Witnessing first-hand the transformative benefits of utilising rapid prototyping in our design process. The ability to seamlessly go from digital design to physical model in a matter of hours has revolutionised our workflow, allowing us to quickly iterate and refine our concepts.
One of the most underappreciated aspects of 3D printing is the wide and ever-evolving array of printing techniques available. Navigating these diverse technologies and understanding their respective advantages, limitations and ideal applications can be a daunting task. However, with extensive experience in this field, we have developed a deep understanding of the nuances between the various 3D printing methods.
Over the past 25 years, we have extensively used, tested and developed an abundance of prototypes and products using 3D printing, exploring a multitude of printing techniques and materials. This wealth of hands-on experience has equipped us with invaluable insights, allowing us to provide a concise yet comprehensive guide to the most common and impactful 3D printing methods.
A 3D printer essentially translates 3D digital data, typically generated in CAD software or 3D modeling programs, into a physical, three-dimensional object. The printer software achieves this by first ‘slicing’ the 3D model into thin, successive layers. It then builds the physical model layer-by-layer by printing each slice one on top of another.
There are four primary types of 3D printing technologies. Each has its unique advantages and disadvantages, making them suitable for specific applications.
FDM uses a heated nozzle to extrude plastic filament layer by layer.
SLA uses a laser to cure a liquid resin layer by layer.
SLS uses a laser to fuse powdered material layer by layer
How it works: DLP uses a projector to project patterns onto a vat of resin, curing the resin one layer at a time
Testing internal fittings of white water kayaks in some of the toughest white water in the world. Using SLS 3D printed parts for key internal kayak outfitting components, we pushed the robustness of the material to the absolute limit. By subjecting these critical parts to the extreme forces and turbulence of one of the world’s largest volume rivers – the White Nile – we were able to conclusively prove the design and performance of our innovative kayak fittings.
Making photorealistic models for marketing material. Relying on the precision print quality and superb finish of SLS printing, we produced fully functional prototypes that were indistinguishable from the final production parts. These high-fidelity models became invaluable for our marketing efforts, allowing us to showcase our groundbreaking kayak designs long before the actual tooling and manufacturing was completed. The photorealistic quality of these 3D printed models ensured our customers and partners could visualise the end product in vivid detail, driving pre-sales and generating unparalleled excitement for the launch.
Making Jigs for production tooling. By utilising three-dimensional dovetail joints, we were able to split large 3D models into printable sections of manageable size. Leveraging the speed and economy of FDM printing, we were then able to quickly fabricate these intricate jigs and test our tooling theories in a fraction of the time and cost of traditional methods. This agile approach to prototyping allowed us to iterate and refine the production process, ensuring a seamless transition to full-scale manufacturing.
