey of the existing capabilities of additive manufacturing for both private and commercial purposes and a consideration of the possibilities of its future.

In this book, I review many current additive manufacturing technologies. Some are early uses of a technology or process with numerous limitations and caveats regarding their use. I also explore what types of desktop machines are available to buy and use straight away while also looking at those kits that require some assembly on the user's part. I dive into the software you will need (often as freely available open-source downloads) and then look at the tips and tricks needed to design for the 3D-printing process. This book won’t make you an expert in all aspects of 3D printing, but it will give you a good overall starting point for learning the art of 3D printing and an opportunity to explore additive manufacturing systems. I hope that you’ll be excited by the amazing potential of 3D printers — excited enough to buy your own desktop machine and learn how to design and make useful, practical, and fun objects for you to use and share.

Every time this book has been updated, it's always wonderful to see many of the things discussed as early concept ideas and research turned into realities, now being used in everyday life. 3D printing is truly changing the way we design and make products as individuals and extensively in wider world industries. It's a technology that's already touched your life even if you haven't realized it yet.

Foolish Assumptions

You may find it difficult to believe that I've assumed anything about you; after all, I haven’t even met you! Although most assumptions are indeed foolish, I made these assumptions to provide a starting point for this book.

• You have the ability to download or access programs in a web browser if you want to try some of the applications I review in this book. (It also helps to have an open mind and enthusiasm about the future and what additive manufacturing can produce.)
• If you want to buy and use a desktop 3D printer of your own, you need to be familiar with using hand tools like spanners and screwdrivers. We are still at the point where regular maintenance, servicing, and changing consumable items are a part of owning a 3D printer. You will also need a computer and software, much of which is free to download and use.
• You do not need any experience with 3D design. However, it helps to have a basic understanding of how a 3D model is just like any other digital model; we're just using that digital data to reproduce physical objects.
• It is important to understand that the current level of sophistication of 3D printers is close to the first dot-matrix paper printers. They’re slow, and most are still limited to a single material; many offer only a single color or one type of plastic type at a time. Just as the evolution of dot-matrix printers led to inkjet and laser technologies that added speed and full color to paper printers, 3D printers are adding capabilities quickly. But please don’t assume that all 3D printers will follow the same rapid adoption of full color and astonishing print speeds that 2D printers experienced in the past. That would be foolish indeed. We are still working with physically melting or solidifying resin materials and not at an atomic level of manufacturing.
• I try to use two common terms for separating a 3D printer you could use at home (desktop 3D printing) and many of the vastly more complicated and expensive machines used by industry (industrial 3D printers). The main difference between the two types, apart from the cost, is that industrial 3D printers tend to be able to use more robust materials such as metal and produce a higher level of detail, accuracy, or repeatability in the finished parts.
• I also don't expect you to know all about product design or the fundamental properties of materials. Where possible, I'll try to explain the most common materials used by both desktop and industrial 3D printers.
• Working with 3D printers is very rewarding, but you should learn how to adjust and tune your own desktop 3D printer. 3D printers are all different, so when things go awry you will be able to fix the issues yourself. It is not necessary to be a do-it-yourself handyman. However, a certain familiarity with basic tools and methods will help you to use your 3D printer, whether you assemble it yourself or buy a fully built and tested machine.

Icons Used in This Book

As you read this book, you’ll see icons in the margins that indicate material of interest (or not, as the case may be). This section briefly describes each icon in this book.

Tips are nice because they help you save time or perform some task without a lot of extra work. The tips in this book give you timesaving techniques or pointers to resources that you should check out to get the maximum benefit from 3D printing.

Remember icons mark the information that’s especially important to know. To extract the most important information in each chapter, just skim these icons.

The Technical Stuff icon marks information of a highly technical nature that you can normally skip.

The Warning icon tells you to watch out! It marks important information that may save you headaches or keep you and your equipment from harm.

Beyond the Book

In addition to what you’re reading right now, this product comes with a free access-anywhere Cheat Sheet that covers the basics of 3D printing. There I've listed various 3D printers, control electronics, and aspects about the assembly of a RepRap 3D printer...