Ultimaker white paper

Getting started with office 3D printing

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Getting started with office 3D printing

Table of contents

1. Introduction 3

2. Workflow and integration 5

3. Setup and staffing 10

4. Operating 3D printers in the office 12

5. Conclusion 15

1. Introduction

This white paper is designed to support businesses that are considering the potential of 3D printing as an in-house tool. The aim is to highlight how and why 3D printing can be more widely adopted in-house to enable improved product development cycles and reduced cost through more agile design and prototyping operations. This is not necessarily as intimidating, or as cost-intensive, as might be imagined and this white paper will illustrate how to leverage these opportunities and provide insight into how this can realistically be achieved.

The key opportunities that bringing a desktop 3D printer in-house offers include:

• Faster prototyping cycles• Less interruption to the design process, not broken by long part lead times

outsourced to a third party• The ability to carry out and evaluate more design iterations leading to a

higher quality final product• Fast ROI and cost savings for the business compared with outsourcing

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Taking control in-houseBringing the FFF 3D printing process in-house with a desktop 3D printer has proved itself an effective way of optimizing the product development workflow in terms of lead times, improved product quality, and those all-important costs.

Many companies have already made the transition across a broad spectrum of industrial sectors, including the aerospace, automotive, industrial design, engineering, architecture, medical, and product design fields. Desktop FFF 3D printers make rapid prototyping truly rapid, with faster turnaround times, increased numbers of product iterations to check and test form and function, and reduced overall delivery lead times. Today’s highly capable desktop FFF

platforms can also add value for applications beyond prototyping, such as molds, tooling and one-off and low volume end use parts, such as customized jigs and fixtures.

These benefits are universally recognized today, however, for many companies the transition to bring 3D printing in-house with the necessary workflow integration is daunting. This white paper aims to overcome the issues that contribute to this.

3D printing technologyThe manufacturing sector is currently experiencing significant disruption as advanced technologies, including 3D printing, become more deeply embedded across a variety of industries. Disruption, by its very nature, can be unsettling and uncomfortable for individual organizations, but being hesitant when embracing disruptive new technology can limit long term success. As ‘Industry 4.0’ takes hold across the world and digitalization becomes prevalent, an agile approach to product development and manufacturing is fundamental – and one key enabler of agility is bringing 3D printing in-house.

3D printing technology has existed for more than three decades, with a notable surge in awareness, accessibility, and adoption in the early 2010s when 3D printing was widely featured in the media. Today 3D printing has evolved into an industry in its own right – a sub-sector of the $12 trillion global manufacturing industry. The 3D printing industry has also experienced a great deal of diversification. There are many different

3D printing process classifications, each with advantages and disadvantages depending on their application.

The fused filament fabrication (FFF) process is the most widely adopted 3D printing process in the world today. The process involves plastic material (typically in filament form) being fed through a heated nozzle or extruder, which can then be deposited in thin layers to form a part. Single or multiple extruders can be used, and these are controlled horizontally, to deposit layers on the build platform, which has automated vertical controls, and moves after each layer is completed.

Advantages of the FFF process are many and varied, including the easy availability of commonly used plastic materials, such as ABS which exhibits good structural properties, and PLA which is very easy to print in any conditions. These materials are inexpensive and ideal for producing prototypes for testing multiple iterations of a product without breaking the bank.

1.Gatherrequirements

2.InitialDesign

3.Productprototype

4.Testprototype

5.Finalproductionrun

Yes

Does it meetyour needs?

No

A typical product development process

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2. Workflow and integration

There is no doubt that, perceived or real, barriers to adoption exist for many companies when it comes to bringing 3D printing in-house. The first one that must be broken down and overcome is not a practical one, but rather the cultural attitudes and misconceptions within an organization that may exist around 3D printing.

This can be caused by fear of change and disruption, but standing still is no longer an option, and remaining competitive in a digital world is essential. There are a variety of considerations that might make a transition of this nature seem daunting – the design software, compatibility issues, materials, the machines themselves, as well as practicalities such as space allocation, staff training, and safety. However, when companies take the time to break these down and address them individually, often the ‘problems’ can become opportunities.

Integrating 3D printing into an existing work environment will require internal communication and collaboration. Management needs to figuratively buy in to the benefits it will bring, as well as literally buy in the hardware and supporting tools and training required. Preparation and understanding are the key here. It is highly unlikely that any organization involved in product development today is completely unfamiliar with the concept of 3D printing – but doing it in-house may be resisted by some. It is a transition that is much easier to make today, and should not be feared.

A typical product development process

Time and money will need to be invested to bring 3D printing in-house, but the rewards can be huge – in real numbers that affect a company’s bottom line positively. This chapter aims to demonstrate how this is possible by overcoming the perceived barriers, and highlighting the positive effect in-house 3D printing can have on a typical product development workflow.

In-house 3D printing does not necessarily change any part of this workflow (although it can, in certain cases, negate the need for tooling). Instead it makes it more efficient, can significantly reduce the costs and time involved, and ultimately results in higher quality products by enabling more design iterations.

Cost per part

$3

$41

$115

In-houseFFF

OutsourcedFFF

OutsourcedSLS

Project lead time

In-houseFFF

OutsourcedFFF

9 hours

6 days

7 days

OutsourcedSLS

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In-house or outsource?

Any business that develops physical products will require prototypes at certain points in the design cycle. Doing this requires in-house facilities or outsourcing all prototypes to suppliers. Outsourcing prototyping needs (whether using additive processes or conventional techniques) adds significant costs and lead times to product development cycles and can constrain the entire workflow. This is where the transition to in-house desktop FFF 3D printing can deliver real value.

Typical examples based on averages for a 60 cm3 prototype. In-house costs exclude labor, hardware, and other overheads, which vary depending on circumstances.

The cost reduction per part is easily demonstrable, plus the time savings that can be achieved through faster iterations bring comprehensive benefits to organizations that have brought 3D printing in-house. It is this combination of time and cost savings that can bring competitive advantages by streamlining in-house processes in a way that results in better products, which reach their intended market faster.

At the concept development stage of any new product, any competent designer understands the value of holding a physical representation of their design in their hands. For consumer products, interacting with that product physically is essential and getting market feedback even more so. Similarly, with industrial products and components, the need to assess form, fit and function is also vital.

Early prototypes help designers to quickly and more easily identify issues with a design, and correct them. The more iterations of a prototype go through physical interaction, with more feedback, the more successful the design – and, notably, the design for manufacture.

Any company that outsources the production of prototypes is at the mercy of the terms and conditions of its service provider in terms of lead times, availability, delivery, and shipping. Today, most 3D printing service providers offer a number of options and it is possible to pay a premium for faster delivery. However, clients are usually looking at an absolute minimum of one day, which can get very expensive, with the average being three to seven days for a more economical option and for more complex parts this can extend to weeks.

Prioritize iterations ‘Best of both’ Prioritize speed

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Define requirements

Concept prototyping

Functional prototyping

Production

Define requirements

Concept prototyping

Functional prototyping

Production

Define requirements

Concept prototyping

Functional prototyping

Production

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Tim

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Costs aside, in terms of time there is only a finite number of iterations possible when outsourcing, particularly if companies are working to a deadline within a supply chain.

For every part, you also need to go through the hassle of finding a supplier, sharing design files, and then invoice.

This is where an in-house 3D printer comes into its own – by providing a much more flexible approach and enabling a more iterative design process.

A desktop FFF printer in the same office or even building allows for the production of multiple iterations of a new product early on in the development process because the lead time for the first prototype can literally be reduced from

a week down to hours – the same day as the design is finalized. In real terms this means that a designer or engineering team can develop a more seamless process, where design timelines are in their control, not dictated by a third-party supplier.

During a typical design process, it is not as if everything comes to a standstill while waiting for the part fulfilment. Development will continue and features are often changed, which is problematic in that it can make the prototype redundant even before the designers and engineers have it back in their hands. In-house FFF 3D printing avoids this, making it possible to quickly and easily 3D print cheaper prototypes in just a few hours. So decisions can be made more quickly and based on more accurate prototypes and data.

With lead times for a part reduced from days to hours, a designer has more options:• Reduce overall product development lead times to get a product to market faster, with more

feedback, ahead of competitors, and achieve greater market share• The ability to undertake many more iterations within an equal product development cycle time to

achieve a better, more thoroughly tested, higher-quality final product• Or, a ‘best of both worlds’ scenario, that achieves a simultaneous decrease in development time

and an increase in the number of design iterations

FFF 3D printing is a fast and, with the right 3D printer, user-friendly process that can produce reliable and valuable early prototypes. However, the process does have its limitations and therefore does not negate alternative processes depending on the demands of the project.

In reality, it may still make sense to outsource if alternative 3D printing processes are more suitable for a specific application. This could be because you need a large production run, you need a part with strength not possible using FFF, or you require an especially smooth surface finish.

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Design and software

Product design, whether for an industrial or consumer market, is a discipline that demands a varied skill set. Designing in 3D modeling software is now widespread and a prerequisite for making the most of 3D printing. There are countless 3D modeling software options available to designers, including the most popular professional suites such as SolidWorks, Siemens NX, Inventor, Fusion 360, and AutoCAD, as well as freely available, tool-rich options such as Blender and SketchUp.

Much like 3D printing processes, each software suite has its own advantages and disadvantages, so it is not uncommon for designers to use multiple design software options, particularly as interoperability has become less of an issue. Today, most 3D modeling software is compatible with industry standard 3D printing file types, such as STL, 3MF, and OBJ files, which in turn are

compatible with 3D printer software, such as Ultimaker Cura. Ultimaker have even developed plugins for specific 3D modeling suites (such as SolidWorks and Siemens NX) that enable direct 3D printing from CAD software, as well as direct integration built in to Autodesk Fusion 360 and HP’s 3D scanning software. This hugely simplifies the software integration process and workflow.

Preparing a digital model for 3D printing does demand a new way of thinking about design compared with traditional design practices – such as making sure your design files are a suitable resolution – but it is not difficult to integrate into existing software workflows, and training and external support is readily available. For example, you can find manuals and video tutorials for Ultimaker Cura on the Ultimaker website.

Materials

When adopting FFF 3D printing into an in-house workflow, the material options can be a barrier to adoption due to the perception that choice is limited.

But this is far from the case, particularly when prototyping is the dominant application, because today there are a wide range of cost-effective filament options for 3D printing that can replicate the properties of the final parts. Indeed, today’s 3D printing filament materials are so advanced that they are being utilized for tooling and final production applications. The diverse range of materials available, including all of the most common types of

thermoplastics, and some advanced composite materials, should never be a barrier to adoption for prototyping.

For general concept prototyping applications, the most common material is PLA, which has proved to be ideal for producing fast and reliable prototypes safely. This material is ideal for quick, basic form and fit testing. With a dual-extrusion 3D printer, such as the Ultimaker 3 or Ultimaker S 5, it can be used with PVA water-soluble support material to produce geometrically complex parts easily and with minimal post processing.

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A print before and after PVA support material is removed

However, for more highly functional mechanical prototyping there are industrial grade material options, including ABS, nylon, polycarbonate, copolyester, polypropylene, and polyurethane. This provides a wide scope when prototyping applications which demand specific material properties such as chemical resistance, durability, dimensional stability, impact resistance, flexibility, or heat resistance.

For every designer, materials are fundamental to the design and its performance. Working with these materials directly, using in-house 3D printing, does not have to be a complicated transition as today there are a range of tools available to help, including Ultimaker Cura preconfigured 3D printing profiles that have been developed and tested by experts to ensure the best results with a specific material.

Some properties of your model can even be tuned when using 3D printing software like Ultimaker Cura, for example choosing less infill in your model for greater flexibility, or increasing it for a more robust part. A dual-extrusion 3D printer also gives the option of material combinations for even more possible properties.

Despite giving choice and quality close to industrial-standard manufacturing, desktop 3D printing doesn’t have to be complex. A good way to ensure you have a smooth introduction to 3D printing is to make sure your printer has an open filament system – which means you can use any supplier’s material filaments.

This not only prevents you from becoming locked in to a closed system, but also enables a greater choice of materials to suit your needs. Instead of being limited to what your 3D printer manufacturer offers, you can use filaments from specialist material suppliers, including composite materials, with a huge variety of mechanical and aesthetic properties.

Another way to ensure great results with minimal effort is by taking advantage of any preconfigured printing profiles in 3D printing software. In Ultimaker Cura, all of the 3D printing parameters for a specific material are preconfigured to the Ultimaker material profile. This simplifies the process greatly, eliminating the need to directly input parameters, speeds up the process dramatically and provides the best print results. But Ultimaker 3D printers also have an open filament system, so they can be used with other manufacturers’ materials.

Chapter summary• Analyze which outsourced orders you can replace with in-house 3D printing• Choose compatible CAD software and train staff to design for FFF 3D printing• Decide which materials you will use and understand their mechanical and printing properties

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3. Setup and staffingIn this section, we’ll look at some of the organizational considerations to think about when making the transition to in-house FFF 3D printing. Important issues include personnel requirements, in terms of both training of existing staff and further recruitment to bring in specific skills, as well as establishing buy-in across the organization. Another subject to fully understand – and disseminate companywide – is the ecosystem around your 3D printer, which comprises software, hardware, materials, and benefits. A 3D printer is not much use on its own! All parts of the process should fit together efficiently to maximize its potential. The logistics of a new in-house 3D printing setup is also important and will be covered here.

Personnel and resourcesDesigners and engineers will be familiar with designing for manufacturability (DfM); for conventional manufacturing this has traditionally involved rules for assembly, most notably for complex products or parts. 3D printing enables a different approach – one that frees designers from many traditional design constraints. However, this different approach demands a learning curve when it comes to designing for additive manufacturing (DfAM).

Training existing in-house designers and engineers on FFF 3D printing technology can be achieved via a wide range of options available from vendors, resellers and independent third

parties. Training in this area will build on their existing skill set and if proposed in the right way should prove to be an exciting and new opportunity.

One approach that some companies follow when setting up an in-house 3D printing initiative is to establish a ‘taskforce’, which brings together a team of 3D printing talent (through training or by finding staff with existing skills) that can then advocate and disseminate the advantages of the technology throughout various other teams in the organization.

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LogisticsWhen bringing 3D printing in-house, it is important to consider the physical work environment and how you will operate the printers. Some systems are more office friendly than others. Desktop 3D printers, by their very nature are generally considered clean and safe for an office environment, and are quiet enough to work alongside designers.

However, if one 3D printer is serving multiple designers or teams, or multiple 3D printers are considered necessary to service the entire operation effectively, the better option might be to establish a central area for 3D printing which gives easy access to different departments. Alternatively, it could be better to install the 3D printer or printers near to other key equipment in the workspace.

While noise is generally not a big issue for single 3D printer installations, if multiple 3D printers are installed, it can be preferable that they are together in a separate area to reduce the effect of the overall noise.

Other practical considerations include ventilation – but this is really only an issue for specific materials (such as ABS) where the fumes produced, while not dangerous, can be unpleasant without suitable mitigating measures. Ultimaker provides guidance in each material safety data sheet.

There is no right or wrong answer when it comes to placement of 3D printers in the office. Finding the best location within the space you have and making it work for all employees comes down to prioritizing who will be using it the most and the space available.

Chapter summary• Ask your seller about training when buying 3D printers• Consider setting up a taskforce team to pioneer 3D printing• Analyze available office space and where you will place 3D printers

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4. Operating 3D printers in the officeSo far, this white paper has considered all of the issues around the decision-making process and installation. But what can you expect once the 3D printers are up and running? If you have made the right personnel and training decisions, these practical operational issues should fall into place, but will need attention. For example, managing the use of the printers, planned maintenance, and support with any issues that may arise with 3D printers.

Networking and security

Single 3D printer for multiple users.

It is not uncommon for a company embracing FFF 3D printing in-house for the first time to test the water with a single 3D printer, which will be utilized by multiple users across the organization. It is a sensible approach that initially minimizes capital expense while allowing the company to analyze how the technology is received and used, and monitor cost and time savings. However, it is also not uncommon for a single 3D printer in an environment like this to quickly exceed expectations and be in demand. This then poses the problem of who gets priority on print jobs. Of course, at this point it might be time to consider investing in a multiple 3D printer set-up.

Multiple 3D printers for multiple users.

A cost analysis report for desktop FFF 3D printing might demonstrate that multiple 3D printers would benefit a multi-disciplined organization. This can take the form of one unit on each designer’s desk, or, to support simpler logistics, centrally locating the units in a dedicated space.

Whichever setup an organization opts for, users must establish their preferred workable system with the 3D printers – either via USB, SD Cards, or a network – to coordinate print job management.

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There are multiple approaches that can be taken in this regard and the decision on the best approach for an individual organization will lie directly with the company. The primary choice is essentially between connectivity and security priorities. For multiple users of a single 3D printer or multiple users of multiple 3D printers it is fairly straightforward to set up a connected network using readily available tools. One such tool is Ultimaker’s Cura Connect, which allows multiple users to send print jobs to one or more printers via Wi-Fi.

This connectivity has significant workflow advantage in terms of accessibility and coordination between project stakeholders.

The core feature of Cura Connect is the ability to group multiple printers together. This enables a continuous production workflow, as jobs are automatically scheduled and delegated to printers without the need to keep going to the printer to start each print job.

In terms of the security of such networks, Cura Connect can be made as secure as the network it runs on, so if it is a closed network with password protection it should meet company security standards. However, for organizations that have particularly strict security policies and prohibit internal and external networks around IP issues, alternative measures can be used, such as USB sticks or SD cards.

Practical operationsLike any other type of hardware, 3D printers need to be routinely maintained and cleaned to ensure optimum performance and long lifespan. While none of the components should be overlooked, perhaps the most vital component for FFF 3D printers in this respect is the extruder. The extruder nozzle (or nozzles on dual models) is critical to the smooth operation and output of the 3D printer. If not regularly monitored and cleaned, this is the component that can cause the most issues if it becomes blocked or is operating too close to the print bed.

Another really important component that can affect output is the build plate itself – regular cleaning of the plate is essential for the highest quality prints, otherwise you will not be printing onto a flat surface. Periodic calibration of the build plate will ensure consistently accurate

and reliable prints. For extra ease of use, choose a 3D printer with automatic or ‘active’ bed leveling which scans the build plate and compensates for any natural, tiny variations in the build plate surface.

Any staff training on the use of the 3D printers should always include these day-to-day practical issues, however, key maintenance instructions can be posted near any or all of the 3D printers themselves as a daily reminder. As with any machinery, taking care of maintenance and routine cleaning will reduce issues and downtime. Most 3D printer vendors today will also supply a dedicated resource base aimed at maintenance and troubleshooting. Check that the manufacturer or vendor offers lifetime, fast-response support, as well as a warranty and spare parts.

Additional toolsTo get the best from any desktop FFF 3D printer, there are a number of tools that will help ensure smooth operations and minimize post-processing of parts. The following is an advisory list that will serve an in-house 3D printing set up well:

Spatula or palette knife

On occasion, you might find that your 3D print has stuck a bit too well to your build plate, or wish to remove a part quickly before the plate has cooled. When this happens, a spatula or palette knife normally solves the problem by gently easing under the print and carefully lifting it up.

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Deburring tool, knife, or cutting pliers and cutting mat

A deburring tool is great for cleaning up modeled holes, and for removing small pieces of plastic from your printed parts to make the end result look smoother and cleaner. A knife and cutting pliers will help you remove support structures.

Adhesion sheets

Adhesion sheets are compatible with most materials, and boost adhesion to the build plate, which is an important preparation step. They are easy to remove and can be used multiple times. Another advantage is that they are specially developed to cope with high temperatures. However, it’s important to check that the sheet is applied correctly, as any air bubbles will mean you won’t have a flat printing surface.

Glue stick

Covering the build plate with soluble glue can really improve adhesion for some materials with minimal effort or investment. (Always check the manufacturer’s material advice.)

Screwdrivers and hex key screwdrivers

These are useful for periodically re-tightening the gantry screws and the stepper motors of your 3D printer. Hex nuts and bolts are widely used in 3D printer assembly, so it is also a wise idea to have a set of hex key screwdrivers and wrenches.

Tweezers

Tweezers are useful to have to hand for desktop 3D printing. They are great for plucking any oozing filament from the extruder nozzle before it starts printing and are also handy for cleaning up parts, post printing.

Oil and grease

Sometimes, you’ll need to lubricate the X and Y axles of your 3D printer, just to ensure they keep running smoothly. Usually all it takes is a single drop of oil to resolve any issues with dryness. For the Z trapezoidal lead screw, grease can be a better option. Ultimaker 3D printers include both. It is important not to use spray can lubricants, as this affects the axle coating and can cause damage to your printer.

Digital caliper

A digital caliper has many applications in 3D printing, including checking the precision of your prints, and you can also use it to dimension parts to replicate in CAD software.

Check if your manufacturer or vendor offers a starter kit or add-on pack, as well as what comes in the box of your 3D printer.

Chapter summary• Create a maintenance schedule and train operators to perform required tasks• Ensure your 3D printer comes with lifetime support• Make sure your 3D printing workspace has all the tools you need

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5. ConclusionAny company that is considering bringing desktop FFF 3D printers in-house should first be well equipped with the necessary information and tools.

While 3D printing enthusiasts will tell you that ‘the possibilities are endless’, they can also seem overwhelming. This is why a pragmatic approach is required when investing in 3D printing technology – one that is based in reality, based on identifying key time and cost saving opportunities. Essentially the mindset

and culture of the entire organization has to buy in to this, and leadership needs to be shown by the staff who will be using the 3D printers the most.

The measurable advantages of bringing desktop FFF 3D printing in-house have been outlined here in terms of improving product quality and getting it to market faster. However, over time, less measurable advantages also become more clear within a company as creativity is fueled and innovation increases.

Explore more 3D printing knowledgeLearn more 3D printing skills and discover how it can drive your business. Read more guides, white papers, and business cases at ultimaker.com/knowledge

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About Ultimaker

Ultimaker has been in operation since 2011, and over the years has grown to become a market-leader; creating powerful, professional, and accessible desktop 3D printers with offices in the Netherlands, New York, Boston, and Singapore plus production facilities in Europe and the US. Ultimaker’s team of over 300 employees continually strives to offer the highest-quality 3D printers, software, and materials on the market to accelerate the world’s transition to local digital manufacturing.

General inquiries: info@ultimaker.comFind a local reseller: ultimaker.com/en/resellers