Author: Calum Osborne

How 3D Printing Works

Calum Osborne

3D printing turns a digital design into a solid three-dimensional physical object by adding layer after layer of material. The process varies by technology, from desktop printers that melt plastic to industrial machines that use lasers to fuse metal powder.

3D Printing

3D printing (or additive manufacturing) is the process of turning a digital model into a solid physical object by building up layers of material. This differs from traditional manufacturing processes that work by cutting away material (a subtractive process). Visit Our Website for more information.

3D printed objects can be made of a wide range of materials, from PLA plastic used for toys and food containers to titanium surgical implants. The technology is often employed in prototyping and research, but it has also become a valuable tool for businesses that are looking to shorten the product development cycle or create custom products.

The process starts with a digital model that can be designed using a 3D design software program like TinkerCad, which is available on the Windows computers in the OTS labs, or from a pre-existing model downloaded from one of many online repositories. The file is then imported into a software program that’slices’ the model into thin layers. Each slice is an instruction to the printer on how to build up a particular part of the object.

Slicing software also calculates factors like print time, layer height and infill density to determine how long the printed object will last and the best settings for it’s strength. The sliced model is then sent to the 3D printer, which builds up each layer of the object until it is finished. Depending on the model, post-processing steps may be required to remove support structures and smooth the surface of the object.

All of the 3D printers in the OTS labs use the same basic printing method, but they vary by technology. Desktop printers use a filament-like material that is heated and melted by the print head to deposit onto a platform, creating each layer of the object. The melted plastic hardens as it cools. The machine then moves the print head and the platform in X and Y and Z directions respectively to deposit another layer of the object, which is then fused to the previous layer.

Other methods, such as direct metal laser sintering (DMLS) and directed energy deposition (DED), use powdered or wire metal source materials that are heatened by the printhead to form the desired object. The DED method is more precise, but it takes much longer to complete and produces less material than the other two processes.

Materials

3D printing uses a variety of plastics and resins to create physical models from virtual designs. Oftentimes, these prints are used to rapidly turn out prototypes during the design phase of new products. They can also be put to use during manufacturing as a means of creating finished, functional parts. Objects created using 3D printing range from plastic figurines and mold patterns to steel machine parts and titanium surgical implants.

The most popular 3D printers use a process called fused deposition modeling, or FDM, to create objects. This technique involves heating up filament and extruding it onto the print bed in layers. The heated filament bonds with the previous layer to form a solid, three-dimensional object.

There are several different types of 3D printer filament available, with each offering unique properties. PLA (Polylactic Acid) is the most common 3D printing material, offering high strength and excellent layer adhesion. It can be printed in a wide range of colors and has an attractive, smooth surface that accepts paint and super glue well for further customization.

ABS (Acrylonitrile Butadiene Styrene) is another popular option, known for its resistance to corrosive chemicals and physical impact. It requires a vented environment and has longer print times than PLA, but it produces a tougher, more durable finish.

Photopolymer resin is used for more advanced projects that require higher levels of detail and a more rigid structure. The resin is cured with UV light during the printing process, which helps to prevent warping or cracking once the print is finished. This type of printing is ideal for complex research prototypes and small figurines that need to retain detailed features.

Nylon is an extremely versatile material for 3D printing, with helpful qualities that make it useful in a broad array of applications. Nylon for 3D printing is available in several formulations, including PA6 and PA66, which are stiffer versions, and PA12, a flexible version. Nylon is a tough, durable plastic with good heat resistance and chemical resistance, making it an excellent choice for end-use components that will be exposed to harsh environments.

Designing for 3D Printing

The 3D printing process transforms a digital model into a solid physical object by adding layer upon layer of material. It is used to create tools and prototypes that would be too difficult or expensive to produce with traditional manufacturing methods. It is also used to make replacement parts for existing equipment and to create medical devices, such as dentures and splints.

The first step in designing for 3D printing is to begin with a clear concept in mind. Whether it is functional, like a tool or a prototyping part, or artistic, such as a sculpture or piece of jewelry, this will guide your design decisions. It is also helpful to sketch your idea on paper to help you visualize it and consider important factors, such as size, shape, and material.

Once you have a model in mind, you can use a variety of CAD software programs to make the necessary adjustments. These can include using smoothing settings to reduce rough edges, fixing overhangs by removing supports, and adding infill to increase strength. Additionally, slicing software can be used to convert the 3D model into a file that will be read by a 3D printer. This process can be time consuming and requires some experience to get right.

Once the model is ready, it can be printed on a variety of materials, including plastics and metals. Post-processing, such as sanding or polishing, may also be needed to achieve a desired finish. In addition, some models may require support structures to keep them stable while printing, which can be added in a number of ways.

It is also important to remember that the digital version of your design must contend with the laws of physics when it comes out of the printer’s nozzle. For example, a horizontal section that is not supported from below, such as a bridge, will sag and may need to be reinforced with supports. These can be added to the CAD model, or generated automatically by the slicing software and printed along with the part.

With a little practice, you will be able to use these processes to bring your creations from the computer screen into the real world. Once you have mastered the basics, it is fun to experiment with more advanced designs and materials.

Getting Started with 3D Printing

Unlike the kind of printing you’re more familiar with, which involves ink-on-paper, 3D printers use layers to create three-dimensional objects. During the process, a plastic polymer is heated and deposited in successive layers until the desired object has been completely built. This plastic is usually a type of polymer, like PLA (polylactic acid), PETG, or ABS (acrylonitrile butadiene styrene). Other materials such as metals can also be printed with some specialized industrial printers.

To create a print, you’ll need a digital 3D model and a slicer software program that can translate that model into instructions the printer can understand. There are several different programs that can do this, but the most user-friendly and affordable options are TinkerCAD or Cura. Using these programs, you can design your own models, or find ones online. Some popular sites to check out are Thingiverse and Shapeways.

Once you have your file and a suitable printer, the most important thing to remember is that 3D printing is an additive process, meaning that it builds up your object layer by layer until it’s complete. As a result, every print has its own unique challenges that you’ll learn from as you go along. If you don’t have experience with 3D printing, it’s best to start with something simple, such as a phone stand or keychain. These small experiments will help you get the hang of things, and will give you confidence before moving on to bigger projects.

In addition to learning how to print, it’s important to understand the post-processing that’s required for some prints. Depending on the material and your design, it may be necessary to smooth the surface of the printed object, paint it, or assemble multiple parts. It’s best to take your time when performing these tasks, as they can significantly affect the quality of your finished print.

We’re here to help you take your 3D print project from idea to physical object. Please submit your request well in advance of when you need your print completed, so that we can ensure someone is available to oversee the printing and that the printer will be working.

The Many Forms of Plastic Mold Designs

Calum Osborne

The type of American Plastic Molds used depends on the design of the plastic part. Molds with undercuts, threads and other complex features take longer to produce than simpler ones.

Plastic Mold

Injection molds have cavities and cores that shape the external and internal geometry of a part. Proper mold structure increases longevity. Slower cycle times also enhance mold durability.

Rotational moulding is a popular plastic molding process that uses hollow shapes to create high-quality polymer products. Its versatility and efficiency make it a popular choice in many industries, including automotive parts, food storage containers, toys, and water tanks. The steps for rotational moulding include accurately filling the mold, controlled cooling, and careful removal of the finished product. These steps ensure a strong and durable product.

First, the resin is pulverized to a fine powder. This powder is then loaded into a container or mould that is sealed shut. Then, it is rotated while heated to melt the polymer. Unlike injection or blow molding, which use an injector to force the polymer into the mould, rotomolding relies on gravity and centrifugal forces to draw the melted polymer into the hollow shape of the mould. Once the melted polymer is in place, the mold is cooled and allowed to harden.

The rotomolded product is then ready for use, and there is less waste than with other plastics manufacturing processes, such as injection or extrusion blow molding. Additionally, the rotomolded product can be decorated or branded with a wide variety of finishes. This process is ideal for creating consumer and medical products that need to be marked or branded with text, graphics, or other visual elements.

The most common materials for rotomolding are commodity based thermoplastics, such as low-density or high-density polyethylenes. This type of polymer is available in powder form, which simplifies the rotomolding process. In addition, polyethylenes offer good chemical resistance and low water absorption. However, a number of other materials are also being rotomolded, including polypropylenes and nylons.

One of the primary challenges with rotomolding is its long cycle times. Heating and cooling the large surface area of the mold takes time, especially when working with a thin wall material such as polyethylene. In addition, a significant portion of the polymer is exposed to the environment while rotating and heating, which causes degradation. This greatly limits the use of engineering plastics and reduces impact strength. The long cycle times also require that the molds be cleaned, inspected, and bolted shut between cycles, reducing productivity.

Extrusion Moulding

Plastic extrusion is a popular choice for manufacturing long linear products, such as pipes and tubes. The process is also well suited for creating thin sheets and films, such as those used in vinyl signs and window frames. It can be faster and more cost-effective than injection molding, especially for longer production runs. It can also be more efficient, since it produces less waste material in the form of sprues and runners — the channels through which molten plastic travels before entering the mold cavity. This efficiency aligns with sustainable manufacturing practices and reduces the environmental impact of production.

The first step in the extrusion moulding process is to mix base plastic material granules with any colorants, stabilizers, and additives that are desired. These additives can impart flame resistance, lubrication for easier shaping, or any other desired properties. This melted mixture is then fed through an extruder, which functions much like a giant blender, mixing and melting the plastic while keeping it homogenous. It’s then forced through a die, which shapes it into its final profile. The shape of the die determines whether you’ll end up with a pipe, a tube, or a piece of plastic film. Once the shaped plastic has cooled and solidified, it can be cut to length and finished as required.

Another advantage of the extrusion process is that it can be used with a wide range of polymer types, including both thermoplastics and thermosets. This allows manufacturers to select the best material for each specific project, ensuring the quality and strength of the final product. It’s important to note, however, that the type of plastic chosen will significantly affect the process’s speed and efficiency, as well as its overall effectiveness.

Continuous Moulding

Continuous moulding is a process in which liquid plastic is poured into a particular mold to harden and create the desired shape. This method of manufacturing is popular for creating products that require strength and durability. The liquid plastic is heated to high temperatures during the process so that it can maintain its shape and be trimmed afterward. It’s important to use the right tools and equipment to ensure that the process goes smoothly and effectively. There are many different types of molding processes available to manufacture your products, including injection moulding, extrusion forming, continuous injection, and cold stamping. Each one has its own advantages and disadvantages.

Injection moulding is a process that involves heating a polymer to above its melting point and injecting it into a mold. This type of moulding is ideal for producing large quantities of identical parts and complex geometries. The process can be used with a wide variety of materials, including thermoplastics and thermosets. The most common polymers for injection molding include PVC, PET, ABS, and PP.

SSI has experience with the injection molding of complex parts, such as gears, pumps, valves, and machine housings. This process requires a high degree of accuracy and precision, and can be difficult to master. However, with the proper techniques and expertise, injection molding can be a cost-effective and efficient way to produce large volumes of parts.

During continuous injection, inserts are held in a position within the mold cavity by a retractable core that is removed at some time during the injection process. The process aims to reduce the rejection rate of the final product, as well as increase production.

The molded metal, called a “strand,” exits the base of the mold and is cooled by a series of rollers. A group of rollers may also be used to bend the strand at an angle, such as 90 degrees. The strand is then cooled again to prevent oxidation.

There are several common defects that can occur during the continuous casting process. These include oscillation marks, surface cracks, and scarring. The causes of these defects are varied and may include improper cooling, lubrication, or problems with the mold.

Cold Stamping

Cold stamping is a type of metal processing technique that uses pressure to reshape sheet metal. It can be done at room temperature, and it can be used to create parts of various shapes and sizes. It can also be combined with other processes, such as hydroforming or extrusion, to create more complex products.

During the stamping process, a metal strip is pressed between two dies. The force applied to the dies can cause a separation or plastic deformation. The result is a part with a specific shape, size, and precision. This method is particularly effective for producing small to medium-sized components. It can also be used to decorate printed materials with metallic foils, a popular option for creating high-quality, eye-catching products.

In addition to providing an effective way to produce parts, cold stamping is also a cost-effective solution. Compared to other metal processing methods, cold stamping produces fewer waste materials and offers better dimensional accuracy. In addition, it can be performed as an inline process, reducing the number of steps in production. In addition, it allows manufacturers to create intricate designs and patterns that can be used for a variety of applications.

A wide range of industrial sectors use cold stamping to create a variety of products. This includes the automotive industry, machinery manufacturing, daily necessities, and electrical appliances. The process can be used to punch out parts in a wide variety of shapes, from the second hand on an instrument to car panel and longitudinal beams. Moreover, it can be used to make parts that are difficult or impossible to process using other methods.

The molds used for cold stamping can be made from different types of steel, depending on the product and the required manufacturing precision. In general, they need to have good toughness and fatigue fracture properties to prevent sudden brittle failure under operating conditions. Moreover, the molds must have adequate strength to withstand repeated stress loads and provide long service life.

During the cold stamping process, the metal is pushed through a series of rollers at room temperature. This process reduces the amount of heat needed to form the metal, and it also improves surface finish. The resulting product is stronger than hot rolled metal, and it can be cut to precise dimensions.

Concrete Staining – A Cost-Effective Way to Enhance and Transform Your Property Surfaces

Calum Osborne

Concrete Staining is a cost-effective way to enhance and transform your property surfaces. It can be applied to both new and old concrete surfaces, indoors and out.

Concrete Staining

Acid stains are reactive stains that react with the calcium in the concrete to create a variegated, marbled effect. They require proper surface preparation and neutralization.

Concrete stain colors add color to new and existing concrete surfaces. Stains create a natural look with variegated color effects that imitate stone or masonry, but unlike paint, concrete stain penetrates the surface of the concrete and will not fade from UV exposure. Stains come in a wide variety of colors to suit any style or design preference.

Acid stains offer earthy colors, imparting rich hues with a warm, variegated finish. They’re popular on interior concrete floors and outdoor patios to bring life to hardscape projects.

They’re often paired with lighter acid stains, like Desert Amber or Coffee Brown, to add depth and contrast. These stains are also useful for coloring patchy areas or discolored concrete, as they provide opaque color solutions that conceal imperfections and repairs.

Non-reactive water-based stains are becoming increasingly popular because of their ease of use and predictable results. They work essentially like water color paint, using water to carry pigment and deposit it in the concrete’s pores. This allows for a wider range of hues than acid stains and is less labor intensive.

However, they are not as durable and must be sealed to maintain their vibrant appearance. Additionally, they can wash out quickly if left unsealed on exterior concrete.

For these reasons, we recommend choosing a high-quality concrete dye instead of a water-based stain for new or repaired concrete. Applied heavy and heavily, these dyes can mimic the look of stained concrete while outperforming traditional paint.

Choose a concrete stain color that is appropriate for the project. Before applying, test the concrete to ensure it’s ready for staining by pouring a small amount of water on the surface. If the water soaks into the concrete within 5 minutes, it’s ready to be colored.

If the water doesn’t absorb, the concrete must be etched prior to staining. Brickform offers several etching products to prepare concrete for staining, including CitrusEtch and Concrete Etcher. Once the concrete has been etched, select an acid-resistant stain. For an easier application process, choose a gel-based stain such as DecoGel or ColorWave. These stains are low VOC and odorless and work well on machine troweled and smooth concrete, but they also thrive on lightly textured surfaces.

Stain Types

There are a number of options available for coloring concrete, from water-based stain to acid and penetrating stains. Each has its advantages and disadvantages. Before choosing a concrete stain color, it’s important to consider the type of surface and environment in which the stained concrete will be used. Some stains may require more maintenance than others, and some have different cleaning requirements. It’s also important to evaluate the level of durability and protection the stain provides.

Penetrating stains, which are available in a wide range of colors, work well for interior concrete floors because they seal the surface and protect it from moisture and abrasion. They can be applied using a brush, roller or sprayer and typically dry quickly. Unlike film-forming stains, penetrating concrete stains do not flake or peel and are low in VOCs.

Acid stains are a popular choice for colorizing concrete because they penetrate and react chemically with the concrete, creating natural color variations and mottling effects. They are available in a broad range of earth tones from warm terra cottas to cool blue greens and can be applied to both new and old concrete surfaces, as long as the surface is properly prepared. Acid stains, however, do not hide surface blemishes or imperfections and can chip easily, so proper surface preparation is critical.

Another popular option for staining concrete is the use of water-based stains, which offer a full spectrum of colors and are UV stable. They are easier to apply than acid stains and dry much faster, but they do not have the same depth of color as acid stains or the ability to cover surface blemishes. They can be applied to both new and existing concrete, but require proper surface preparation as per the manufacturer’s guidelines.

The most durable of the concrete stain options is the acid-wash technique, which uses hydrochloric or phosphoric acid to etch the surface of the concrete, allowing the color to deeply penetrate into the concrete pores. This process is very labor intensive and requires specialized equipment and safety measures, but it can create a truly unique and colorful finish for concrete floors.

Staining Process

Staining concrete is a great way to add a professional and aesthetically pleasing look to a building or concrete surface. It is a relatively easy and affordable project for contractors, but it requires a little bit of knowledge about the staining process and proper preparation to achieve lasting results. Staining can be done on new or old concrete, and it can create a variety of looks from deep earth tones to variegated color with marbling effects.

Before starting a staining job, it is important to follow the manufacturer’s directions for proper surface preparation and application. Different chemical stains have their own requirements for a clean surface and different coverage rates. For example, acid stains require a pH neutralizing solution after the stain has been applied to the concrete. The neutralizing solution must be thoroughly rubbed into the surface of the concrete and scrubbed in order to completely neutralize the acid stain.

Water-based stains are much easier to use and offer a wide range of color options. These stains work by filling the pores in the concrete with acrylic polymers and pigments. They can be used to produce translucent or opaque finishes, depending on the amount of colorant that is added. The advantage of using a water-based stain is that the concrete can be sealed with a regular industrial concrete sealer to help protect the stain and improve durability.

Both acid stains and water-based stains must be thoroughly rinsed before the next coat is applied. This is especially crucial after an acid stain has been used. The concrete needs to be rinsed until the water runs clear. It is also important to note that the concrete must be fully dry before applying another coat of stain. If the concrete is not fully dry, it may absorb the stain unevenly and cause an undesirable result.

It is a good idea to mask off areas around doors and walls to prevent accidental staining. This is particularly important when using an acid stain, as it will be difficult to remove any drips that may occur. It is also recommended that you mask off sections of the floor that are not going to be stained. This will allow you to keep the stain away from areas that you may want to lighten or highlight with a different color later.

Staining Options

A wide range of color options exist for concrete staining, allowing you to create the exact look and feel that you are going for. The type of stain you choose depends on your desired appearance and the durability requirements for the surface.

Acid-based chemical stains are renowned for their ability to produce mottled effects and permanent hues. Their transparent nature allows the natural, earthy tones of the underlying concrete to peek through, creating unique character and depth. However, this method of staining is best suited for indoor surfaces as it does not hold up to UV rays and will fade over time.

Water-based stains are a more versatile and user-friendly option for concrete coloring. Unlike acid stains, these formulas don’t use a chemical reaction with the concrete; instead they fill the pores of the concrete and provide a solid color. They are available in a full spectrum of hues and can be mixed to broaden the color selection. Water-based stains can also be applied with a variety of spraying methods including airless sprayers, HVLP sprayers, production guns and a traditional paint roller or brush.

While many consider water-based staining a DIY project, it is recommended that you contact a professional concrete contractor to ensure the proper preparation of the surface and application process. Carefully mask off surrounding areas to avoid unintentional staining and always apply a test sample of the stain to a small, inconspicuous area before applying it to the entire surface.

Stain colors tend to appear darker when wet and will lighten slightly as they dry. Once the stain has cured, it is recommended that you seal it to protect the color and increase its durability.

The staining process can take between 24 and 72 hours, so it is best to plan for this to be a weekend project. Much of the time is spent waiting for the stain and sealant to dry, so this is a great opportunity to relax and enjoy your beautiful new concrete surface! For the best results, choose a stain that is formulated for your intended use. Surfaces that are subject to heavy foot or vehicular traffic, or exposed to outdoor elements should be sealed with a product that provides extra durability and protection.