International Journal of Scientific and Research Publications, Volume 8, Issue 4, April 2018 1

ISSN 2250-3153

Comparison of Different Types of 3D Printing

Technologies
Shiwpursad Jasveer*, Xue Jianbin**

*Department of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics
**Department of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics

DOI: 10.29322/IJSRP.8.4.2018.p7602
http://dx.doi.org/10.29322/IJSRP.8.4.2018.p7602

Abstract- 3D printing is a form of non-traditional machining. Also known as additive manufacturing, it is a method of creating an
object by laying successive layers of material until the whole object is created. Unlike subtractive manufacturing processes which
usually result in up to 80-90% of the material being wasted, there is seldom any wastage of material in 3D printing. The concept of 3D
printing has been around for a long time and its technology has evolved over the years. Different 3D printers make use of different
kind of technologies, printing methods and also different kinds of materials. This paper gives a general introduction to the concept of
3D printing, the different types of printing technologies with their advantages, limitation and compares each of them to different
criteria such as surface finish, dimensional accuracy, material used, post processing requirements etc.

Index Terms- Additive manufacturing, Non-traditional machining, 3D printing, 3D printers

I. INTRODUCTION
Traditional machining such as turning, milling, drilling and grilling has been around for many years and has helped human beings to
build things. Although the technology for traditional machining has evolved in recent years, it has a number of limitations. With the
introduction of non-traditional machining such as electric discharge machining or electric chemical machining, the manufacturing
world has changed and at present nearly all industrial processes require computers and robot technology. These processes stated all
involve removing material from a larger mass of block to get the required shape of the final product. There are constraints such as
fixtures and assembly for many traditional designs and their production processes which are often expensive and add cost to the
production process.

Compared to traditional machining, 3D printing is a process of creating objects directly by stacking layers of material on each other
until the required product is obtained. The layers are stacked up in a variety of ways depending on the technology being used. This
technology allows the design of complex components therefore avoiding assembly requirement at no additional cost. 3D printing
being a tool-less process, significantly reduces the prohibitive costs and lead times. The printing process usually starts with the making
of a 3D digital model. This model can be created using any 3D software programmes or by scanning the product using a 3D scanner
[1]. The model is then layered into slices and is converted into a file which is understandable by the 3D printer. The material
processed by the 3D printer is layered according to the design.

II. CURRENT 3D PRINTING TECHNOLOGIES

All 3D printers do not use the same technology. There are numerous means to print the layers so as to form the finish product. Some
techniques liquefy the material or simply soften it to make the layers whereas others uses high powered UV laser to cure photo-
reactive resin and “print” the object.

Some of the 3D printing technologies that are most broadly utilized these days are:

1) Stereolithography (SLA)
2) Fused deposition modelling (FDM)
3) Selective Laser Sintering (SLS)
4) Laminated object manufacturing (LOM)
5) Digital Light Processing (DLP)

As shown in Figure 1, the very first step to 3D print an object is to make a model of the object using CAD software [3]. The model
describes the geometrical properties of the object. The CAD file is then converted to STL file format. This file format defines the
external closed surfaces of the original CAD model. The STL file also includes the data for each single layer and can make

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calculations for the layers. The STL file is sent to the 3D printer and the printer is setup before build process, where settings include
build parameters, like energy source, layer thickness, etc. The part is then printed by an automated process without any supervision.
When printing is done, the printed part is removed and sent for post processing. After that, the object is ready for application.

Figure 1: Process of 3D printing (from design to printing)

Since there are different 3D printing technologies, the type to be used depends mostly on the kind of object to be made. Each of them
has its claimed benefits and downsides. The next section explains each of the different processes in detail and gives examples of
products that can be produced by each of them.

A. Stereolithography
Stereolithography (SLA) is recognized as the original 3D printing process. SLA is used mostly to create models, prototypes and
patterns. Being a laser based process; it uses ultraviolet laser and a vat of resin to build parts. The laser beam marks the design onto
the surface of the liquid polymer. Exposure to the ultraviolet laser causes the chains of atoms in the polymer gum to connect together
[4]. As the photopolymer resins react to the laser, it forms a solid part in a very precise way.

Figure 2: Stereolithography process

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The Figure 2 shows the setup of SLA. The vat contains the polymer with a movable platform within. The laser beam is focused on the
X-Y axis across the top surface of the resin according to the data input in the printer. The resin hardens precisely where the laser hits
the surface. As one layer is finished, the platform in the vat is dropped by a little along the Z-axis and the next layer is then traced over
the previous layer. This process goes on until the entire object is printed and the platform is elevated out of the vat for removal.

Figure 3: Objects produced by SLA

Stereolithography is most commonly used for prototyping as it is less time-consuming and it is relatively cheaper compared to other
prototyping method. Nevertheless, the SLA process requires support structures for some parts mainly for those with overhangs [5].
These structures need to be manually detached during post processing. Post processes also include chemical bath to clean the object
and subjecting the object in an oven-like machine to fully harden the resin.

SLA is one of the most accurate 3D printing processes with excellent surface finish and smoother surface than most other rapid
prototyping methods. Smooth surface implies a great level of detail and the design is very accurate. Moreover parts can be printed in a
very short period of time depending on its size and shape. Figure 3 show some parts printed using SLA. SLA also allows different
options when it comes to material. Although SLA can produce a large variety of shapes, it is often very expensive.

B. Fused Deposition Modelling

Another technique of 3D printing technique is the Fused Deposition Modelling (FDM). This process is also used for making models as
well as prototyping. 3D printers that run on this technology build a part layer by layer, from the bottom to the top by heating and
extruding thermoplastic filament according to the 3D data supplied to the printer [6]. Each layer solidifies as it is put down and it
bonds to the former layer.

Figure 4: Fused deposition process

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FDM also works on the additive principle. The Figure 4 shows how a part can be produced using FDM. The heated extrusion head
extrudes little dots of thermoplastic fabric to shape a layer. It can travel in the horizontal and vertical directions by a numerically
controlled mechanism. The material hardens straightaway after coming out from the spout.

Figure 5: Typical objects printed by FDM

FDM is cheaper than SLA as it uses actual plastic instead of simulating plastic like material by projecting laser on resin. Similar to
SLA, printing parts in FDM requires supports for complex structures. Therefore parts printed by FDM also require some post
processing. But compared to SLA, FDM process is less accurate. The process can also be time consuming for some particular
geometry. Moreover the material used in FDM is limited to thermos plastic. Figure 5 shows objects printed by FDM.

C. Selective Laser Sintering

Another technology used by today’s 3D printer is the Selective Laser Sintering (SLS). During this process, tiny particles of plastic,
ceramics or glass are joined by heat from a high powered laser beam to form a solid.

Figure 6: Basic setup of SLS

As shown in Figure 6, the laser is traced across a powder bed according to the data file. The powder inside the powder bed is tightly
compressed. The laser moves in the X and Y directions. The laser then hits the surface of the powdered material; it sinters the particles
to each other to give form to a solid. When one layer is completed, the powder bed lowers in the Z direction and the levelling drum
(roller) smoothes the powder over the surface of the bed. The laser then continues to trace and form the design required. The process
repeats itself until the whole object is printed. The object is then left to be cooled down.

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The build chamber needs to be completely sealed because it is necessary to maintain the temperature during the process to be the same
as melting point of the powdered material. The powder bed is removed from the machine when the process is completed, and the
excess powder is easily taken out of the printed object. The Figure 7 displays some parts which are 3D printed by SLS.

Figure 7: Parts printed by SLS

One of the major advantages of SLS is that it does not require any structure support for complex parts as needed in both
Stereolithography and Fused Deposition Modelling. Because the part lies on a bed of powdered material, no supports are necessary.
This advantage itself helps save material and reduces production cost. There is also no much need of post processing [7]. Moreover
SLS is capable of printing geometries that cannot be done using other 3D printed method. Using SLS, parts with complex interior
components can also be printed and there is no problem of removing supports and damaging the part. As a result, time is saved on
assembly. Parts printed by SLS are usually very durable and robust. This technology now rivals those produced in traditional methods
like injection moulding and are already used in many end-use application like automotive and aerospace.

Parts produced by SLS can be in different materials such as plastic, glass, and ceramics and with the advance in its technology it can
also print metal. SLS is also widely utilized for printing tailor made products like hearing aids, dental retainers and prosthetics.
Moreover objects printed with SLS don't necessitate any molds or additional tooling making it convenient for any user to print high
complexity parts or particularly delicate object.

D. Laminated Object Manufacturing

In the method of Laminated Object Manufacturing (LOM), sheets of plastic or plastic materials are laminated or fused together by
high temperature and pressure and then shaped to the required form with a computer controlled laser or blade [8].

Figure 8: Laminated Object Manufacturing process

As shown in the Figure 8, LOM 3D printer makes use of a continuous sheet of material which may be plastic or paper. A mechanism
of feed roller spread the material along the build platform. The material is primarily coated with adhesive. When the laminating roller
is heated and passed over the surface of the material, its adhesive melts and the roller press it onto the platform. A computer controlled
laser or blade then cuts the material into the wanted form or pattern. Furthermore the laser removes any excess of material so that it is
easier to remove the object when all the processes are completed.

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After the first layer of the object is formed, the build platform then drops by a small amount. The second layer of material is then
drawn across the platform and the heated roller passes over it, binding it to the one beneath. This procedure is performed repeatedly
until the whole object has been formed. When printing is completed, the object is removed from the build platform. Excess materials
are then cut away [9]. Afterwards some minor post processing is done. This may include sanding, painting or varnish to keep out
moisture.

Figure 9: Prototypes printed by LOM

The cost for LOM is very low and the material is readily available. The printed parts have a similar look and feel of wood and can be
worked with and finished in similar manner. The Figure 9 shows some prototypes that have been printed using LOM technology.
Another advantage of Laminating Object Manufacturing is that it does not involve any chemical process or reaction and no enclosed
chamber is needed. Therefore it makes it easier to build larger models. However this method is not ideal for making objects with
complex geometries or to produce functional prototypes. For these reasons, LOM is only used to make scaled models and conceptual
prototypes that can be tested for design or form.

E. Digital Light Processing

Another technology used by 3D printers is the Digital Light Processing (DLP). DLP is a similar process to Stereolithography. The
main dissimilarity between these two methods is the light source. SLA uses a laser whereas DLP makes use of conventional light
sources to cure photo sensitive polymer resin.

Figure 10 shows the process of DLP. DLP 3D printer prints objects by projecting them onto the surface of the resin. The exposed resin
hardens and meanwhile the machine build platform lowers down to set stage for a new layer of fresh resin to be coated to the object
and cured by light. The process is repeated until the 3D model is completed. Once completed, the model is sent for post processing to
remove extra support structures and chemical bath for surface finish.

Figure 10: DLP Process

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Like Stereolithography, DLP is also produces parts with high accuracy and high resolution. However one advantage that DLP has over
SLA is that it requires a shallow vat of resin to facilitate the process. This generally results in less waste and lower running costs. Also
DLP can be a faster process than SLA as the light source is applied to the whole surface of the vat of polymer resin at a single pass.
DLP based printers makes use of photosensitive resin plastic which is suitable to make non –functional prototypes, highly detailed
artworks, patterns for injection moulding, etc. Parts printed with this method have good strength properties. Figure 11 shows some
prototypes that have been printed using DLP.

Figure 11: Prototypes printed by DLP

However the DLP services can be costly. And also, when the printing is completed, the object requires post processing to remove
unnecessary support structure. Some photopolymer resins can be brittle depending on the object’s design but new improved resins are
on their way to change this.

III. COMPARISON OF 3D PRINTING TECHNOLOGIES

As mentioned in the previous section, not all 3D printers employ the same technique to print objects. While some make use of
thermos-plastic filament, others use conventional light source or laser source to cure molecules in the polymer resin. There are
different filament and resin to be used. Each of these technologies has their benefits and limitations. In this section, a comparison
between these five different 3D printing methods mentioned above is given. The comparison is made upon a number of criteria like
application, overall accuracy, materials options, finishing options and post-processing.

Table I: Comparison of different types of 3D printing technologies

SLA FDM SLS LOM DLP

Ideal for functional

Excellent for form Suitable for prototypes parts with various
Ideal for non-
application
testing functional prototypes
Home use applications
Similar to
Applications Suitable for complex
Best process for SLA
water resistant shape object
material Heat and chemical
resistant

Most accurate Slightly less

Overall printing process Accurate and reliable dimensional accuracy High
not very accurate
Accuracy process Accuracy

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ABS
Paper
Semi-flexible Nylon
Material Thermoplastic Similar to
materials Plastic
Options materials SLA
Glass-Filled Nylon
High temperature Metal
ABs

Wood like Good finish

Excellent surface
Finish Options Standard Finish Standard Finish characteristics and can High
finish
be treated similarly
resolution

Requires post Does not require

Requires post Polishing
Post Processing processing to support structure, less Requires Post
processing to remove
Requirement remove support post processing Painting processing
support structure
structure requires

IV. DISCUSSION AND CONCLUSION

3D printing has revolutionized the way in which manufacturing is done. It improves the design manufacturing and reduces lead time
and tooling cost for new products. As mention in the section above, there are several technologies used by 3D printers to build objects.
The type of technology to be used depends mostly on the object to be manufactured. A comparison was carried out to show which
method is the best fit for a particular job.

Stereolithography is the most popular 3D printing technology. It is widely used nowadays because it provides accuracy along with an
excellent surface finish. It also allows printing of objects using a variety of materials. However it can be expensive and is used mostly
by industries for making of prototypes. Digital Light Processing is quite similar to Stereolithography. The main difference between
these two technologies is their type of light source.

Fused Deposition Modelling is a less expensive process compared to all other 3D printing method. This makes it suitable for home use
application. The level of accuracy and surface finish it provides are worth the manufacturing cost. However, the materials that FDM
supports are limited mostly to thermoplastics.

Selected Laser Sintering is a good choice for building objects with complex shapes and geometries. It does not require additional
support like other 3D printing technologies and does not need much post processing. Nevertheless the final object might not be very
accurate and the surface finish is not so good.

Laminated Object Manufacturing is an ideal choice for non-functional prototype. It does not provide good accuracy level and surface
finish. It also requires much post processing. The material mostly used for this process is paper.

Even though these technologies are different in their own ways, they bring a host of benefits that conventional manufacturing simply
cannot. They can allow customization of products according to the individual needs. They can also build complex products which
cannot be produced physically in any other ways.

ACKNOWLEDGMENT

I’m grateful to my supervisor Mr Xue Jianbin and my senior mate for guiding me throughout the writing of my first paper. I thank the
Nanjing Government for my postgraduate studies scholarship.

REFERENCES

[1] Jabbar Qasim, Alaa Jabbar Qasim, The process and technologies of 3D printing, International Journal of Advances in Computer Science and Technology, Oct 2015.
[2] The free beginner’s guide to 3D printing
[3] C.K. Chua, K.F. Leong, C.S. Lim. Rapid prototyping – principles and applications. World Scientific Publishing, Singapore, 2003

[4] Paulo Jorge Ba´rtolo and Ian Gibson, History of Stereolithographic Processes, Centre for Rapid and Sustainable Product, Polytechnic Institute of Leiria, Leiria,
Portugal

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[5] Ministry of education and employment, Domain Group 3D Printing Workshop Notes, MALTA 2007-2013

[6] Ludmila Novakova-Marcincinova, Ivan Kuric, Basic and Advanced Materials for Fused Deposition Modeling Rapid Prototyping Technology, Manuf. and Ind. Eng.,
11(1), 2012, ISSN 1338-6549

[7] Sabina Luisa Campanelli, Nicola Contuzzi, Andrea Angelastro and Antonio Domenico Ludovico (2010).Capabilities and Performances of the Selective Laser
Melting Process, New Trends in Technologies: Devices, Computer, Communication and Industrial Systems, Meng Joo Er (Ed.), ISBN: 978-953-307-212-8, InTech

[8] Gary Kalmanovich, "Curved-Layer" Laminated Object Manufacturing, HelisysTM Inc.

[9] Fazil O. Sonmez, H. Thomas Hahn- Thermomechanical analysis of the laminated object manufacturing, Rapid Prototyping Journal Volume 4 · Number 1 · 1998 ·
26–36

AUTHORS

First Author – Shiwpursad Jasveer is an international postgraduate student in Nanjing University of Aeronautics and Astronautics.
His current research interests are 3D printing and smart manufacturing. E-mail: [email protected]
Corresponding Author – Jianbin Xue is an associate professor at the college of Mechanical and Electrical engineering in Nanjing
University of Aeronautics and Astronautics. His research interests include Mechatronics, CAD/CAPP/CAM and intelligent
manufacturing. E-mail: [email protected]

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