Advanced Solutions: 3D Printing for Custom Automotive Parts

BLOG

Advanced Solutions: 3D Printing for Custom Automotive Parts

The automotive industry has seen a surge in customization demands as drivers seek personalized solutions for their vehicles. 3D printing for custom automotive parts has revolutionized how performance and aftermarket upgrades are created, offering new possibilities for car enthusiasts, mechanics, and small businesses alike.

What Types of Parts Can You Print?

The limit is your imagination! Print brake rotors or trailer hitches, or custom car parts like air vents and acceleration pedals. Plus, exterior accessories can be rapidly prototyped and adjusted just as easily. You can even print car body parts or specialized fixtures that cater to unique styles.

Custom 3D Printed Car Parts & Prototypes

Prototyping is faster and more cost-effective with 3D printing for custom automotive parts. The ability to quickly iterate designs for automotive applications, whether for exterior accessories or brake rotors, gives designers a competitive edge.

At Solidxperts, our printers help automotive businesses develop prototypes that precisely meet their specific needs.

Nylon and ABS: Durability Meets Functionality

The combination of nylon and ABS offers a strong, durable option for automotive applications. These materials are excellent for ducts and fixtures that need to withstand high heat or mechanical stress. Prints made from these materials are often indistinguishable from those that are traditionally manufactured, in terms of functionality.

Can You Save on Production Costs?

With 3D printing, a.k.a. additive manufacturing, production costs are significantly reduced. Traditional manufacturing methods require expensive molds and tooling, but FDM and fusion-based processes bypass these, allowing for fast prototyping and production. This benefit is particularly useful for small businesses offering aftermarket upgrades.

How Does 3D Printing Improve Aftermarket Customization?

3D printed car parts are a popular choice for creating custom exterior accessories, from car body pieces to brake rotors. Unlike traditional manufacturing methods, 3D printing offers flexibility and precision for these specific needs.

Enhance Performance with Custom Accessories

Additive manufacturing allows you to create custom car accessories tailored to your vehicle’s exact specifications. From flat surface panels to knobs and interior components, printed accessories ensure that you get the perfect fit and functionality for your aftermarket upgrades.

Why is Nylon a Game-Changer in Automotive 3D Printing?

Materials like nylon and carbon fiber have made a significant impact in automotive applications. These materials offer durable solutions for pieces that require strength, such as trailer hitches or knobs. Nylon is often paired with carbon fiber for even stronger automotive applications, increasing functionality and longevity.

Nylon vs. TPU

Choosing the right material can make all the difference in aftermarket upgrades. Nylon offers high strength, while TPU provides flexibility, ideal for custom pieces like knobs or exterior accessories. The versatility of these materials opens doors for pieces that perfectly match a vehicle’s performance requirements.

Considering 3D Printing for Custom Automotive Parts?

When it comes to 3D printing for custom automotive parts, precision and reliability are paramount. At Solidxperts, we provide FDM printers specifically designed for automotive applications, offering advanced features such as heated chambers and large build volumes. These features are crucial for producing strong, durable components like carbon fiber-reinforced nylon parts that meet the rigorous demands of the automotive industry.

Whether you’re creating prototypes to fine-tune designs or manufacturing final products, Solidxperts’ 3D printing solutions ensure superior quality and functionality. Our printers excel at delivering high-performance parts, from exterior accessories and fixtures to critical performance parts, all while reducing production costs and allowing for rapid iteration.

With Solidxperts’ advanced 3D printing technology, you can produce custom car parts that not only meet but exceed expectations.

Do You Need a Heated Chamber?

A heated chamber is crucial in maintaining consistent material temperatures during the printing process. This feature ensures that car body pieces, especially those requiring a smooth, flat surface, maintain quality throughout production.

Durable, Custom Car Parts from Your Desktop

Solidxperts offers desktop 3D printers capable of producing high-quality custom car pieces right from your workspace. Some of the printers in our lineup are designed to handle advanced materials like carbon fiber and ABS, making them perfect for manufacturing durable fixtures, nozzles, and more.

Precision and Functionality with Markforged

Markforged industry-leading printers are designed to handle a wide range of materials, from carbon fiber and nylon to TPU and ABS, ensuring high strength and durability.

You can produce car parts with reinforced carbon fiber filaments, delivering strength comparable to metal while significantly reducing weight—perfect for automotive applications where both strength and lightness are crucial. Whether you’re working on brake rotors, ducts, or structural performance parts, the precision of Markforged printers ensures accuracy down to the finest details.

Additionally, Markforged’s heated chambers and cloud-based software, Eiger, optimize print performance and streamline the process, lowering production costs and shortening turnaround times.

With these cutting-edge technologies, Solidxperts empowers clients to achieve remarkable results, making additive manufacturing a cost-effective and highly functional solution for any automotive customization project.

Conclusion

3D printing has transformed the way we approach custom automotive parts, offering unmatched flexibility, speed, and precision in manufacturing. Whether you’re a small business looking to reduce production costs or a car enthusiast seeking unique aftermarket upgrades, 3D printing is the key to unlocking endless possibilities. From performance parts to interior accessories and fixtures, the ability to tailor each component to your vehicle’s specific needs is now more accessible than ever.

With nylon, carbon fiber, TPU, and other advanced materials available, you can produce durable, high-quality prints that not only perform well but also last longer. For everything from prototypes to ducts to finishing with flat surfaces, Solidxperts’ range of 3D printers ensures precise and functional results for any automotive application. As the demand for customization grows, now is the perfect time to explore how 3D printing can revolutionize your approach to automotive manufacturing.

Any questions? Need help? Ask one of our experts.

Whether you’re ready to get started or just have a few more questions, you can contact us toll-free:

The Rise of Robot-as-a-Service: Revolutionizing Business Automation

BLOG

The Rise of Robot-as-a-Service: Revolutionizing Business Automation

Return

A robot showcasing a holographic graph in a modern office setting

Introduction

Robot(ics)-as-a-Service, or RaaS for short, is an emerging business model that works kind of like how you subscribe to apps or online services, but for robots. This innovative approach offers robotic automation solutions on a subscription basis, allowing companies to harness the power of advanced robotics without the hefty upfront investment. For small and medium-sized enterprises (SMEs), RaaS presents an exciting opportunity to stay competitive and agile in a dynamic market.

Industries that make stuff, sell stuff, or help keep us healthy are jumping on this trend to better automate tasks while keeping costs down.

What is Robot-as-a-Service (RaaS)?

RaaS provides businesses with access to robotic systems through a subscription model. It mixes old-school robotics with new tech like AI, machine learning, and cloud computing to make it easier and cheaper for businesses of all sizes to get into automation.

Instead of purchasing and maintaining robots, companies can rent them, paying regular fees that cover the cost of the machines, maintenance, software updates, and support services.

This approach offers scalability, reduced risk, and access to the latest robotic technologies, making automation more accessible and cost-effective.

The Growing Importance of RaaS in Business Automation

RaaS offers a cost-effective, scalable solution for businesses to improve efficiency and agility in a dynamic market. Thanks to its inherent flexibility and growth potential, it allows businesses to optimize their operations without high upfront costs, using a subscription or usage-based model.

Also, RaaS adapts to changing market conditions, enabling quick adjustments in robotic resources and maintaining predictable costs. Providers handle maintenance, upgrades, and support, ensuring the latest technology is always in use.

Exploring the Benefits of RaaS for Businesses

RaaS makes it easier and more cost-effective for businesses to leverage advanced robots. Businesses can boost productivity and flexibly adapt how they operate to keep up with highly competitive markets.

Cost Efficiency and Scalability

By adopting a RaaS model, organizations find it simpler to make their processes more efficient and bring in new automation ideas. Predictable costs make it easier for new businesses to start using this technology, and services can be tailored specifically to what each business needs.

Also, RaaS allows businesses to scale their robotic operations up or down based on their needs. This flexibility is particularly useful for industries with fluctuating demands, such as manufacturing, warehousing, and logistics.

Enhanced Productivity and Operational Flexibility

At the heart of the RaaS model, you’ll find a big boost in how much work gets done and how flexible operations can be. With RaaS on their side, companies can smooth out their processes, become more efficient, and quickly adjust when their customer wants and needs change.

Impact of RaaS on Key Industries

Manufacturing

RaaS revolutionizes manufacturing by enabling SMEs to automate production lines, reducing labor costs and increasing efficiency. With flexible subscription models, companies can scale their robotic workforce based on demand, ensuring optimal productivity without significant capital expenditure.

Warehousing and Logistics

In warehousing and logistics, RaaS can streamline operations by automating tasks such as sorting, packing, and transportation. This leads to faster order fulfillment, reduced errors, and improved inventory management, essential for maintaining a competitive edge in the fast-paced e-commerce sector.

Healthcare

RaaS can enhance healthcare delivery by providing robotic assistance in surgeries, rehabilitation, and patient care. These advanced robotic solutions can improve precision, reduce recovery times, and increase the overall quality of care, making them invaluable assets for healthcare providers.

Aerospace and Defense

In aerospace and defense, RaaS supports complex manufacturing processes and maintenance tasks. Robotic systems can handle intricate assembly operations, conduct inspections, and perform maintenance in hazardous environments, improving safety and efficiency.

How SOLIDWORKS Supports RaaS Adoption for SMEs

The SOLIDWORKS portfolio offers a comprehensive suite of tools that can support SMEs in adopting an RaaS model:

SOLIDWORKS 3D CAD: Essential for designing robotic components and systems, SOLIDWORKS 3D CAD allows for precise modeling and assembly, ensuring robust and efficient robotic solutions.
SOLIDWORKS Simulation: This tool enables SMEs to test and validate robotic designs under real-world conditions, ensuring reliability and performance before deployment.
SOLIDWORKS Electrical: By integrating electrical systems with mechanical designs, SOLIDWORKS Electrical ensures seamless functionality and reduces the complexity of robotic systems.
SOLIDWORKS PDM (Product Data Management): Managing design data and documentation, SOLIDWORKS PDM ensures version control and collaboration, crucial for developing and maintaining robotic systems.
SOLIDWORKS Manage: Providing advanced data management capabilities, SOLIDWORKS Manage helps SMEs oversee the lifecycle of robotic systems, from development to deployment and maintenance.
SOLIDWORKS Composer: This tool aids in creating technical documentation, ensuring that RaaS clients have access to clear instructions for operating and maintaining robots.
SOLIDWORKS Visualize: High-quality rendering and visualization capabilities of SOLIDWORKS Visualize help create compelling marketing materials and presentations, essential for promoting RaaS offerings.

Tips and Strategies for Successful RaaS Deployment

To make sure a RaaS setup works well, companies need to think about a few key things. First off, they should really look into what they specifically need and want to achieve, then pick a RaaS provider that has the right robots and tech for those needs.

It’s also crucial to get how the service model and pricing work with the chosen provider. This means looking at initial costs, ongoing fees for subscriptions, and any extra charges that might pop up.

On top of this, it’s important for businesses to train their employees so everyone knows how to use these robotic tools properly. And don’t forget about keeping in touch with your RaaS provider regularly; talking things through can help sort out any bumps along the way during setup or later on down the line.

By following these steps and using robotics within an appropriate service model, businesses can effectively use RaaS to achieve successful automation.

Conclusion

By leveraging the SOLIDWORKS software portfolio, SMEs can design, simulate, and manage robotic systems effectively, facilitating the adoption of the RaaS model. This not only democratizes access to cutting-edge robotic technology but also empowers SMEs to enhance their operational efficiency, reduce costs, and stay competitive in their respective industries.

Embracing RaaS with the support of SOLIDWORKS tools can unlock new levels of innovation and productivity, enabling SMEs to thrive in an increasingly automated world.

Any questions? Need help? Ask one of our experts.

Whether you’re ready to get started or just have a few more questions, you can contact us toll-free:

Unlocking 3D Creativity: Designing Complex Shapes Made Easy

BLOG

Unlocking 3D Creativity: Designing Complex Shapes Made Easy

Return

Grey-suited figures seated around a large table with science fiction inspired 3D architectural plans

Introduction

When it comes to the creative process, the 3D Sculptor and 3D Creator roles on the 3DEXPERIENCE platform provide a user-friendly interface that allows you to easily manipulate and shape complex parts. These tools offer a streamlined workflow and powerful CAD capabilities, making the design process more efficient and intuitive. With x3D Sculptor and 3D Creator at your fingertips, the art of crafting intricate shapes becomes a seamless journey.

3D Sculptor, 3D Creator, and the 3DEXPERIENCE Platform

The 3DEXPERIENCE platform roles 3D Sculptor and 3D Creator revolutionize the way designers and engineers approach complex shape design. By harnessing the power of these browser-based functionalities, you can break down intricate concepts into manageable steps, starting with basic shapes and gradually evolving them into sophisticated designs. This streamlined workflow not only enhances design flexibility but also enables quick iteration and realization of creative ideas. With advanced features tailored for various industries, 3D Sculptor and 3D Creator are paving the way for unlocking limitless creativity.

3D Sculptor Enhances Design Flexibility

The 3D Sculptor role simplifies the creation of complex parts by starting from basic shapes and using advanced tools for intricate designs. It allows easy manipulation of compound shapes and complex geometries, ensuring your creative vision is realized. Additionally, access to a variety of Sub-D tools within the xShape app enhances your ability to refine and perfect designs with precision and flexibility. These capabilities empower you to push the boundaries of design, achieving higher levels of complexity and detail.

Create complex parts using basic shapes
Use advanced features for working with compound shapes
Easily manipulate and shape complex geometries
Access additional Sub-D tools in the xShape app

Explore the free xShape Master Class to hone your skills!

3D Creator Streamlines Your Design Workflow

With 3D Creator, on the other hand, the focus is on streamlining the design process. This tool provides traditional parametric modeling tools in its xDesign app, allowing you to easily create and modify designs using curves and surfaces. The combination of Sub-D modeling in 3D Sculptor and parametric modeling in 3D Creator gives you the flexibility to mix and match tools as needed, ensuring that you have the right tools for the job.

Provides traditional parametric modeling
Allows for easy creation and modification of designs using curves and surfaces
Offers a seamless workflow with 3D Sculptor

3D Sculptor and 3D Creator for Complex Shapes

The advantages of using 3D Sculptor and 3D Creator for complex shapes are numerous. These tools not only enhance design flexibility but also streamline the design process, saving you time and effort. With their intuitive interfaces and powerful capabilities, you can easily create and modify complex geometries, whether you’re starting from basic shapes or working with compound parts. Additionally, these tools facilitate collaboration in design projects, allowing team members to work together seamlessly and share their ideas.

Simplifying the Creation of Complex Geometries

Creating complex geometries can be a challenging task, but with 3D Sculptor and 3D Creator, it becomes much simpler. These tools provide a range of features and tools specifically designed to simplify the creation of complex shapes, including the use of simple shapes as building blocks. Whether you’re working with compound shapes or intricate parts, you’ll find that these tools offer the flexibility and precision needed to bring your designs to life. By starting with basic shapes and gradually building up the complexity, you can create unique and innovative designs without the limitations of traditional tools.

Enhancing Collaboration in Design Projects

Collaboration is a vital aspect of any design project, and 3D Sculptor and 3D Creator make it easier than ever to work together seamlessly. With these tools, team members can collaborate in real-time, sharing their ideas and making modifications on the fly. This not only speeds up the creative process but also ensures that everyone’s input is taken into account. Whether you’re working on a design project with colleagues or collaborating with clients, 3D Sculptor and 3D Creator provide the necessary tools to enhance collaboration and bring your designs to life.

Step-by-Step Guide to Designing with 3D Sculptor

Designing with 3D Sculptor is a straightforward process that allows you to unleash your creativity and create complex shapes with ease. Here is a step-by-step guide to help you get started:

Start by launching the 3D Sculptor app in your browser.
Choose a basic shape to serve as the foundation for your design.
Use the push and pull technique to manipulate the shape and create the desired complex geometry.
Access additional Sub-D tools in the xShape app to refine and fine-tune your design.
Save your design and export it for further use or collaboration.

Starting Your First Project: Tips and Tricks

To set yourself up for success, start by selecting a basic shape that closely resembles your final design. This simplifies the process and provides a solid base upon which to build. From here, you can push and pull your base to manipulate the shape, adding layers of complexity and detail.

As you progress, don’t hesitate to experiment with different Sub-D tools. These tools are invaluable for refining and perfecting your design, allowing you to achieve the intricate details that will make your project stand out.

Begin with a clear idea of the complex shape you want to create
Start with a basic shape that closely resembles the final design
Utilize the push and pull technique to manipulate the shape and add complexity
Experiment with different Sub-D tools to refine and perfect your design

Advanced Techniques for Refining Your Designs

Once you’ve mastered the basics, it’s time to elevate your designs with advanced techniques. Combining parametric modeling techniques with Sub-D modeling can offer added flexibility and control. Experiment with different surface finishes and textures and discover unique effects that add depth and character to your creations. This hybrid approach allows you to fine-tune your designs with mathematical precision while retaining the creative freedom of Sub-D modeling.

Use advanced Sub-D tools to add intricate details to your design
Combine parametric modeling techniques with Sub-D modeling for added flexibility
Experiment with different surface finishes and textures to enhance the visual appeal of your design
Take advantage of the collaboration features to gather feedback and make adjustments

Frequently Asked Questions

What is a Role on the 3DEXPERIENCE platform?

A Role on the 3DEXPERIENCE platform refers to a set of permissions and capabilities assigned to a user, determining what actions they can perform within the software. Each role is tailored to specific functions or responsibilities, ensuring that users have access only to the tools and features necessary for their tasks. By assigning roles appropriately, organizations can optimize workflow efficiency and data security within the platform.

What are some techniques for designing complex shapes in 3D modeling?

Designing complex shapes requires a combination of creativity and technical skills. Some techniques include starting with basic shapes and gradually building up complexity, using Sub-D modeling tools for organic shapes, and leveraging parametric modeling for precise control over dimensions and features.

How do you ensure manufacturability when designing complex shapes?

When designing complex shapes, it is important to consider manufacturability. By utilizing tools like Manufacturing Definition Creator, you can create 3D and 2D definitions that ensure your design can be manufactured correctly. This helps eliminate potential issues and ensures a smooth transition from design to production.

What software tools are commonly used for designing complex shapes?

There are several software tools commonly used for designing complex shapes, with 3D Sculptor and 3D Creator being popular choices. These browser-based tools offer powerful CAD capabilities and streamlined workflows, making them ideal for tackling the challenges of complex designs and organic shapes.

What are the challenges faced when designing intricate geometries?

Designing intricate geometries can present several challenges. These include maintaining the integrity of the design while adding complexity, ensuring the manufacturability of the final product, and managing the interdependencies between various features and dimensions. However, with the right tools and techniques, these challenges can be overcome.

What role does parametric design play in creating complex shapes?

Parametric design allows designers to manipulate basic shapes and explore different possibilities in creating complex shapes. It provides the flexibility to modify dimensions, curves, and surfaces, making it easier to iterate and refine designs. The parametric approach streamlines the creative process and enables designers to achieve complex shapes efficiently.

Any questions? Need help? Ask one of our experts.

Whether you’re ready to get started or just have a few more questions, you can contact us toll-free:

Why Material Matters: Choosing the Best 3D Printing Filament

BLOG

Why Material Matters: Choosing the Best 3D Printing Filament

Return

Colorful spools of 3D printing filament on a cluttered work bench

The Basics of FDM 3D Printing Materials

When it comes to 3D printing, the material you choose is just as important as the printer itself. Filament is the thermoplastic feedstock used in fused deposition modeling (FDM) 3D printers. It is a continuous slender plastic thread spooled into a reel, with diameters ranging from 1.75 mm to 2.85 mm. Filament comes in various types, each with its own unique properties.

3D printers use different mechanisms to extrude the filament and build up layers to create your final model.

How Filament Choice Impacts Your 3D Printing Project

The choice of 3D printing filament can have a significant impact on the outcome of your 3D printing project. Different filaments have different properties, such as strength, flexibility, and temperature resistance. Understanding these properties and how they relate to your project is crucial for achieving the desired results.

For example, if you’re printing functional parts that require strength and durability, ABS or PETG would be suitable choices. On the other hand, if you’re creating decorative or artistic pieces, PLA or specialty filaments like wood or even metal may be more appropriate.

Exploring Just a Few Types of Available 3D Printer Filaments

PLA (Polylactic Acid)

PLA is one of the most popular filaments for 3D printing. It is a biodegradable and environmentally friendly filament that is derived from renewable resources such as cornstarch or sugarcane. PLA is easy to print with and offers good dimensional accuracy. It is known for its vibrant colors and smooth surface finish. PLA is commonly used for prototyping, hobbyist projects, and decorative prints. It is compatible with most commercially available FDM printers and can be printed at lower temperatures compared to other filaments.

ABS (Acrylonitrile Butadiene Styrene)

ABS is a popular filament known for its durability and impact resistance. It has a higher melting temperature compared to PLA, making it suitable for functional parts that require strength and toughness. ABS is commonly used in applications such as automotive parts, electronic enclosures, and industrial prototypes. It can be challenging to print with due to its tendency to warp and emit strong fumes during printing. However, with proper printer settings and a heated bed, ABS can produce high-quality prints with excellent mechanical properties.

PET (Polyethylene terephthalate)

PET is a popular 3D printing filament known for its strength and flexibility. Its durability and impact resistance ensure long-lasting printed objects, while its flexibility allows for complex shapes without cracking. Additionally, it offers excellent chemical resistance and is food-safe, making it suitable for kitchen items. PET is easy to print with a lower risk of warping and can be used on most standard 3D printers. Being recyclable, it also provides an eco-friendly option for various 3D printing projects.

PETG (Polyethylene terephthalate glycol)

PETG is a variation of PET that offers improved impact resistance and chemical resistance. It’s a versatile filament known for its balance of strength, flexibility, and temperature resistance. It is commonly used for functional parts, mechanical components, and consumer products that require durability and impact resistance. PETG has excellent layer adhesion, making it ideal for strong and durable prints. Additionally, it is FDA-approved for food contact, making it a popular choice for printing kitchen utensils and containers.

TPU (Thermoplastic polyurethane)

TPU is a flexible filament that is widely used for creating elastic parts and prototypes. It offers excellent resistance to abrasion, chemicals, and oils, making it suitable for applications that require flexibility and durability. TPU is commonly used in industries such as automotive, footwear, and prosthetics. It can be printed with ease on most FDM printers and does not require a heated bed. TPU is available in various shore hardness ratings, allowing for different levels of flexibility and elasticity in prints.

Specialized 3D Printing Filaments

In addition to the common filaments used in 3D printing, there are specialized filaments that offer unique properties for specific applications. These filaments are often infused with different materials to enhance their properties. Some examples of specialized filaments include carbon fiber-infused filaments, which offer high strength and rigidity, and metal-infused filaments, which allow for the printing of metal-like objects. These specialized filaments are commonly used in industries such as aerospace, automotive, and jewelry.

Onyx by Markforged: High Performance Carbon Fiber

Onyx is a high-performance carbon fiber filament developed by Markforged. It combines the strength and rigidity of carbon fiber with the ease of printing with nylon. Onyx is known for its excellent dimensional stability, high strength-to-weight ratio and resistance to heat and chemicals. It is commonly used in industries such as aerospace, automotive, and defense for applications that require lightweight yet strong parts. Onyx can be printed on Markforged 3D printers, which are specifically designed to handle the unique properties of this filament.

Metal 3D Printing: Stainless Steel, Copper, and more

3D printing with metal filaments allows for the creation of metal-like objects without the need for traditional metalworking processes. These filaments are composed of a mixture of metal powder and a binding agent. After printing, the object can be further processed to remove the binding agent and sinter the metal particles together, resulting in a solid metal part.

While an expensive and infrastructure-heavy investment, 3D printing with metal filaments offers the ability to create complex geometries and customized metal parts with good mechanical properties.

Factors to Consider When Selecting a Filament

When choosing a filament for your 3D printing project, consider factors like strength, durability, flexibility, temperature resistance, and printer compatibility. Filaments such as ABS, PETG, or carbon fiber are suitable for strength, while TPU works well for flexibility. For high temperatures, consider polycarbonate. Always remember to check compatibility with your printer’s settings!

Assessing the Strength and Durability Needs of Your Project

When selecting a filament for your 3D printing project, it is essential to assess the strength and durability needs of your project. Consider the intended use of the printed object and the level of stress it will be subjected to. If you require high strength and impact resistance, filaments like ABS, PETG, or carbon fiber-infused filaments may be suitable. These filaments offer excellent mechanical properties and can withstand heavy loads and impacts.

Considering Flexibility and Elasticity for Functional Parts

For functional parts that require flexibility and elasticity, it is important to consider filaments that can meet these requirements. TPU is a popular choice for flexible prints. It offers excellent flexibility and resilience, making it ideal for applications such as phone cases, prosthetics, and wearables. TPE (Thermoplastic elastomer) is another flexible filament that provides a soft and rubber-like texture. It is commonly used for creating gaskets, seals, and other parts that require high flexibility.

Temperature and Environmental Resistance

Temperature and environmental resistance are important considerations when selecting a 3 D printing filament. Different filaments have different temperature ranges at which they perform optimally. For example, PLA can be printed at relatively low temperatures (180-230°C) and is suitable for most everyday applications. On the other hand, filaments like polycarbonate (PC) and polyetherimide (PEI) have higher temperature resistance and can withstand elevated temperatures (up to 340-380°C). These filaments are commonly used in applications that require exceptional heat resistance, such as aerospace components and automotive parts.

Cost-Effectiveness and Availability

Cost-effectiveness and availability are key factors when selecting 3D printing filament. PLA is popular for being affordable and widely available, as well as eco-friendly. PETG is valued for its strength and durability with better impact resistance than PLA. While PLA and PETG are cost-effective and common, ABS and Nylon may be pricier but offer unique strengths. ABS provides high strength and temperature resistance for functional parts, while Nylon offers flexibility and durability for specialized applications like gears. Finding this balance depends heavily on the user, projects, and printing frequency.

Consider how you prefer to source your materials. Are you more comfortable dealing with a consistent supplier, or are the readily available 3D printing filaments on Amazon enough for your needs? It’s important to consider the specific requirements of your project and budget constraints when selecting a 3D printing filament. By balancing cost-effectiveness and availability, you can ensure that you choose the best filament for your 3D printing needs.

Balancing Quality with Budget Constraints

Similarly, choosing the right 3D printing filament involves balancing quality and budget. High-quality filaments offer superior performance but come at a higher cost. Research and comparing brands can help find affordable options with satisfactory results. Reading reviews and seeking recommendations can identify cost-effective choices. Experimenting with different types of filaments can help strike a balance between quality and budget based on project requirements.

Application-Specific Recommendations

Different 3D printing applications require different 3D printing filament types to achieve optimal results. By selecting the right material for your specific application, you can ensure that your 3D prints meet the desired functionality and performance requirements.

Prototyping with Precision: Choosing the Right Material

When it comes to precision prototyping, choosing the right 3D printing filament is crucial to achieve accurate and detailed prints. Different materials offer varying levels of precision and surface finish.

PLA (Polylactic Acid) is a popular choice for precise prototyping due to its low shrinkage and excellent dimensional accuracy. It provides smooth and clean prints, making it ideal for visual models and product prototypes. Additionally, PLA is easy to print with and offers a wide range of colors to choose from.

ABS (Acrylonitrile Butadiene Styrene) is another material suitable for precision prototyping. It offers better temperature resistance and durability compared to PLA, making it suitable for functional prototypes that require strength and impact resistance.

PETG (Polyethylene Terephthalate Glycol) is also a good option for precision prototyping. It offers a balance of strength, flexibility, and dimensional stability, making it suitable for a wide range of applications.

By selecting the right material for precision prototyping, you can ensure that your prints accurately represent your design and meet your quality expectations.

Functional Parts and Mechanical Components: What Works Best?

When it comes to printing functional parts and mechanical components, choosing the right filament is essential to ensure durability and performance. Different materials offer varying mechanical properties and characteristics.

TPU (Thermoplastic Polyurethane) is an excellent choice for parts that require flexibility and resilience. It offers high elasticity and impact resistance, making it suitable for gaskets, seals, and other flexible components.

Nylon is known for its exceptional strength and toughness, making it ideal for functional parts that require durability and high load-bearing capabilities. It also offers good chemical resistance, making it suitable for applications in harsh environments.

ABS (Acrylonitrile Butadiene Styrene) is a versatile material that provides a balance of strength, impact and temperature resistance. It is commonly used for functional parts in various industries, including automotive and aerospace.

By choosing the right filament for functional parts and mechanical components, you can ensure that your 3D prints meet the required performance standards and withstand the intended applications.

Frequently Asked Questions

How does the choice of filament material impact the quality of a 3D printed object?

The choice of 3D printing filament plays a crucial role in determining the quality of a 3D printed object. Different materials have unique properties such as strength, flexibility, and durability, which directly affect the performance and appearance of the printed object. Factors such as layer adhesion, dimensional accuracy, and surface finish are influenced by the filament material used.

How do I determine the best 3D printing filament for my project?

To determine the best filament for your 3D printing project, consider the specific requirements of the print, such as desired strength, flexibility, and temperature resistance. Additionally, take into account the printer compatibility and budget constraints. Conducting research and consulting experienced users can provide valuable insights and recommendations.

Any questions? Need help? Ask one of our experts.

Whether you’re ready to get started or just have a few more questions, you can contact us toll-free:

How the Concept Cars of Tomorrow Are Made With 3D Printing

BLOG

How the Concept Cars of Tomorrow Are Made With 3D Printing

Return

Located in the heart of the UK’s auto industry, Vital Auto is an industrial design studio with deep expertise in automotive design. The company’s illustrious clientele includes many of the major automotive manufacturers, such as Volvo, Nissan, Lotus, McLaren, Geely, TATA, and more.

“Clients typically come to us to try and push the boundaries of what’s possible with the technology available,“ said Shay Moradi, Vital’s VP of Innovation & Experiential Technology. When manufacturers don’t have time for experimentation themselves, they rely on Vital Auto with any kind of challenge to turn ideas, initial sketches, drawings, or technical specifications into a fully realized physical form.

Read on to learn how Vital Auto—a customer of Formlabs’ fastest growing UK reseller, SolidPrint 3D—creates high-fidelity prototypes and concept cars, rapidly working through iterations using a variety of advanced tools, including a large fleet of Form 3L and Fuse 1 printers.

The Making of a Concept Car

Vital Auto was founded in 2015 when three friends got together, quit their jobs, and decided to set up a shop—fittingly—in a garage. One of the first contracts the company took on was for the NIO EP9 supercar concept, which instantly set the team on a course to producing extremely realistic, high-fidelity vehicular prototypes.

Depending on the client’s request, the team will start anywhere from simply a sketch on a piece of paper to an already designed vehicle. They develop cars from a blank sheet and design all the mainframes, all the exterior and interior elements, open/closings, and interactive elements. With five to 30 people working on a single concept, a typical project could take anywhere from three to 12 months.

During this time, a typical show car goes through up to a dozen core design iterations, and within those, there can be further iterations of smaller components until the design meets the expectations of the customer.

“It’s all well in our industry to look at virtual properties as a means of evaluating a product before it goes to market. However, I think there’s always going to be a place for physically manufactured objects as well. There’s nothing that beats the sensation and feeling of holding an object in your hands with the correct weight, with the correct proportions, and the dynamics of how the physical environment changes your perception of that physical object,“ said Moradi.

“Most of our customers will come to us with a new idea, an innovative idea, and something that’s never been done before. So the challenges for us are new every single day and they’re endless,” said Anthony Barnicott, Design Engineer in charge of additive manufacturing. “These challenges can range from, how can we produce this number of parts in this amount of time to, how can we make a sustainable product or how can we make a part that achieves a particular weight while still achieving a particular performance.”

While traditional show cars are normally made just from milling clay, the team also uses three- and five-axis CNC milling, hand forming, hand clay modeling, and GRP composites. These traditional processes are, however, often not ideal for producing the custom parts required for one-off concepts.

“We’ve used 3D printing from day one. We wanted to introduce it to our manufacturing processes, not only to reduce costs but to give the customer more diversity with their designs and their ideas,” said Barnicott.

Today, Barnicott runs a whole 3D printing department, including 14 large-format FDM printers, three Formlabs 3L large-format SLA printers, and five Fuse 1 SLS printers.

“In terms of capacity, all those printers have run 100%, 24/7, pretty much since day one. We use these printers for all areas of our concepts and designs. Typically, we would use the Fuse 1s for our production-based parts and we would use our Form 3Ls for our concept-based parts,” said Barnicott.

Manufacturing Complex Designs From Multiple Materials With the Form 3L

“We use the Form 3L machines for anything that is an A-class finished surface. So typically in an automotive environment, and interior where you have parts that are not being trimmed with leather or Alcantara or some sort of cloth material. Formlabs materials give us a nice, smooth finish for our painters to work with, we can use these parts straight out the printer, straight onto a vehicle,” said Barnicott.

“What interests me most about the Form 3L machines is their versatility, the ability to do a material change in less than five minutes and the variability of those materials going from a soft, flexible material to a hard and rigid material for us is priceless,” said Barnicott.

The team uses the Form 3L’s with multiple materials for a wide array of applications, for example:

Air Vents

“It’s a common challenge for us as a business where customers will approach us with a proprietary product and want to encase it in their own design. Once, a customer approached us with a proprietary air vent from another vehicle that they wished to have inside their own interior. We used 3D scanning technology to reproduce this part digitally and then created an external skin. We first produced this in the Draft material to test out the design and allow the customer to verify it. From there, we moved to the White material to produce a production-ready part.”

Switch Packs

“When working with incredibly intricate designs, such as small switch packs, what we’re able to do is use multiple materials to achieve a mechanical product that not only functions correctly but can be used in a real-world environment. [For these switch packs], we combined harder materials, such as the Tough 2000 for the top surface, with the lighter, more cost-effective materials for the internals.”

Door Seals

“Typically, door seals for automotive applications can be incredibly costly to produce. there’s simply no other way other than extrusion molding to produce them. This comes at, not only a very large tooling cost but also a long lead time as well. We were able to experiment with one of Formlabs’ newest materials, the Flexible 80A. The Form 3L enabled us to produce sections of this door seal overnight to test various geometries and was printed within 50 microns of the actual design.”

Having the Form 3L empowers the team to produce multiple iterations of parts in most cases within 24 hours. They ended up buying three different machines so they could produce up to three different iterations of a part at the same time, even using three different materials. They can then pass on the cost savings to the customer or offer more value by showcasing multiple design options for the same price.

“One of the beauties of using additive manufacturing is the compression of a timeframe. So what do you do in that span of time that you have freed up? We sort of seeing it as extending the possibility space into imagining alternatives, into adding more iteration loops in the process,“ said Moradi.

“There are many products we produce that we simply wouldn’t be able to without our Form 3Ls. With some of the most advanced manufacturing techniques, such as seven-axis CNC machining, we’d be able to produce these parts, but it would come at a huge compromising cost,” said Barnicott.

Complementing CNC Machining for Mechanical Parts With the Fuse 1

“The Fuse 1 one was our first venture into SLS technology. As a small business, this is a technology we thought we would never be able to have on-site. With the Fuse 1, not only do we have one of the machines, but we actually have five of the machines on the site. What these machines enable us to do is produce structural mechanical parts very quickly, not only for testing but for physical applications in most of our concepts. This process would have typically been done by CNC machining, either on our site or off-site, depending on the geometry, and we would have to wait two to four days to get the parts in our hands. The Fuse 1 enables us to cover all of this on-site and have parts in our hand in most instances, less than 24 hours,” said Barnicott.

The team mainly uses the Fuse 1s for mechanical parts, such as door hinges, door handle inners, door internals, and structural applications. They can use these parts straight off the printer, with minimal finishing. Some of the applications where the team used the Fuse 1s include:

Air Duct

“A lot of automotive interior parts can be incredibly tricky to produce without going down the traditional injection molded route. Items such as internal air ducts and vents, items that are never seen, but yet require a large cost to produce. We use the Fuse 1 to produce these parts. It allows us to be much more versatile with the designs we put in the vehicle without incurring the large costs that they would typically have.”

Brake Caliper

“Sometimes we produce parts whereby the customer simply wants to see what their brand will look like on a specific part. That means we have to produce a part rather quickly so we can apply their brand to it. We use the Fuse 1 to produce these parts, such as a brake caliper, and we can produce the logo in different areas of the caliper in different colors for the customer to review.”

Interactive Concept for a Supercar

“3D printing has allowed us to combine both the SLA and SLS materials to work our way through design iterations on a specific project. This allows us to quickly produce multiple iterations, combining both processes, using them for their specific properties, to achieve a final design. This can be anything from mechanical parts to clear parts to check their optical quality and output.”

While it’s often said that additive manufacturing is here to replace subtractive manufacturing, the Vital Auto team sees benefits in combining different technologies to leverage their best qualities.

“We use the two processes together to help support each other. We have many parts where we would use subtractive manufacturing and then use additive manufacturing to produce all the finer details. This allows us to have a much more cost-effective way of producing a lot of our concept models,” said Barnicott.

Creating High-Fidelity Concept Cars With 3D Printing

“The progression in technology and 3D printing over the last 10 years is phenomenal. When I first started, producing low-volume, niche vehicles, some of the products that we produce today would simply have been inaccessible. And not only am I able to produce these parts today, but I’m also able to produce them very cost-effectively, very quickly,” said Barnicott.

3D printing not only helps the team create better products faster but also attracts new business. They found that many of their customers turn to them because they want to have access to the latest technologies and they want to have their components made using the latest cutting-edge materials.

“There are certain things that you just can’t class as emerging technologies anymore. 3D printing is one of those things. It’s advanced to a point where everything that we produce is good enough for use in the final presentation stage with all the layers of making that we apply on top of that. 3D printing has gone from almost a novelty to becoming an absolutely inseparable part of what we do,“ said Moradi.

Contact an Xpert

Any questions? Need help? Ask one of our experts.

Whether you’re ready to get started or just have a few more questions, you can contact us toll-free:

Fun fact: 5 Amazing Objects Created with a 3D Printer

BLOG

Fun fact: 5 Amazing Objects Created with a 3D Printer

Return

Written by Senior Technical Representative – SolidXperts USA, John Nolin

There are many new uses for industrial quality 3D printers. The strength and part quality from plastic or composite printers and the price point for metal 3D printers has improved significantly over the last 5 years.

Largest in the World

Recently in the news, the UMaine Advanced Structures and Composites Center achieved 3 separate Guinness World Records related to producing an entire full scale boat with world’s largest polymer 3D printer.

The boat is a 25 foot long model 3Dirigo, that weighs 5000 lbs and has already undergone initial testing in the Alfond W² Ocean Engineering Laboratory.

Reaching new terrain

Similarly, BowHead Corp produces the Reach adventure cycle that allows disabled persons to enjoy mountain bike or similar trail systems. The steering and suspension components are composite 3D printed and some power train components are metal 3D printed.

Christian Bagg is wheelchair bound himself and developed the first explorer cycle for his own use to better enjoy the Rocky Mountain area by the Bow River where he lives.

Better Robots

Several BattleBots teams use 3D printed components as weapons, drive systems, and chassis parts. Robots such as Overhaul and Sawblaze have been competing and winning with 3D printed parts since the 2016 season.

3D printed end effectors are a popular user upgrade or customization for traditional manufacturing pick & place robots. Also, several makers of warehouse robots and systems are incorporating 3D printed components within their end products.

A Smarter Dummy

The crash test dummy that certifies your next new car or truck has the proper safety design to protect you, has ribs and other parts that are 3D printed. The printed part design provides strengths similar to bones and allows wires and sensor electronics to be incorporated easily without interfering with the behavior in a crash.

3D printed molding fixtures are also used in the production of flexible crash test dummy neck rings. The printed molds are much more durable than other soft mold options and much less expensive than machined metal mold forms.

Forming new music

Wind instruments are generally hand formed by bending hard brass and similar tubing into the proper shape. The bending tools need to have the proper strength but not introduce any scratches which may ruin the sound of the finished product. 3D printed bending fixtures with internal reinforcement perform the job and are much faster and less expensive than traditional wood form production. For the French Horn shown, even some levers and finger pads were 3D printed.

The technique can be applied to more industrial applications such as rigid tubing pieces or microwave waveguide sections.

Several designs also exist for various sort of electric string instruments. The variety extends all the way from professional quality electric violins to a home built ukulele or guitar.

These amazing products are just a sampling of what is being accomplished recently with higher quality 3D printers and improved, lower cost materials. The SolidXperts website has several 3D printers with capacities for the inventor at home, all the way to the large firm producing metal components for test and end use.

For more information on our range of Markforged 3D printers or to talk to an Xpert, click here.

Any questions? Need help? Ask one of our experts.

Whether you’re ready to get started or just have a few more questions, you can contact us toll-free:

Request a Quote

Advanced Solutions: 3D Printing for Custom Automotive Parts

What Types of Parts Can You Print?

Custom 3D Printed Car Parts & Prototypes

Nylon and ABS: Durability Meets Functionality

Can You Save on Production Costs?

How Does 3D Printing Improve Aftermarket Customization?

Enhance Performance with Custom Accessories

Why is Nylon a Game-Changer in Automotive 3D Printing?

Nylon vs. TPU

Considering 3D Printing for Custom Automotive Parts?

Do You Need a Heated Chamber?

Durable, Custom Car Parts from Your Desktop

Precision and Functionality with Markforged

Conclusion

The Rise of Robot-as-a-Service: Revolutionizing Business Automation

Introduction

What is Robot-as-a-Service (RaaS)?

The Growing Importance of RaaS in Business Automation

Exploring the Benefits of RaaS for Businesses

Cost Efficiency and Scalability

Enhanced Productivity and Operational Flexibility

Impact of RaaS on Key Industries

Manufacturing

Warehousing and Logistics

Healthcare

Aerospace and Defense

How SOLIDWORKS Supports RaaS Adoption for SMEs

Tips and Strategies for Successful RaaS Deployment

Conclusion

Unlocking 3D Creativity: Designing Complex Shapes Made Easy

Introduction

3D Sculptor, 3D Creator, and the 3DEXPERIENCE Platform

3D Sculptor and 3D Creator for Complex Shapes

Simplifying the Creation of Complex Geometries

Enhancing Collaboration in Design Projects

Step-by-Step Guide to Designing with 3D Sculptor

Starting Your First Project: Tips and Tricks

Advanced Techniques for Refining Your Designs

Frequently Asked Questions

What is a Role on the 3DEXPERIENCE platform?

What are some techniques for designing complex shapes in 3D modeling?

How do you ensure manufacturability when designing complex shapes?

What software tools are commonly used for designing complex shapes?

What are the challenges faced when designing intricate geometries?

What role does parametric design play in creating complex shapes?

Why Material Matters: Choosing the Best 3D Printing Filament

The Basics of FDM 3D Printing Materials

How Filament Choice Impacts Your 3D Printing Project

Exploring Just a Few Types of Available 3D Printer Filaments

Specialized 3D Printing Filaments

Factors to Consider When Selecting a Filament

Assessing the Strength and Durability Needs of Your Project

Considering Flexibility and Elasticity for Functional Parts

Temperature and Environmental Resistance

Cost-Effectiveness and Availability

Balancing Quality with Budget Constraints

Application-Specific Recommendations

Prototyping with Precision: Choosing the Right Material

Functional Parts and Mechanical Components: What Works Best?

Frequently Asked Questions

How does the choice of filament material impact the quality of a 3D printed object?

How do I determine the best 3D printing filament for my project?

How the Concept Cars of Tomorrow Are Made With 3D Printing

The Making of a Concept Car

Manufacturing Complex Designs From Multiple Materials With the Form 3L

Air Vents

Switch Packs

Door Seals

Complementing CNC Machining for Mechanical Parts With the Fuse 1

Air Duct

Brake Caliper

Interactive Concept for a Supercar

Creating High-Fidelity Concept Cars With 3D Printing

Fun fact: 5 Amazing Objects Created with a 3D Printer