Industrial 3D printers: components, configurations, and impact on production quality

3D printing is increasingly revolutionizing industrial processes by combining efficiency and flexibility. In our blog, you will learn everything about the most important materials, the role of filaments and how customized components ensure precision and reliability. Learn what needs to be avoided and how properly sizing your 3D printer components makes all the difference.

Industrial 3D printing to optimize production processes

Over the last few years, 3D printing has evolved from promising niche technology to a key technology in industrial manufacturing. While originally primarily used for prototypes and model construction, 3D printing is now increasingly revolutionizing production processes in various industries. Companies around the world use additive manufacturing to produce faster, more cost-effectively, and with greater flexibility. The additive printing process offers the potential to produce complex 3D-printed parts in the shortest time and to precisely meet individual customer requirements.

A decisive advantage of additive production lies in its freedom of design. While conventional methods such as injection molding or CNC milling are often limited by tools or machines, 3D printing can now manufacture complex geometries that were previously unthinkable. Moreover, products can be manufactured while consuming less material, thus conserving resources. This is only one of many aspects demonstrating that 3D printing has long since grown beyond prototype construction and now plays a significant role in the future of industrial manufacturing.

3D printing - more than just plastic

Plastics were the first materials used in additive production, and they are still the most commonly used materials in 3D printing. Particularly thermoplastics, such as PLA (polylactic acid), ABS (acrylonitrile butadiene styrene) and PETG (polyethylene terephthalate glycol), are used in numerous industrial applications because they are readily available, cost efficient and versatile. High-performance plastics and engineering plastics also play an increasingly important role for demanding applications. The introduction of metal into 3D printing was a critical step in taking the technology to the next level and making it usable for highly specialized industrial applications. Metals such as stainless steel, aluminum, titanium and nickel alloys are now regularly used in additive production and enable parts to be printed that meet the requirements of a wide range of industries. Resins, also known as photopolymers, are another important material in industrial 3D printing. These materials cure under the influence of UV radiation and offer extremely high precision, which is advantageous for detailed applications, such as medical equipment.

From plastic for fast and cost-effective prototypes, to metals for high-strength components, or resins for detailed and precise applications - each material offers specific advantages for different industrial requirements. See our blog on the design of 3D printers for a summarizing article about the components of a 3D printer and its functionality.

Filament for 3D printers

Filaments are one of the most common forms of material used in 3D printing. Additive production, in particular methods such as Fused Deposition Modeling (FDM), use the filament as a raw material and deposit the latter layer by layer to shape the desired 3D object. Selecting the correct 3D printing filament depends greatly on the requirements of the respective project. PLA plastics are often sufficient for simple prototypes, whereas more robust materials such as ABS, PETG or even nylon are preferred for functional components or mechanically stressed parts. In order to achieve the best results, industrial users must therefore carefully weigh the material properties and also the printing conditions.

3D printing - errors and challenges

Despite the impressive advances and the enormous potential offered by 3D printing for industry, the technology is not without challenges. As with any innovative manufacturing method, 3D printing encounters potential application errors and technical obstacles. Successful implementation in practice is therefore often more complex than expected.

Layers and contours

The thickness of the layers and the number of contours (perimeter) are two of the most important settings that directly influence print quality and mechanical strength. The layer height indicates how thick each deposited material layer is. Thinner layers (e.g. 0.1 mm) lead to a higher level of detail and smoother surfaces, but also to longer printing times. Thicker layers (e.g. 0.3 mm) allow for faster printing, but at the expense of surface quality. The number of contours describes the printed thickness of the outer walls of an object. More contours mean greater strength because the object has more material along the edges. This is particularly important for parts that are mechanically stressed or in which the exterior walls play a significant structural role.

3D printing support structure

One of the greatest challenges in 3D printing, especially in complex geometries, is the need for support structures. These supports are added during the printing process to stabilize overhanging or suspended parts of the object and prevent the material from sagging or collapsing. Among other things, the special challenges are that the areas on which the support structures rest can leave behind rough surfaces after the structures are removed, which in turn requires additional post-processing steps. The removal of the 3D-printed support structures themselves can also be difficult and time-consuming, in particular in complicated designs or smaller 3D-printed parts. In order to minimize these challenges, it is important to optimally position the support structures and to resort to minimalist support shapes as much as possible.

3D printing infill

The infill for 3D printing refers to the internal pattern of a 3D-printed object and influences the stability and also the weight of the end product. While the exterior contours of an object are printed over the entire surface, the interior often consists of a grid pattern to save material and shorten the printing time. The density of the infill is specified in percent and describes how much of the interior of the object is filled. A higher density results in a more stable, but also heavier and more expensive component. A lower density of 10-20 % may be sufficient for components with non-structural relevance, whereas mechanically resilient parts require a higher density. Different patterns such as honeycombs, grids or triangular patterns have different effects on stability and print time. Honeycomb patterns often provide a good balance between strength and material savings, while denser patterns such as the triangular pattern provide greater stability, but require more material and print time.

Components for industrial 3D printers - advantages and disadvantages

Industrial 3D printers are complex machines designed for precision, reliability and efficiency to meet demanding manufacturing requirements. Industrial models include a variety of advanced components optimized for larger volumes, higher speeds and the use of specialized materials. Selecting the right components is decisive for manufacturing high-precision and reliable 3D printers. At MISUMI, you can order a wide range of high-quality 3D printer components that have been specifically developed for the requirements of modern manufacturing solutions. This includes linear motion components, rotary motion components, and a variety of frames, guards, and auxiliary components.

Accuracy of components for 3D printers

The accuracy of a 3D printer is largely determined by the precision of its motion axes. The more precisely the print head or the component moves along the axes, the more accurate the printed end product will be. High-quality linear systems permit minimal tolerances and accurate end products. High precision requires regular maintenance to prevent play and wear. Wear parts such as guides and spindles must be inspected at regular intervals and replaced if necessary. In addition to more time spent, this can also lead to higher costs. As a result, companies must carefully consider how much accuracy is required for their specific requirements in order to achieve the best-possible cost-benefit ratio.

Sizing components for 3D printers

Sizing an industrial 3D printer significantly influences its potential uses and efficiency. A sophisticated 3D printer design optimizes the printer for the respective application. A large printing volume permits larger components to be manufactured in a single printing operation. This is particularly advantageous in mechanical engineering. However, the complexity of the motion control systems and the frame structure increases with increasing printing volume. Larger machines also require stronger and more precise motion control components and a more robust 3D printer design to ensure accurate printing results. This often leads to higher costs and increased maintenance costs.

Customized components for 3D printers

MISUMI offers standardized and also individually configurable components for 3D printers. While standardized components are ideal for companies looking for proven, off-the-shelf solutions, configurable components can be adapted to individual design specifications and technical requirements. The greatest advantage lies in the flexibility that customized components offer. They allow each component to be perfectly matched to the respective application, whether in terms of size, material, durability, or mechanical properties. The ability to design a component precisely according to one’s own specifications not only reduces the potential for operational inefficiencies, but also extends the service life of the machines and the quality of the end products. Companies that choose customized solutions benefit from reduced downtime and increased manufacturing reliability over the long term, as the components are specifically tailored to their needs.