EXPLORING UNLIMITED POSSIBILITIES IN … of today, more 3D printing technologies have been developed...

Hong Kong Head Office 香港總公司China Offices 中國辦事處Dongguan 東莞 Chongqing 重慶 Guangzhou 廣州 Shanghai 上海Tianjin 天津 Changchun 長春 Qingdao 青島 Wuhan 武漢

Milton Plastics Ltd 萬通塑料有限公司

TECHNICAL HANDBOOKPRINTING

EXPLORING UNLIMITED POSSIBILITIES IN PRINTING

三維打印技術手冊

探索打印無限可能

3D

3D

萬通集團成員

Hong Kong Head Office 香港總公司China Offices 中國辦事處Dongguan 東莞

Chongqing 重慶 Guangzhou 廣州 Shanghai 上海 Tianjin 天津

Changchun 長春 Qingdao 青島 Wuhan 武漢

Milton Plastics Ltd 萬通塑料有限公司TECHNICAL HANDBOOK

PLASTICS INDUSTRY

PRINTING

FDM


三維打印技術手冊塑料行业


3D

3D

DLP/SLA

SLS

三維打印技術手冊塑

料行業

3D PRIN

TING

TECHN

ICAL HAN

DBOOK PLASTICS IN

DUSTRY

3D PRINTING TECHNICAL HANDBOOKPLASTICS INDUSTRY

EditorTechnical Services Department

Published byMilton Plastics Ltd

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the publisher.

三維打印技術手冊塑料行業

編者技術服務部

出版發行萬通塑料有限公司

本書由萬通塑料有限公司獨家出版。未經出版者許可，任何單位和個人均不得以任何形式複製或傳播本書的部分或全部內容。版權所有，翻印必究。

MILTON PLASTICS LTD

02

About Milton

Established in 1990 in Hong Kong, Milton Plastics Ltd (“Milton”) is a leading solutions provider in plastics industry.

We offer broad portfolio of plastics materials with strong distribution network covers Hong Kong, Dongguan,

Guangzhou, Shanghai, Tianjin, Qingdao, Wuhan and Chongqing.

Milton has extensive network with international renowned plastics material producers including KRAIBURG TPE,

Covestro, Lanxess, Celanese, and INEOS Styrolution. One of the key milestones was the successful partnership with

KRAIBURG TPE GmbH, a leading thermoplastic elastomers producer in Germany and the major supplier in Europe

market. Our partnership is built upon our trust and long lasting relationship since 1997, we have a joint venture to

set up KRAIBURG TPE China Company Ltd in 2004 to further strengthen our relationship and the development in

China.

Quality and diversity are the cornerstones of our success and essential for sustainability. We serve the key market

segments as follows:

Automotive

Consumer goods

Electronics and electrical

Information and communications technology

Medical

Our experienced technical specialists are dedicated to project management, offer solutions from material selection to

mold and product design, from 3D printing to processing technology, as well as after sales service to meet the

evolving needs of customers. We provide holistic, flexible and reliable supply chain management to ensure on-time

delivery to meet the keen manufacturing requirement.

In order to expand the domestic market and fulfill various customers’ needs, we have established Hong Kong Plastics

(Dongguan) Ltd and Hong Kong Plastics (Shanghai) Ltd to support VAT and foreign currency invoicing. This is another

milestones of the group continues to drive the way we support our customers. As one of the leading solutions

provider in plastics industry, Milton has been committing to provide professional technical services and quality

products. Milton is your reliable partner.

Milton’s success has been built on continuous learning, effective business model and strategies. We will further

expand our range of products and services to meet the evolving customers’ need. We also strive for excellence to

enhance our knowledge, networks and services to keep ahead in the plastics industry.

萬通塑料有限公司

03

公司簡介

萬通塑料有限公司（「萬通」）於1990年在香港成立，我們致力為塑料行業提供全方位解決方案，為客戶提

供廣泛的塑料及多元化的服務。我們的總部位於香港，銷售網絡覆蓋中國多個主要城市，包括東莞、廣

州、上海、天津、青島、長春、武漢和重慶。

我們與多個國際知名的塑料生產商，如凱柏膠寶、科思創、朗盛、塞拉尼斯和英力士苯領等保持密切合作

關係，當中，我們與凱柏膠寶的伙伴關係尤其緊密。凱柏膠寶是德國的熱塑性彈性體生產商，並且是歐洲

各地區的主要供應商，我們自1997年已建立伙伴關係。隨着雙方之間的互惠、互信關係漸趨成熟，為了進

一步鞏固業務發展，我們於2004年在香港成立了凱柏膠寶中國有限公司，奠定萬通與凱柏膠寶緊密合作

的伙伴關係。

多元化的塑料種類和專業服務是我們成功和可持續發展的關鍵，尤其針對以下行業：

電子零件及電器

汽車

資訊及通訊科技

醫療

優質消費品

除了為客戶提供切合產品需要的原料外，我們的技術顧問亦專注於項目開發，由最初的原料選擇、制模和

產品設計、3維打印、加工技術以至售後服務各個階段，提供綜合性的咨詢及技術支援服務，讓客戶在設

計及生產過程中，更能得心應手。

為積極拓展中國內銷業務，配合客戶於國內報關與稅制的需要，我們分別成立東莞港塑塑料有限公司和

港塑塑料貿易（上海）有限公司，為客戶提供靈活的平台，可以支持美金及人民幣交易，並提供增值稅發

票。我們在國內各省市擁有完善的運輸及倉庫和網絡，提供穩定可靠的物流服務，務求讓客戶以最快捷、

可靠的方式獲取貨物，讓他們能更有效控制生產進度和成本。我們不僅努力成為專業可靠的塑料分銷商，

更憑藉我們專業技術和優質服務贏得客戶的信任與支持，成為並肩共進的供應商和合作伙伴。

然而，我們並不會因現有的成功而自滿，我們會精益求精，通過持續的學習、敏銳的觸角及靈活的策略，

一方面加強員工的技術、經驗及專業知識，另一方面迎合客戶的不同需要。我們更會積極開拓產品和服務

範疇，以及通過我們的業務網絡，緊隨市場的變化而不斷蛻變求新。事實上，無論是管理層或僱員，我們

都一直堅持不斷學習— 這正是我們今日得以在業界佔據領先地位的原因，也是我們將來能繼續保持領先

之道。

PREFACE

04

“Places like this are who we are. We create. We innovate. We build. We do it together”, remarked the then U.S.

President Obama in January of 2015 during a routine visit to manufacturing plants in Tennesse. Yet, the car that

Obama stood beside at the time was anything but ordinary. In fact, it was a full-scale replica of a Shelby Cobra, the

legendary sports car, that had been 3D printed in a mere six weeks. This momentous exhibition was both intentional

and deeply symbolic. The impressive manufacturing feat not only promoted the domestic manufacturing industry in

the U.S. but also exemplifies the unmistakable shift in the landscape of global manufacturing driven by technological

advancement. This printed supercar, in particular, epitomizes the sweeping adoption of 3D printing technology,

including with state-of-the-art composite materials and to help reduce the weight by half and enhance the car

performance and safety.

I was galvanized by this compelling display, and I noticed similar trends emerging elsewhere. The German

government, for instance, has recently scaled efforts to promote an “Industry 4.0”, in which 3D printing plays an

increasingly pivotal role. Consequently, in 2016, I began to plan an introduction of 3D printing technology to the

plastics manufacturing industries of Hong Kong and Mainland China. In the time that followed, we have collaborated

closely with various renowned and established brands, both domestic and overseas, to keep abreast of the latest 3D

printing technology. Through seminars and lectures, our understanding of this specialty matured as we engaged in

discourse with students of tertiary educational institutions as well as stakeholders in the plastics industry. One of the

products of this growth has been the “3D Printing Technical Handbook”, which the Technical Services Department of

Milton has compiled to empower product designers and engineers in the plastics industry with more expertise on 3D

printing technology.

Source: President Barack Obama and Vice President Joe Biden view a 3D-printed carbon fiber Shelby Cobra car during a tour of Techmer PM in Clinton, Tenn., Jan. 9, 2015. (Official White House Photo by Pete Souza)

PREFACE

05

Yet, 3D printing is not completely new. Its meteoric rise can be

traced back to 1860 when French artist François Willème used

photosculpture to surround the subject with cameras and

capture a 3-dimensional perspective, which inspired the earliest

3D prints. In 1981, Hideo Kodama, a scientist of Nagoya

Municipal Industrial Research Institute in Japan, then invented

two additive manufacturing fabricating methods of a 3D plastic

model with a photo-hardening polymer. Not long later, in 1984,

3D Systems, Inc. of the U.S. invented stereolithography (SLA) to

print a 3-dimensional object by linking each part of the target

object, thus allowing a leap in the development of 3D printing.

As of today, more 3D printing technologies have been developed for plastics, such as FDM, SLS, SLA, and DLP.

Furthermore, the typical plastic materials for 3D printing has continued to expand from ABS plastics to various

engineering plastics, as well as from hard-plastics to soft Thermoplastic Elastomers (TPE). Looking ahead, I believe

that 3D printing will definitely serve to increase efficiency and reduce costs of the plastic industry, especially as a vital

tool for rapid prototype testing and project development.

Over the past 27 years, Milton Plastics has strived to be a leading supplier of engineering plastics material and

specialty polymers in China, which has evolved into strong business presences in key regions throughout the country.

Milton’s achievements are unequivocally rooted in its creativity, curiosity, and team spirit. Over the years, Milton’s

technical support and project development team have given a powerful impetus to the product research and

development of automotive, medical, information and communication technology brands. As we continue to innovate,

we are the first engineering plastics material supplier with 3D plastic printing services to be supported by the

Dedicated Fund on Branding, Upgrading and Domestic Sales (BUD Fund). This fund and support are provided by the

Trade and Industry Department of the HKSAR, which underscores Milton’s pioneering work in the plastic material

supply sector. Moving ahead, Milton will continue to explore and develop advanced technologies and solutions that

can benefit the plastics industry. We aim to do so by maintaining a passion for innovation and curiosity and seek to

share the success with our working partners.

Mr. Bobby Liu

CEO

November 2017

序言

06

“Places like this are who we are. We create. We innovate. We build. We do it together”（我們就是在這地方，我們創

造。我們創新。我們建立。我們一起完成），在2015年1月，時任美國總統奧巴馬和副總統拜登帶領大批

傳媒到位於田納西州參觀一所工廠使用3維打印技術，用6位技術人員花了6週完整複製的一台傳奇跑車

Shelby Cobra，奧巴馬總統在跑車傍說了這些話。這刻意的安排除了推動美國本土製造業最重要的是向世

界證明製造業因科技發展而正在發生重大變化。這台超跑的精彩之處是採用了先進複合材料的3維打印技

術，使其車身重量削減了一半，同時汽車性能和安全性也有所提高。

這事情深深的影響著我，加上德國近年大力推動工業4.0中，3維打印更是扮演重要角色。因此我自2016

年開始構思如何將3維打印技術引進到香港和大陸地區的塑膠製造業，至今年與國內外著名品牌合作體驗

3維打印的最新技術，並舉辦一連串的研討會和講座，與大專院校學生和塑膠業界的持分者進行交流，為

使塑膠業界產品設計師和工程師對3維打印技術更了解更由萬通技術服務部編製「三維打印技術手冊」。

資料來源：美國總統奧巴馬 (Barack Obama)和副總統拜登 (Joe Biden)於2015年1月9日在田納西州克林頓市的Techmer PM巡演期間觀看3維打印的碳纖維Shelby Cobra跑車（Pete Souza官方白宮照片）

序言

07

誠然，3維打印並非新事物，歷史可追溯至1860年法國藝

術家弗朗索瓦 (Francois Willeme)採用圍繞主體的照相器材獲

取3維物體的雕塑方法是3維打印的啟蒙概念，至1981年

日本名古屋工業研究所的科學家小玉秀男發明了兩種利用

光硬化聚合物的增材製造3維塑料模型的方法和1984年美

國3維公司發明了立體光刻，通過建立列印目標物體每部

分之間的聯繫來列印3維物體，令3維打印有飛躍的發展。

時至今天，已發展出更多種類的3維打印技術，在塑膠上有

FDM, SLS, SLA, DLP等等，能使用的塑料種類亦不斷擴大，

由最初的ABS至多種工程塑料，更由硬塑至軟性的熱塑性彈性體也可以用3維打印出來，3維打印勢將為

各塑膠行業帶來高效率、低成本、快速成型測試和項目開發的重要工具。

在過去27年，萬通塑料致力成為中國領先的工程塑料和特殊聚合物的供應商，業務遍及全國主要地區。

萬通的成績在於創造力、好奇心和團隊精神，萬通的技術支援和項目開發團隊多年來為國內外的汽車、醫

療、資訊和通信科技品牌實踐新產品開發作出了重大的幫助。而在推廣塑膠3維打印技術服務上，更是首

家獲香港特區政府工業貿易處在發展品牌、升級轉型及拓展內銷市場的專項基金 (BUD Fund)支持的工程塑

料供應商，可見萬通確實是塑料供應領域的先行者。展望將來，萬通將繼續保持創新思維和好奇心，發掘

更多有利塑膠業的先進技術和解決方案，與合作夥伴共享成功。

廖錦興先生

行政總裁2017年11月

TABLE OF CONTENTS

I. What is 3D Printing

II. History of 3D Printing

III. Computer-Aided Design (CAD)

IV. Principle of 3D Printing

V. Process of 3D Printing

VI. 3D Printing Technology

i. Fused Deposition Modelling (FDM)

ii. Selective Laser Sintering (SLS)

iii. Stereolithography (SLA)

iv. Digital Light Processing (DLP)

VII. Appendix

10

11

15

17

23

24

25

43

56

69

78

目錄

I. 什麼是3維打印技術

II. 3維打印技術歷史

III. 電腦輔助設計（CAD）

IV. 3維打印技術基本原理

V. 3維打印技術過程

VI. 3維打印技術

i. 熔積成型法 (FDM)

ii. 選擇性鐳射燒結 (SLS)

iii. 光固化成型法 (SLA)

iv. 數位光處理 (DLP)

VII. 附錄

79

80

84

86

92

93

94

112

125

138

147

WHAT IS 3D PRINTING

10

3D Printing is the additive manufacturing process of creating a three-dimensional object from a digital design. Layers

of material are deposited under computer control.

Objects can be of almost any shapes or geometry. Digital model data can be obtained from a 3D computer-aided

design (CAD) model, or other source of CAD file. No machining, casting or assembly is compulsorily needed after 3D

printing.

HISTORY OF 3D PRINTING

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11

The first attempt to create solid objects layer-by-layer-like took place in late 1960s, at Battelle Memorial Institute. An

experiment that involved intersecting two laser beams of differing wave length in the middle of a vat of resin,

attempted to solidify the same photosensitive polymer resin at the point of intersection.

Another significant attempt occurred in late 1970s. A series of patents on solid photography was granted to Dynell

Electronic Corporation. The invention involved the cutting of cross sections by computer control, using either a milling

machine or a laser, and stacking them in register to form a 3D piece.

1980s

— Hideo Kodama, a Japanese professor of Nagoya Municipal Industrial Research Institute invented a single-beam

laser curing approach, which was the first idea of Stereolithography (SLA). He published a paper titled Three-Dimensional Data Display by Automatic Preparation of a Three-Dimensional Model that outlined his experiment

of fabricating 3D plastic models with photo-hardening thermoset polymer. A photosensitive polymer resin was

polymerised by an ultraviolet light. In 1981, he published a second paper titled Automatic Method for Fabricating a Three-Dimensional Plastic Model with Photo Hardening. Unfortunately, he did not file the patent

requirement.

— Alain Le Mehaute, Olivier de Witte, and Jean Claude Andre filled their patent for the stereolithography process.

However, it was abandoned by the Alcatel-Alsthom and CILAS because of lack of business perspectives.

— Charles Hull, the founder of 3D Systems, deposited a first patent for stereolithography (SLA). He defined the

process as a “system for generating three-dimensional objects by creating a cross-sectional pattern of the

object to be formed”. He was also recognised for co-creating the STL file format, most common 3D printing file

format in the present.

— Carl Deckard at the University of Texas, brought a patent for the Selective Laser Sintering (SLS), which was the

other 3D printing techniques that fused powder grains together locally by a laser. Also, Scott Crump, a co-

founder of Stratasys Inc. filed a patent for Fused Deposition Modelling (FDM), which was the third main 3D

printing technique.

— EOS GmbH Electro Optical System was found in Germany by Drs Hans Langer and Hans Steinbichler. The first

EOS Stereos system was created for industrial prototyping and production applications of 3D printing. The EOS

systems are currently been recognised around the globe.

Over less than ten years, the three main 3D printing techniques were patented.

12

1990s

— A patent of Fused Deposition Modelling (FDM) was issued to Stratasys, who developed several 3D printers for

both professional and individual usages. Its first FDM printing machine was marketed.

— Z Corporation obtained an exclusive license from the Massachusetts Institute of Technology. They created the

Z402, which produced models using starch-based powder and plaster-based powder materials, and a water-

based liquid binder based on inkjet printing technology by MIT. Arcam MCP technology and Selective Laser

Melting also emerged at the same time.

— At the same time, CAD tools for 3D printing were developing. Sanders Prototype (now known as Solidscape)

was the first developer of specific tools for additive manufacturing. It introduced a high-precision polymer jet

fabrication system with soluble supporting structures.

— The first application of 3D printing by medical researchers started in 1990s, which combined medicine and 3D

printing for medical usage. Engineered organs bought new advanced to medicine in 1999. Scientists at the

Wake Forest Institute for Regenerative Medicine used a synthetic scaffold coated with the patient’s own cells.

The process had little to no risk of rejection because it was made with the patient’s cell.

2000s

— The first 3D printed working kidney was created that was capable of filtering blood and producing diluted urine

in an animal. Time was needed for it to be recognised and transplanted into a patient. 3D printed kidneys are

now perfectly working and the researchers are experimenting on accelerated growth to transplant organs very

rapidly.

— RepRap project was initiated, which consisted in a self-replication 3D printer. It led to the spreading of the

FDM 3D desktop 3D printers.

— The Spectrum Z510 was launched by Z Corporation, which was the very first high-definition colour 3D printer

on the market.

— The first Selective Laser Sintering (SLS) machine was produced.

— The first 3D printed prosthetic limb was invented. It incorporated all parts of a biological limb and without the

need for any later assembly. In the current medical situation, medical prosthesis and orthosis are cheaper and

extremely fast to be obtained, combining with 3D scanning.

— FDM 3D printer started innovating due to the openness of FDM patents in public domain. There was a drop of

the cost of desktop 3D printers, and consequently, since the technology was more accessible.

— Sculpteo, one of the pioneers of the now flourishing online 3D printing services, was created.

His

tory

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3D P

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Com

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13

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2010s

— The FDM patent was expired. 3D printing was getting into common imaginations and practices.

— Urbee was the first 3D printed prototype car was built. Its body was fully 3D printed using a very large 3D

printer.

— A 3D food printer was begun to be built by Cornell University. NASA is now researching the ways that astronauts

could 3D print food for in space.

— Many medical 3D printing advances: tissues, organs, and low-cost prosthesis. The first prosthetic jaw was

printed and implanted.

— President Brarck Obama mentioned 3D printing as a major issue for the future in his State of the Union

speech.

— NASA brought a 3D printer in space to make the first 3D printed object off of the earth.

— Carbon 3D issued their revolutionary ultra-fast CLIP 3D printing machine.

— Daniel Kelly’s lab announced being able to 3D print bones.

Nowadays new 3D printers are being issued with more efficiency, higher printing speed, and new 3D printing

materials access.

14

A BRIEF HISTORY OF 3D PRINTING

CHUCK HULL INVENTS STEREOLITHOGRAPHY (SLA)

STRATASYS COMMERCIALIZES 3D PRINTING. CALLS IT FUSED DEPOSITION MODEKING (FDM)

THE FIRST FUNTIONAL ANIMAL KIDNEY IS PRINTED

RESEARCHERS 3D PRINT THE SCAFFOLDING FOR A

NEW BLADDER THEN GROW CELLS ON IT

ORGANOVO PRINTS THE FIRST HUMAN BLOOD VESSEL

REPRAP FOUNDED WITH THE GOAL OF CREATING A FREE/ OPEN SOURCE

PRINTER THAT CAN REPLIEATE ITSETF

A CHINESE COMPANY FIGURES OUT HOW TO 3D PRINT 2000 SQFT HOUSES

A WOMAN IN NORWAY BECOMES THE WORLD’S FIRST RECIPIENT OF A 3D

PRINTED SKULL TRANSPLANT

2010s

2005

1980s

1999

2000s

1990s

COMPUTER-AIDED DESIGN (CAD)

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15

Computer-Aided Design (CAD) is a computer technology that designs products and documents. CAD facilitates the

manufacturing process by transferring detailed diagrams of a product’s materials, manufacturing processes,

tolerances, and dimensions with specific conventions for the object. It could be used to produce detailed two-

dimensional and three-dimensional diagrams, which could be rotated to be viewed from any angle.

The CAD software is likely to give some suggestions, or even a clue concerning the structure of the ultimate object

applying scientific facts about utilised materials. That will help to predict the behaviour of the object under various

conditions.

A Computer-Aided Design (CAD) file contains information about dimensional representation of an object. The printing

process consists of consequent printing of layer by layer. Hence the file format that printing machine uses shall have

the information for each layer.

A 3D CAD file must be prepared before 3D printing. Format of CAD file are including

STL, OBJ, AMF, 3MF, STP, PRT, IGS

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METHODS OF CREATING CAD FILE

METHODS OF CREATING CAD FILE Designing by CAD software

Below are several types of different 3D modelling software either commercial or free that could be used for

designing 3D models.

Reverse engineering

When there is no CAD file, or a copy of a real object is wanted, reverse engineering can be used.

A solid object will be scanned by a 3D scanner and processed to become parametric scan data. 3D virtual

model will be created by scan data. 3D CAD file will be created and matched with the original designed

features. Error between CAD file and the objects will be modified and reduced.

A 3D scanner is a device that collects digital data on shape and appearance of a real object by analysis.

PRINCIPLE OF 3D PRINTING

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Additive manufacturing is a term to describe set of technologies that create three-dimensional objects by adding

layer-upon-layer of material. Diverse materials can be use in different additive manufacturing techniques. There are

some common features for all additive manufacturing, such as the usage of computer together with special 3D

modelling software.

MODELLINGThe prototype is designed in 3D CAD software.

SUBTRACTIVE MANUFACTURING

ADOTIVE MANUFACTURING

DIFFERENCE BETWEEN SUBTRACTIVE & ADDITIVE MANUFACTURING

18

FINISHING

PRINTINGErrors are examined before printing a 3D model from an STL file. The STL file needs to be processed that

mathematically slicing and orienting the object into a series of thin layers and produces a G-code file containing

instructions tailor to a specific type of 3D printer.

Printer resolution describes layer thickness and X-Y resolution in dots per inch (dpi) or micrometres (µm). Typical layer

thickness is around 100 µm although some machines can print layers as thin as 16 µm. X-Y resolutions is

comparable to that of laser printer. The particles (3D dots) are around 50 to 100 µm in diameter.

The objects can be printed in several hours depending on the type of machine used, size and number of models

being produced simultaneously.

FINISHINGThe model is finished as a solid object. Unused materials are removed to obtain a greater precision with a higher

resolution. Post-processing included smoothing the surface by using chemical vapour, polishing and printing in

multiple colours may be needed.

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SUBTRACTIVE MANUFACTURINGSubtractive Manufacturing is the traditional machining process. The model is prototyped by removing the materials

from a stock which is not needed. The object is processed by several machinery methods such as CNC milling,

grinding, turning and drilling.

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ADVANTAGES OF USING ADDITIVE MANUFACTURING1. Complex designs can be created

3D printing allows for easy customisation. Designs can be changed by modifying its CAD file. No additional

tooling or other manufacturing processes is needed for a new designed product. It enables engineers to

produce multiple versions of a single design in a cost-effective manner. Each and every item can be customised

to meet the users’ specific needs.

2. Quick prototyping time

Speed of 3D printing is faster since it is an additive manufacturing method. An object can be produced directly

without additional manufacturing processes. Modifying a design during production will not lead to significant

time delays as no tooling required to create an object. It is an effective method for developing prototypes, and

for designers or entrepreneurs to do market testing or low volume production runs, or even launch their

products through crowdfunding sites in a short period of time.

3. Lower cost of manufacturing

When a traditional manufacturing method is processed, for example casting or injection molding, each part of

each product requires a new tooling. The toolings are the factor of increasing the manufacturing cost rapidly.

Numerous products will be produced by using the same tooling and design. They will be sold to cover the

manufacturing costs.

Alternatively, for each time, only a single object will be made by 3D printer. Toolings are not needed. The fixed

cost is lowered. Therefore, no additional costs or lead times are required between modifying the design of an

object. Ultimately, this leads to substantially lower the amount of capital that is needed to scale up production.

The manufacturers can be able to increase the profitability of their business model.

In addition, 3D printing can reduce energy usage by using less eliminating steps in the production process. The

3D object can be lighter, more durable and the fuel burn can be reduced. Re-manufacturing parts through

additive manufacturing processes can return end-of-life products to “like new” condition using only 2 to 25

percent of the energy that will be required to build a whole new part.

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4. Reduce labour resources

At least one technician is needed to control the 3D printer. The technician does not need to require any

professional manufacturing skills. Once the 3D printer starts working, the object is printed automatically. The

labour resource is reduced as the number of technicians decreased.

5. Fewer materials consumption

Many conventional manufacturing processes are subtractive. The subtractive manufacturing machines work by

removing material from a block that is bigger than the product itself will be. The removed materials are wasted

and cannot be reused. For many products, it’s normal to lose 90% of the raw material during this process.

Alternatively, 3D printing is an additive manufacturing process that creates an object from the raw material

layer by layer. Only the material that is required is used. Material will only be wasted from supporting structures,

and/or in post processing. More than 90% of the raw materials could be well used and less material is wasted.

Additionally, most of these materials can be recycled and repurposed into more 3D printed objects.

3D Printer

Time Cost Man Power Materials usage

CNC

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DISADVANTAGES OF USING ADDITIVE MANUFACTURING1. Higher cost for large production runs

Despite all of the benefits of manufacturing through additive methods, 3D printing is not yet competitive with

conventional manufacturing processes when it comes to large production runs. In most cases, this turning

point is between 500 and 10,000 units, depending on the material and the design. As the price of printers and

raw materials continue to decrease, the range of efficient production is expected to increase further.

2. Less material choices, colours and finishes

There are more than six-hundred 3D printing materials available today. However, the choices are limited

compared to conventional product materials, colours and finishes. The number of new materials added to the

3D printing rapidly every year, including plastics, wood, metals, composites, ceramics, and even chocolate.

3. Limited strength and endurance

In some of 3D printing technologies, the strength of material is not uniform due to the layer-by-layer fabrication

process. As such, the printed parts are often weaker than their traditionally manufactured counterparts.

Repeatability is also in need of improvement. Parts made on different machines may have slightly varying

properties.

4. Lower precision

3D printing is a method of creating objects at a precision of around 20–100 microns. For users who are

creating objects with few tolerances and design details, 3D printing offers a great way for making products real.

For objects requiring more working parts and finer details, it will be difficult to compete with the high precision

capabilities of certain manufacturing processes.

PROCESS OF 3D PRINTING

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1. A 3D model is produced by computer-aided design software.

2. The 3D model in CAD format is needed to transform to STL (standard tessellation language), which is the

format initiated to be read by 3D printers.

Standard Tessellation Language (STL) and 3D Manufacturing Format (3MF) are the most commonly used file

format.

3. A STL file can be operated by a computer which connected to a 3D printer.

The device can be established. Each device has its own prerequisites for how to use it for each new print.

Various materials can be added or refilled into the printer. Materials can be selected which best achieve the

specific properties required for the object. A tray as a basis or some supporting materials may be added.

4. The 3D printer can be turned on to print the object.

The whole procedure is mainly automatic. The thickness of layers is thin and it can be modified depending on

the size of the object, machine and materials employed. The procedure may take several hours or even days.

Errors shall be checked and avoided occasionally.

5. The printed object(s) could be taken out of the printer.

6. Post-processing may be needed after an object is 3D printed.

The remaining powder or the supporting structures shall be removed from the object in the finishing process.

Time may be needed for the materials to solidify.

7. Finally the object is ready to be used.

3D PRINTING TECHNOLOGY

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4 common techniques are listed as below. They are classified into two categories according to the types of materials

used.

Thermoplastic — solid materials

Thermosetting plastic — liquid materials

Other 3D Printing technology

MJP — 3D SYSTEMS

CJP — 3D SYSTEMS

FUSED DEPOSITION MODELLING (FDM)

STEREOLITHOGRAPHY (SLA)

POLYJET — STRATASYS

SELECTIVE LASER SINTERING (SLS)

DIGITAL LIGHT PROCESSING (DLP)

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FUSED DEPOSITION MODELLING (FDM)Introduction

FDM is an additive manufacturing technique that commonly used technology for modelling and prototyping. The

machine dispensed multiple materials to build up the model and soluble supporting filament by extruding

thermoplastic filament. It is also called Fused Filament Fabrication (FFF).

History

FDM was developed by S. Scott Crump in 1988.

In 1989, Crump patented FDM technology and founded Stratasys. FDM printing machines were being sold

since 1991.

In 2004, RepRap Project initiated a self-replicating 3D FDM printer.

FDM Processing

The filaments will be guided from a reel attached into a heater through the drive wheels. The filaments will be melt to

a semi-liquid state and transfer to the liquefiers. Predetermined path will be created by the software on the computer.

The extrusion nozzles will extrude molten materials and move in horizontal and vertical directions (x-direction and

y-direction) to form the object on the build platform, which will move in z-direction. As the material is extruded as a

layer of the object on this path, it instantly cools down and solidifies, providing the foundation for the next layer of

material until the entire object is manufactured.

Supporting filament may be generated if needed. It will be required if the angle of the slope overhang excess 45

degrees. It will be removed or dissolved upon completion of the print.

FUSED DEPOSITION MODELLING (FDM)

PRINT MATERIAL

SUPPORT MATERIAL

PRINT HEAD

3D PRINTED PART

SUPPORT MATERIAL

BUILD TRAY

PLATFORM

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FILAMENTFILAMENT

Filament Creating

The raw materials will be put into the hopper of extruder. Screw and heat bands in the extruder will heat the raw

material past their temperature of glass transition (Tg). They will become extrudate and be pressed out by a die into

the water tank with sizing plate for cooling process. The materials will be in small flattened filament shape. They will

be pulled by a pull roller and then be cut and removed by a wind-up or cut-off machine.

Material Types

Solid thermoplastics will be classified into 3 categories according to their heat deflection temperature (HDT).

Standard Thermoplastics

Standard thermoplastics were defined that their HDT are below 100 degree °C.

Polylactic acid (PLA), PA12, Acrylonitrile Butadiene Styrene (ABS), and ASA are the common polymers used.

FDM MATERIAL

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POLYLACTIC ACID (PLA)


PLA is a renewable plastic material offered as a low cost material option for rapid prototyping.

Features

Fast printing

Good tensile strength and material toughness

Low melting point

A number of different colour options are available.

Properties Test Method U.S. Metric

Heat Deflection Temp (HDT) @66 psi ASTM D648 127°F 53°C


Glass Transition Temperature (Tg) DMA (SSYS) 145°F 63°C

Specific Gravity ASTM D792 1.24 g/cc

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ABSPLUSABSPLUS

ABSplus is a true production-grade thermoplastic.

Features

Mechanically strong and stable, toughness and strength

A wide range of colours including ivory, white, black

Application

For static dissipation




Glass Transition Temperature (Tg) DSC (SSYS) 226°F 108°C

Specific Gravity ASTM D792 1.04

Rockwell Hardness ASTM D785 109.5

Flame Classification UL94 HB (0.09”, 2.50 mm)

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ABSIABSI

ABSi suitable for light transmission component.

Features

Strength is superior to standard ABS

Translucent nature

Natural colour and other colours are available.

Applications

automotive, aerospace, and medical

device


Heat Deflection Temp (HDT) @66 psi, 0.125” unannealed ASTM D648 188°F 86°C




Rockwell Hardness ASTM D785 R108

Flame Classification UL 94 HB (0.059”, 1.5 mm)

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ABS-M30ABS-M30

Features

By comparing with standard ABS, ABS M30 is

Up to 25 to 70 percent stronger

Greater tensile, impact, and flexural strength

Significantly stronger layer bonding

More durable and smooth

Several colours including natural, white, black

Applications

conceptual modelling, functional

prototyping, manufacturing tools and

higher quality end-use-parts




Glass Transition Temp (Tg) DMA (SSYS) 226°F 108°C




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ABS-M30IABS-M30I

Features

Can be gamma or EtO sterilised

High mechanical strength

Biocompatible that complies with ISO 10993 and USP Class VI

Applications

Suitable for medical, pharmaceutical

and food packing industries








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ASAASA

Features

Production-grade thermoplastic

Good mechanical strength and UV stability

Several fade-resistant colours including white, ivory and black

Applications

Suitable for functional prototyping and

practical production parts for outdoor

use






Rockwell Hardness ASTM D785 (Scale R, 73°F) 82

Flame Classification UL94 HB

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NYLON 12 (PA12)NYLON 12 (PA12)

Features

High impact resistance

Exceptional dimensional accuracy

82–95 degree after post-processing

Engineering plastics

Engineering plastics were defined that their HDT are between 100 and 150 degree °C.

Example: PC/ABS, PC, TPU and TPE

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PC/ABSPC/ABS

Features

Superior impact strength

High strength and heat resistance

Exhibits excellent feature definition and surface finish

Applications

Conceptual modelling, functional prototyping,

manufacturing tools and production parts

Automotive, electronics, telecommunications

applications and industrial equipment

manufacturing








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POLYCARBONATE (PC)

POLYCARBONATE (PC)

A true industrial thermoplastic

Features

Superior mechanical properties and heat resistance

High tensile and flexural strength

Accuracy, durability and stability, creating strong parts that

withstand functional testing

Applications

Use for in-house, manufacturers in

automotive, aerospace, medical device

equipment and other industries

Prototyping, tooling and fixtures


Heat Deflection Temp (HDT) @ 66 psi ASTM D648 280°F 138°C

Heat Deflection Temp (HDT) @ 264 psi ASTM D648 261°F 127°C





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eFLEX (TPU)eFLEX (TPU)

Features

Semi-transparent, environmental-friendly, soft texture, with high resilience

Fluent printing, high elastic, good molding, milk white

Properties Shore

Hardness 87 A

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ELASTIC (THERMOPLASTIC ELASTOMERS TPE)

ELASTIC (THERMOPLASTIC ELASTOMERS TPE)

Features

Fluent printing, high elastic

Milk white

Properties Shore

Hardness 85 A

Engineering plastics with high performance

Engineering plastics with high performance were defined that their HDT are above 150 degree °C.

Example: ULTEM

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Features

Well-rounded mechanical, chemical and thermal properties

FST (flame, smoke and toxicity) rating

High strength-to-weight ratio

Applications

ULTEM 9085 is ideal for aerospace,

automotive and military applications


Heat Deflection Temp (HDT) @ 264 psi, 0.125” unannealed ASTM D648 307°F 153°C



Rockwell Hardness ASTM D785 —

Flame Classification UL94 V–0 (1.5 mm, 3 mm)

ULTEM 9085ULTEM 9085

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Features

Great strength and thermal stability

Highest heat resistance, chemical resistance and tensile strength

of any FDM thermoplastic

Food-contact and biocompatibility with NSP 51 and ISO 10993/

USP Class VI certifications

Applications

Suitable for automotive, aerospace,

medical and food-production industries,

and autoclave-sterilisable medical

devices


Heat Deflection Temperature (HDT) @ 66 psi, 0.125” unannealed ASTM D648 421°F 216°C

Heat Deflection Temperature (HDT) @ 264 psi, 0.125” unannealed ASTM D648 415°F 213°C



Rockwell Hardness ASTM D785 109

Flame Classification UL94 V0 (1.5 mm), V0,

5VA (3 mm)

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BENEFITS OF USING THERMOPLASTICFilaments

1. Production-grade thermoplastics

Same strong, stable and durable plastics as traditional injection-molded plastic parts

Products printed with FDM will be in high performance and engineering-grade. It is the only 3D printing

technology that makes use of production-grade thermoplastics. Functional, conceptual, and final end-use

products could be produced with mechanical, thermal and chemical quality.

2. Excellent material properties

Repeatability

Stable and predictable materials allow for repeatable results

Enables DDM (Direct Digital Manufacturing)

Suitable for different industries

No toxic materials

Low temperature operation

3. Numerous types and colours

More types of material selection available than other 3D printing techniques

4. Durable and stable

Able to maintain a stable shapes and physical properties mechanically and environmentally

Stable geometry and mechanical properties, withstanding rigorous environments

5. Economical

Lowest cost of 3D printing materials

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PRACTICAL EXAMPLES

PRACTICAL EXAMPLES

APPLICATIONS

Industry Medical

Application Inner cover of medical waste recycle bin

Material TPE

Lead time Less than 2 hr

Products Requirement Build different kind of cover in short period for testing

Material property of cover need fulfil requirement

Save tool cost

Features of FDM

Printing materials Filament

Material type PLA, ABS, PC, TPE, and TPU

Filament diameter 1.75 mm or 2.85 mm

Printing speed General

Printing Accuracy 0.15 to 0.20 mm

Printing requirements Low investment cost for machine, maintenance and filament

Able to print large size products (depends on materials)

Support structure is required

Wide range for color selection

Recycling printing materials

Products Rough in surface, post process is required

Suitable for parts with simple structures

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BENEFITS OF USING FDM1. Low cost of operation

Increased accessibility, expanded prototyping opportunity

Simplified cost justification

Low maintenance costs

2. Clean, simple and user-friendly technology

Ease of use

Unattended, light out printing

Simple printing process — increased user accessibility

Convenient to remove the soluble supporting structures by water

Facility friendly

Quiet and fits in any office environment because of the compact size of the machine

No facility modifications required.

3. Durable parts with high stability

4. Fast lead times comparing with conventional manufacturing methods

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Introduction

Selective Laser Sintering (SLS) is an additive manufacturing technique that melts and solidifies layers of powdered

material in finished objects by directed energy beam.

Two newer techniques are listed below which are transformed from SLS.

Selective Laser Melting (SLM) is the process that sinter or melt metal powder using directed energy beam.

Electron beam melting (EBM) uses metallic powder to make fully homogenous metal parts by using an electron beam

and parts were built in a vacuum, which allows the use of higher oxygen-receive metals.

History

In 1979, R. F. Housholder filled a patent of primary idea of SLS but it was not being commercialised.

SLS was developed and patented in the 1980s by engineers in the Department of Mechanical Engineering at The

University of Texas at Austin. Carl Deckard was a UT Austin student who had the first idea of using a laser to melt

particles of powder together to create a 3D object for manufacturing.

Under the guidance of mechanical engineering professor Joe Beaman, Deckard built the first SLS machine in 1986

and named it as Betsy. Prototypes were manufactured by sintering, or melting, powder layer by layer.

OBJECT BEINGFABRICATED

SCANNER SYSTEM

FABRICATIONPOWDER BED

LASER

ROLLER

POWDER DELIVERYSYSTEM

POWDER DELIVERY PISTON FABRICATION PISTON

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The University of Texas System filed the first SLS-related patent based on Deckard’s inventions and it was issued in

1987 that defined the SLS processes.

Deckard, Beaman, and a few partners formed the first SLS company (NOVA Automation) which eventually became

Desk Top Manufacturing (DTM) Corporation in 1989. DTM became the first student and faculty-led start-up at UT

Austin.

Deckard and Paul Forderhase, who was the fellow graduate student of Beaman, built the second SLS machine in

1989, named as Bambi.

DTM launched its first line of modern SLS production machines SinterStation in 1992, and they were commercially

successful.

Since 2000s, SLS began to be commonly used in the production of molds, prototypes and parts that need to be

made from a strong, durable material. SLS is widely used in the aerospace and medical device industries.

In 2001, 3D Systems, the biggest competitor to DTM and SLS technology, acquired DTM.

Process

A thin layer of solid material powder is applied on top of the building surface, all inside a hot chamber with

temperature just under the materials’ sintering point. A laser beam lights a two-dimensional section of the object on

that surface and focuses on a tiny spot. The temperature of the powder increases and excesses the sintering

temperature. The powder particles will be sintered together. Once a layer has been solidified, the print bed moves

down slightly as the other bed containing the powder moves up. A new layer will be spread on top of the one by a

roller. The process repeats until the last 2D section of the object is melt and the desired object has been completed.

The last step is to uncover the solid object from burying within the unsintered powder.

SLS Material

SLS plastic powder

Most commonly used SLS material is Polyamides (PA12). Nylon (PA12) can have additives to change properties such

as colour, strength, flexibility and stiffness. It offers durability, strength and extraordinary abrasion resistance among

others. Its elastic regions under load are wide. 3 colours are available, including black, white and grey. It is not

translucent or transparent.

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FS6028PA PA6 NYLON POWDER

FS6028PA PA6 NYLON POWDER

Features

Maintain excellent mechanical properties and creep resistance

characteristics under high temperature

Excellent stiffness

Size stability, high-precision and suitable for complex surface

Low water absorption and easy-to-process

Pale yellow

Application

Production parts of prototype and

end-use parts with strength, accuracy

and high heat deflection temperature

properties

Connect parts for car intake pipes.

Properties Metric

Heat Deflection Temp (HDT) @1.8 MPa 97.8°C

46

PA11 PA1101 PA1102

PA11 PA1101 PA1102

Features

Made out of renewable raw materials (castor oil)

Elasticity and high impact resistance

High elongation at break

Excellent resistance to chemicals (particularly hydrocarbons,

aldehydes, ketones, mineral bases and salts, alcohols, fuels

and detergents as well as oils and greases)

Acceptance criteria

Cytotoxicity according to DIN EN ISO 10993-5

Defined in directive 2007/47/EC (Medical Device(s))

No clinical medical studies concerning the use of PA11

in any particular Medical Device have been performed,

and approval from the European Directorate for the

Quality of Medicines (“EDQM”) or other governmental

authorities for use in Medical Devices has neither been

sought nor received

Not use for any Medical Product application other than

body orthesis, orthopedic insole/arch-support, surgical

guides and tools, therapy masks and dental models

Not to be introduced into human body for more than

30 days and not to replace any epithelial surface or the

surface of the eye for more than 30 days

Black and White

Applications

Mechanically loaded functional prototypes

and series parts with long-term moving

elements

Interior components for crash relevant parts

in the automotive industry

Small to medium sized parts, thin walls and

lattice structures

Properties Test Method Metric

Heat Deflection Temp (HDT) @1.8 MPa ISO 75-1/-2 46°C

Heat Deflection Temp (HDT) @0.45 MPa ISO 75-1/-2 180°C

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PA12 PA2105

PA12 PA 2200/2201

PA12 PA2105

PA12 PA 2200/2201

Features

High precision

High surface quality

Colour capability

Light skin colour

Applications

Dental models

Features

High strength and stiffness

Good chemical resistance

High selectivity and detail resolution

Various finishing possibilities (e.g. metallisation, stove

enamelling, vibratory grinding, tub colouring, bonding, powder

coating, flocking)

Bio compatible according to EN ISO 10993-1 and USP/level

VI/121 °C

PA 2200 — Approved for food contact in compliance with the

EU Plastics Directive 2002/72/EC (exception: high alcoholic

foodstuff)

PA 2201 — Approved for food contact in compliance with FDA,

21 CFR, §177.1500 9(b) except for alcoholic foodstuff

Applications

Fully functional plastic parts of highest

quality

Use for prostheses and realisation of

movable part connections

48

PA12 PA3200 GF

PA12 PA3200 GF

PA 2210 FRPA 2210 FR

Features

Flame retardant

Free of halogens

Higher stiffness compared to unfilled PA 12

High Crystallinity, Thermal Stability, Homopolymer

General Chemical Resistance, Grease Resistance, Oil Resistance

Acceptance criteria

JAR 25 (aviation)

UL 94 (Electrical & Electronics)

Applications

Aircraft and Aerospace, Automotive,

Electrical and Electronical, plastic parts

in devices and appliances

Features

Low coefficient of friction

High stiffness

High mechanical wear-resistance

Good thermal loadability

Excellent surface quality

High dimensional accuracy and detail resolution

Applications

Final parts within the engine area of

cars

Deep-drawing dies

Any other applications which require

particular stiffness, high heat distortion

temperature and low abrasive wear

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CARBONMIDE (PA12–CF)


Features

Increased electrical conductivity

Excellent stiffness

Maximised strength and hardness

Light weight

Applications

Metal replacement

Aerodynamic components in motor

sports application

Mechanically stressed parts

50

PEEK EOS HP3PEEK EOS HP3

Features

Heat stabilised or stable to heat

General Chemical Resistance, Hydrolytically Stable

High-performance polymer for SLS

Tensile strength (95 MPa) and Young´s modulus (4400 MPa),

100 percent higher level than PA 12 and PA 11

Excellent high temperature performance

Temperature ranges within 180 °C (mechanical dynamic),

240 °C (mechanical static) and 260 °C (electrical)

High wear resistance

Outstanding chemical resistance

Best fire, smoke and toxicity performance

Good hydrolysis resistance

Potential biocompatibility and Sterilization

Applications

Highest demanding applications e.g. in

medicine, aerospace industry or

motorsports

Replace for stainless steel and titanium

in medical applications

Adequate metal replacement where

light weight and fire resistance are of

largest importance in aerospace and in

motorsports


Heat Deflection Temp (HDT) @ 1.8 MPa ISO 75-1/-2 165°C

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LUVOSINT® TPU X92A-1 & X92A-2


Features

High strength and high abrasive resistance

Shore A 88

Natural color

TPU X92A-2 is modified from TPU X92A-1 enhanced reproduction

of fine detail. It is white color and better for colouring

Applications

Garment industry, shoe and sports

industry, pipes, sealings, prosthetics

and many more applications

Properties Test Method Value

Vicat-softening Temperature VST A ISO 306 ISO 306 90°C

Shore A hardness — 88

52

Features

Higher strength and diminished elasticity compare with TPU

X92A.

Shore A 97

White color

X97A-1 WT approximates to the property profile of a polyamide (PA)

but better abrasion resistance

Applications

Garment industry, shoe and sports

industry, pipes, sealings, prosthetics

and many more applications

Properties Test Method Value

Vicat-softening Temperature VST A ISO 306 ISO 306 90°C

Shore A hardness — 97

LUVOSINT® TPU X97A-1 WT


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BENEFITS OF USING SLS MATERIAL1. More material selection

Except thermoplastic powder, metal powder, ceramic powder, quartz sand powder can also be selected as

sintering materials simple manufacturing process

Complete design freedom. Excess unsintered powder acts as a support for the structure as it is produced,

which allows for complex and intricate shapes to be manufactured with no additional support needed.

No supporting structure is needed. Prototypes and parts with complex shapes could be produced directly.

2. High material utilisation

The unsintered powder could be reused without material waste.

3. High production accuracy

Complex geometry designs could be produced. Accuracy of prototype is up to ± 0.05 mm

4. Wide range of applications

Material types are diverse. Sintered parts could be produced for different purposes, such as for structural

and functional testing, metal molding, casting precise core of wax and core of sand.

54

PRACTICAL EXAMPLES

PRACTICAL EXAMPLES

APPLICATIONS

Industry Medical

Application 3D robotic prosthetic device (Ekso Bionics)

Materials PA12 + CG

Products Requirement Produce according to body shape

High loading capacity requirements

Flexible to modify design

Shorten production time

Industry Manufacturing

Application Safety Shell for industrial robotic arm (AIRSKIN)

Material TPU

Products Requirement Saved cost of tooling

Increase number of robotic arms

Increase productivity

Protect safety of workers

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Industry Footwear

Application Running shoes insole (Under Armour Architech)

Material TPU

Products Requirement FEA simulation technology. Analysis data of kinematics, dynamics and

material properties to create best cushioning structure of the insole

Complex shapes and not suitable for injection molding

Withstand the highest strength of training. Enhance stability, shock

absorption capacity. Suitable for weight training and avoid injury.

Features of SLS

Printing material Thermosetting photosensitive polymer powder

Material Types PA66, PA12, PA12 + GF, PA12 + CF, PEEK, TPU, metal powder and gypsum

powder

Printing Speed Faster than FDM

Accuracy 0.05–0.15 mm

Requirements High investment cost because of machine maintenance and material

costs

Support structure is no needed

Reusable materials

Products Sandy surface, surface finishing is better than FDM

Able to print products with complex shapes and structures

Able to print metal products on sintered parts directly or indirectly. Higher

strength than other 3D printing techniques

May need post processing, polishing and spraying

Benefits of using SLS

The cost of production of SLS is relatively lower than SLA due to the ability of outputting extremely large

quantities in a single run.

No supporting structure is required for overhanging and unsupported structures. The powder itself provides the

necessary support.

Parts can be created out of a wide selection of materials.

Complexity is not an issue as the unsintered powder can be removed.

56

STEREOLITHOGRAPHY (SLA)STEREOLITHOGRAPHY (SLA)

Introduction

Stereolithography (SLA) is a 3D printing technique for creating models, prototypes, patterns, and production parts in

layer by layer using photopolymerisation. A computer-controlled ultraviolet laser beam hardens the layer of the parts

at a time in the container of resin. It is the oldest method in the history of 3D printing. It is still being used nowadays.

The process of printing involves a uniquely designed 3D printing machine called a stereolithographly apparatus, which

converts liquid plastic into solid 3D objects.

History

SLA was the first additive manufacturing technology to be theorised. In 1970s, a Japanese researcher Dr Hideo

Kodama invented the modern layer approach to Stereolithography by using ultraviolet light to cure photosensitive

polymers. SLA was patented in the 1986. This method was patented by Charles Hull, co-founder of 3D Systems, Inc.

The modern layered approach stated that one layer of the liquid photosensitive polymers could be cured at a time

with an ultraviolet light.

DIAGRAM OF SLA PRINTING PROCESS

ELEVATOR

LASER SOURCE

LASER BEAM

PLATFORM

VAT

RESIN SURFACE

PHOTOPOLYMER RESIN

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Process

A build platform is submerged into a translucent vat filled with curable photosensitive polymer liquid resin. A thin layer

of liquid resin is exposed above the perforated platform.

SLA uses two motors, known as galvanometers, (one on the X axis and one on the Y axis) to break down the design,

layer by layer, into a series of points and lines that are given to the galvanometers as a set of coordinates. Then it

rapidly aims an ultraviolet laser beam across the print area. The laser beam draws a 2D section of desired object. The

photosensitive polymer resin reacts solidifying and thus forming a single 2D layer of the object.

The platform is lowered once the initial layer of the object has hardened. A new layer of resin will be exposed on top

and the process will be repeated for each cross section of the object results in the complete 3D printed object. The

last step is cleaning the final object which is soaked in liquid resin. The object is baked in an ultraviolet oven to

further cure the plastic. Lastly is to remove the supporting structures and to be post processing.

Material Type

Liquid photosensitive resin is used as the printing material for SLA. It is thermosetting plastic resin which material

properties can be close to ABS, PP, PC and TPU (e.g. ABS-like, PP-like, PC-like and TPU-like), but not exactly same.

Rigid resin tend to fail violently crashing in multiple pieces (permanent deformation and failure); General color is

white, transparent or translucent.

LIQUID PHOTOSENSITIVE POLYMER RESIN

LIQUID PHOTOSENSITIVE RESIN

SLA MATERIAL

58

ACCURA 55

ACCURA XTREME

ACCURA 55

ACCURA XTREME

Features

ABS-like

Rigid and strong

Functional assemblies

Short-run production parts

White


Heat Deflection Temp (HDT) @66 psi ASTM D 648 55–58°C


Features

Tough and durable

Resists breakage and handles challenging functional assemblies

Great for snap fits, assemblies and demanding applications

Ideal for master patterns for vacuum casting

Grey color


Heat Deflection Temp (HDT) @66 psi ASTM D 648 62°C


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ACCURA XTREME WHITE 200


Features

Exceptionally tough and durable

Resists breakage and handles challenging functional assemblies

Great for snap fits, assemblies and demanding applications

Ideal for master patterns for vacuum casting

High-Impact-White




60

ACCURA BLUESTONE

ACCURA BLUESTONE

Features

Highest stiffness available

Heat and abrasion resistant

Excellent chemical resistance

Great for wind tunnel models, jigs and fixtures

High-Temperature

Blue


Heat Deflection Temp (HDT) @66 psi UV Post cure only ASTM D 648 65–66°C

Heat Deflection Temp (HDT) @264 psi UV Post cure only ASTM D 648 65°C

Heat Deflection Temp (HDT) @66 psi UV + Thermal Post cure (120°C) ASTM D 648 267–284°C

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ACCURA 25

VISIJET SL FLEX

ACCURA 25

VISIJET SL FLEX

Features

PP-like look and feel

High flexibility, stability and shape retention

High feature resolution and accuracy

Snap-fits assemblies

Accurate

Master patterns for urethane casting

White opaque color

Applications

Automotive styling parts and fascia


Heat Distortion Temp @ 0.45 MPa ASTM D648 61°C

Heat Distortion Temp @ 1.82 MPa ASTM D648 53°C

Features

PP-like

Flexible Plastic

Snap fit assemblies

Master patterns for vacuum casting

Durable functional prototypes

White




62

ACCURA 60

ACCURA CLEARVUE

ACCURA 60

ACCURA CLEARVUE

Features

PC-like/ABS-like

Rigid and strong

Clear and transparent

Applications

Headlamps, bottles and transparent assemblies




Features

PC-like/ABS-like

Rigid and tough

Excellent humidity/moisture resistance

UPS Class VI

Applications

Headlamps, bottles and transparent assemblies

Properties Test Method USA Metric

Heat Deflection Temp (HDT) @66 psi ASTM D 648 115°F 46°C

Heat Deflection Temp (HDT) @264 psi ASTM D 648 106°F 41°C

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ACCURA PEAKACCURA PEAK

Features

PC-like/ABS-like

High heat resistance

Very high rigidity and stiffness

Excellent humidity/moisture resistance


Heat Deflection Temp (HDT) @66 psi; UV Post cure Only ASTM D 648 78°C

Heat Deflection Temp (HDT) @264 psi; UV Post cure Only ASTM D 648 59°C

Heat Deflection Temp (HDT) @66psi; 120°C thermal post cure ASTM D 648 153°C

Heat Deflection Temp (HDT) @264 psi; 120°C thermal postcure ASTM D 648 124°C

64

GODART 8558GODART 8558

Features

TPU-like

Excellent flexibility and toughness

Strong bending resistance

Shore D 30

Natural

Applications

Shoe and sports industry, pipes, sealings,

prosthetics and many more applications

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BENEFITS OF USING SLA MATERIALS1. Single material selection

Properties similar to ABS, PP, PC and TPU

2. High productivity

Faster and more stable

3. Good product appearance

High quality of surface, relatively smooth, high transmittance

4. High forming accuracy

Able to produce complex geometry designs

Prototype accuracy up to ± 0.02 mm

5. Wide range of applications

About 60% of the speed rapid prototyping machines run digital light processing system in the world

66

PRACTICAL EXAMPLES MILTON

PRACTICAL EXAMPLES

APPLICATIONS

Industry Consumer product

Application Cookware

Process SLA

Grade ABS-like (hard) + TPU-like (soft)

Products Requirement Gloss finish

ABS property (hard) + shoe D 30 (Soft)

Industry E & E

Application Parts of printer

Process SLA

Grade ABS-like (hard)

Products Requirement Rigid and good surface finish

ABS property (hard)

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Industry Medical

Application Oxygen mask

Process SLA

Grade ABS-like (hard)

Products Requirement Rigid and light

Transmission > 80%

Industry Consumer product

Application Food container cover + Sealing gasket

Process SLA

Grade ABS-like (hard) + TPU-like (soft)

Products Requirement Gloss finish

ABS property (hard) + shoe A 30 (soft)

68

FEATURES OF SLAPrinting material Liquid photosensitive resin

Material types Less material types, must be liquid photosensitive resin

Printing speed Fast

Accuracy Accuracy up to ± 0.02 mm

Requirements Higher investment cost of equipment, maintenance and material compare

with FDM

Material has toxic and harmful to skin and respiratory system. Protective

gloves and air flow are required

Support structure is needed

The three-dimensional physical and support structure is printed by the

same material, so the need to manually remove the support structure

Printing materials can not be recycled

Products Smooth surface, able to be painted

Able to print products with complex shapes and structure

Limited strength, stiffness and heat resistance

Not suitable for long-term storage

BENEFITS OF USING SLA The products surfaces are smooth and shiny.

SLA is suitable for printing multiple precise objects, and large objects with high precision. Resolution and

surface integrity are at high quality.

An SLA 3D printer curates the liquid resin spot by spot with a laser, so it potentially more precise than DLP 3D

printing.

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Introduction

DLP is a method of printing that makes use of light and photosensitive resin. It takes a design that has been created in 3D modelling software and prints the 3D object by projecting the object, one layer at a time, onto a liquid polymer and hardening it. It is very similar to SLA. Their key difference is the light source. DLP utilises traditional light sources like arc lamps.

History

Dr Larry Hornbeck of Texas Instruments created a semiconductor chip called the digital micromirror device (DMD) in 1987, known as the DLP chip. DLP is used for projectors and uses digital micromirrors laid out in a matrix on DMD. Each mirror represents a pixel in the image for display. The first DLP-based projector was introduced by Digital Projection Ltd in 1997.

Process

A build platform is submerged into a translucent tank filled with liquid photosensitive resin. Once the build platform is submerged, a digital ultra violet light projector located below the machine flashes each layer of the object through the bottom of the tank. The ultra violet light activates the liquid resin into a solid. After the layer has been solidified by the light source, the platform lifts up and lets a new layer of resin flow beneath the object once again. This process is repeated layer by layer until the desired object has been completed. The object will be pulled out of the resin.

PHOTOPOLYMER

LIGHT SOURCE

LENSE

DLP

MOTOR

STAGE

70

E-DENT 400

E-DENT 400

Material Type

Liquid photosensitive resin is used as the printing material for SLA. It is thermosetting plastic resin which material

properties can be close to ABS, PP, PC and TPU (e.g. ABS-like, PP-like, PC-like and TPU-like), but not exactly same.

Rigid resin tend to fail violently crashing in multiple pieces (permanent deformation and failure); General color is

white, transparent or translucent.

Features

Biocompatible Class IIa and FDA-approved solution

Accurate and fine surface finish

Full crowns or multi-unit bridges can be printed

Allow for colour layering and shading.

Applications

Dental

LIQUID PHOTOSENSITIVE POLYMER RESIN

LIQUID PHOTOSENSITIVE RESIN

DLP MATERIAL

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E-MODEL FLEX SERIES

ABS 3SP TOUGH

E-MODEL FLEX SERIES

ABS 3SP TOUGH

Features

Highly accurate

Final-use material with improved elongation

at break

High stability

Low shrinkage and low curling

Low viscosity

Orange, dark grey and green

Applications

Aerospace, entertainment, automotive, consumer

goods, education, medical devices, manufacturing


Heat Deflection Temp (HDT) @ 1.82 MPa ASTM D648 49.5°C

Features

Extremely tough ABS-like

Suitable for high quality prototypes of items

Stable enough for production-quality end use parts

Capable of holding high stress and force

Capable of very high speed builds without sacrificing

its exceptional surface quality

Applications

Aerospace, animation and entertainment,

architecture and art, automotive, consumer and

packaged goods, dental, education, electronics,

manufacturing, orthodontics, sporting goods, toys

Snap-fit items and assembly applications which

require elasticity

Properties Metric

Heat Deflection Temperature (HDT) @ 1.82 MPa 60°C

72

E-TOOL 3SPE-TOOL 3SP

E-CLEAR 3SPE-CLEAR 3SP

Features

Strong, tough, water resistant especially for

applications requiring exceptional clarity

Good rigidity and durableness

Clear without any of the yellowing with age

Low warp potential and biocompatible

Water resistant, high humidity

Use for appearance models with minimal finishing,

tough and functional prototypes, and RTV patterns

Applications

Entertainment, consumer goods, education,

medical devices, manufacturing

Properties Metric


Features

Use for low volume production runs or for the

creation of multiple iterations of a tooling during the

prototyping phase

Faster and more cost-effective

No minimum limit to the number of molded pieces

needed

Good strength and elongation at break

Applications

Aerospace, automotive, consumer goods,

manufacturing, sporting goods, toys

Properties Metric


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ABS FLEX

EC3000

ABS FLEX

EC3000

Features

ABS-like

Tough and stable

Capable of holding high stress and force

Capable of very high speed builds

ABS Flex black, ABS Flex light grey,

ABS Flex white

Applications

Aerospace, animation and entertainment,

architecture and art, automotive, consumer

packaged goods, education, electronics,

manufacturing, sporting goods, toys

Snap-fit items and assembly applications which

require elasticity

Production-quality end use parts

Features

3 times more wax than any polymer based material

Crisp detail with super smooth surfaces

Achieve superior surface quality

Negligible material expansion during burnout

Porosity-free castings due to clean, ash-free burnout

Applications

Jewellery, Manufacturing

74

PRACTICAL EXAMPLES

PRACTICAL EXAMPLES

APPLICATIONS

Industry Footwear

Application Limited 3D Printing Sport Shoes (Adidas and Carbon)

Process DLP

Material TPU

Products Requirement Complex shapes, not suitable for injection molding

Enhanced stability, shock absorption capacity

Suitable for highest strength, weight training and avoid injuries

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Pri

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Appe

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75

FEATURES OF DLPMaterial Liquid photosensitive resin

Material types Less material type, liquid photosensitive resin only

Printing speed Faster than SLA

Accuracy Accuracy up to ± 0.02 m

Requirements lower investment cost of equipment, maintenance and materials than SLA

Material has toxic and harmful to skin and respiratory system. Protective

gloves and air flow are required

Support structure is required

Printing materials can’t be recycled

Products Smooth surface. Able to be painted

Limited strength, stiffness and heat resistance

Not suitable for long term preservation.

Suitable for produce toys and jewelry, etc. High precision but low strength

part

BENEFITS OF USING DLP DLP is suitable for printing a single fine object, and fast printing small object with standard precision

requirement. Resolution and surface integrity will be affected by the size of the printing object.

DLP 3D printers can potentially 3D print faster than an SLA 3D printer, as an entire layer is exposed all at once

instead of one spot at a time with a laser.

The DLP 3D printer is less expensive and easier to change than the laser used by SLA 3D printer.

76

CONCLUSION3D printing techniques and processes continue to grow as 3D printing is frequently changing. The 3D printing industry

continues to innovate the hardware, materials, and processes. Depending on many factors such as budget, design or

function, choosing the appropriate 3D printing process and the right material are important.

3D printing could be used to create many different objects and it is gradually replacing the traditional manufacturing

methods. The additive manufacturing technology will be broadened in the near future.

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3D

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3D

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77

TABLE OF COMPARISONFDM SLS SLA DLP

Material Thermoplastic filament SLS plastic powder Liquid photosensitive resin

Liquid photosensitive resin

Types of materials Most Many Standard Standard

Strength High Superior Standard Standard

Maximum size (mm) 400 x 400 x 400 300 x 300 x 300 300 x 300 x 300 300 x 300 x 200

Appearance Standard Good Superior Superior

Surface texture RoughCan be polished

Slightly roughCan be polished

SmoothShiny

SmoothShiny

Colours MostOpaque and translucent

all colours

GeneralBlackGreyWhite (Opaque)

ManyVirtually unlimitedOpaqueTranslucent

Many

Supporting Required Not required Required Required

Mechanics VariableStrongToughDurable

StrongFlexible

StrongBrittleNew flexible compounds

StrongBrittleNew flexible compounds

Mechanical failure Gradual deformation until fracture

Gradual deformation until fracture

Almost no deformation until sudden fracture

Almost no deformation until sudden fracture

Abrasion resistance Variable Superior Variable Variable

Printing speed Low Standard High Highest

Post processing PolishingPaintingSealingSmoothing

PolishingSmoothingVarnishingDyeingPainting

Polishing (rarely needed)

Painting

Polishing (rarely needed)

Painting

Food compatibility Leakage due to micro-gaps

Yes Only with special resin Only with special resin

Chemicals compatibility

Leakage due to micro-gaps

Highly resistant Not defined Not defined

Cost InexpensivePrinters: inexpensiveMaterial: inexpensive

Most expensivePrinters: seriously

expensiveMaterial: inexpensive

ExpensivePrinters: relatively

inexpensiveResin: can be expensive

ExpensivePrinters: relatively

inexpensiveResin: can be expensive

78

APPENDIX

REFERENCEhttps://www.sculpteo.com/blog/2015/12/09/3d-printing-technologies-sls-sla/

https://www.sculpteo.com/blog/2016/12/14/the-history-of-3d-printing-3d-printing-technologies-from-the-80s-to-

today/

https://www.creativemechanisms.com/blog/additive-manufacturing-vs-subtractive-manufacturing

http://documents.irevues.inist.fr/bitstream/handle/2042/57294/68452.pdf?sequence=1

https://www.techopedia.com/definition/2063/computer-aided-design-cad

https://www.sculpteo.com/en/glossary/cad-definition-en/

http://www.cs.cmu.edu/~rapidproto/students.03/rarevalo/project2/Process.html

http://www.stratasys.com/3d-printers/technologies/fdm-technology

http://www.stratasys.com/materials/fdm

http://www.luvocom.de/en/products/luvocom-3f-made-for-fused-filament-fabrication/

https://formlabs.com/blog/3d-printing-technology-comparison-sla-dlp/

https://www.3dsystems.com/on-demand-manufacturing/stereolithography-sla/materials

79

什麼是

3維打印技術

3維打印技術歷史

電腦輔助設計（

CAD）

3維打印技術基本原理

3維打印技術過程

3維打印技術

附錄

3維打印技術是一種增材製造技術，將三維數據設計轉化成立體實物，透過電腦程序將設計分層，並控制

打印材料分層打印出立體實物。

立體實物可接近任何幾何形狀。三維數據設計模型（CAD圖檔）可透過3維電腦輔助設計軟件 (CAD)或其他途

徑中取得。3維打印後的立體實物無需額外的機械加工、鑄造及裝配。

什麼是3維打印技術

80

1960年代後期，在Battelle Memorial Institute中初次使用增層製造固體實物。實驗中將兩種不同波長的鐳射

光束，在承載着熱固性光敏樹脂的容器裡重叠，試圖將相交點的熱固性光敏樹脂固化。

另一次重大的實驗發生在1970年代後期。Dynell Electronic Corporation獲得一系列關於光固體技術專利。發

明包括使用電腦控制分割截面，及使用銑床或激光將容器裡的材料堆叠，形成一塊立體實物。

1980年代

— 在Nagoya Municipal Industrial Research Institute，日本的教授Hideo Kodama發明了使用單一鐳射光固化

法，這是光固化成型法 (SLA)的最早概念。他發表了第一份論文，名題為Three-Dimensional Data Display

by Automatic Preparation of a Three-Dimensional Model，概述了他利用熱固性光固化聚合物製造3維塑膠

模型，及利用紫外光將光敏物樹脂聚合的實驗。在1981年，他發表了第二篇論文，名題為Automatic

Method for Fabricating a Three-Dimensional Plastic Model with Photo Hardening，可惜的是他沒有為實驗成

果申請專利。

— Alain Le Mehaute、Olivier de Witt和Jean Claude Andre，為他們研究的光固化成型法 (SLA)技術申請專利。

可是由於Alcatel-Alsthom和CILAS缺乏商業視野而放棄。

— 3維Systems Corporation的始創人Charles Hull，首次得到光固化成型法 (SLA)專利。並將光固化成型法定

義為「可透過三維數據設計模型截面，來製造立體實物的系統」；同期，他創立了STL檔案格式，是現

時最普及的3維打印檔案格式。

— 在University of Texas就學的Carl Deckard，為選擇性鐳射燒結 (SLS)技術申請了專利，這是第二種獲

得專利的3維打印技術，通過鐳射激光將粉末顆粒熔合。同年，Stratasys公司的始創人之一，Scott

Crump，為熔積成型法 (FDM)申請了專利。

— Drs Hans Langer和Hans Steinbichler在德國成立了EOS GmbH Electro Optical System。EOS發明了第一部用

於工業製作首辦模型和生產應用的3維打印機，EOS系統現時仍得到全球認可。

3種主要的3維打印技術獲得最少10年的專利。


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什麼是

3維打印技術



CAD）



3維打印技術

附錄

1990年代

— Stratasys開發了數款專業級及個人使用的3維打印機，並申請了熔積成型法 (FDM)的專利，首款FDM

打印機於該年發售。

— Z Corporation獲得了麻省理工學院 (Massachusetts Institute of Technology)的獨家許可。根據麻省理工學

院的水性液體粘合噴墨印刷技術，創造了使用澱粉和石膏粉末製作立體模型的Z402 3維打印機。同

期出現了Arcam MCP技術公司的選擇性鐳射熔化 (Selective Laser Melting)技術。

— 同一時間為3維打印技術而開發的CAD工具出現了。Sanders Prototype（現被稱為Solidscape）是第一

個為增層製造業開發專業工具的人，引進了高精度聚合物的噴墨製造系統 (polymer jet fabrication

system)，系統同時亦具備可溶性支撐結構。

— 醫學研究人員首次應用3維打印技術，將醫學和3維打印技術結合。人工人體器官令醫學變得更先

進。Wake Forest Institute for Regenerative Medicine的科學家使用塗有病人細胞的合成支架，因為它是病

人的細胞製成，使用過程中幾乎沒有排斥的風險。

2000年代

— 製作了首個3維打印的人工腎臟，它能夠在動物體內過濾血液並稀釋尿液。3維打印的腎臟現在完全

正常運作，研究人員正在不斷試驗移植人工器官。

— RepRap項目創立，其中包括自我複製3維打印機。令桌面式FDM 3維打印機普及化。

— Z Corporation推出了Spectrum Z510，是市場上第一部高清晰度的彩色3維打印機。

— 第一台的選擇性鐳射燒結 (SLS)機面世。

— 發明了首款3維打印義肢。結合了生物肢體的所有部分，並不需要任何後續裝配。現今醫學界可利用

3維掃描技術，在短時間內製造低成本的醫療假肢和矯形器。

— 由於FDM專利開放給公眾領域，令FDM 3維打印技術進入新時代。桌面3維打印機的成本下降，技術

更普及。

— Sculpteo成立，成為至今仍發展蓬勃的線上3維打印技術服務的先驅者之一。

82

2010年代

— FDM專利已過期。更多人開始使用3維打印技術。

— Urbee製造了第一款3維打印原型車，車體部份完全使用大型的3維打印機作打印。

— Cornell University開始製作3維食物打印機。美國太空總署 (NASA)正在研究宇航員可以在太空中3維打

印食物的方法。

— 多項醫學3維打印技術正全面發展：生物組織、器官和低成本的義肢。首款3維打印人工下巴出現，

並植入人體內。

— 美國總統巴拉克 • 奧巴馬，他在美國國會演說中提到3維打印技術，將會是未來的一項主要發展項

目。

— 美國太空總署 (NASA)將3維打印技術帶到太空，在地球以外打印出首件3維打印立體實物。

— Carbon 3維發布極具革命性的極速CLIP 3維打印機。

— Daniel Kelly的實驗室宣佈能夠3維打印骨骼。

如今，發行商正在研發效率更高、打印速度更快的新型3維打印機，及新款的3維打印材料。

83

什麼是

3維打印技術



CAD）



3維打印技術

附錄

3維打印的歷史

Charles Hull發明了光固化成型法(SLA)

Stratasys公司為熔積成型法(FDM)申請專利

首次打印動物腎臟器官

研究人員3維打印出塗有細胞的醫用合成支架

Organovo公司打印第一個人類血液導管

RepRap以創建多元開放的打印機為目標研發了自我複製的3維打印機

一家中國公司發現了如何打印2000平方英尺的房間

挪威的一名女性成為世界上第一個接受移植3維打印顱骨的人

1980年代

2000年代

2005年

1999年

1990年代

2010年代

123

84

電腦輔助設計（CAD）

電腦輔助設計 (CAD)是一種電腦技術，應用於設計產品，製作圖檔及文件； CAD有利於生產流程，透過圖檔

可顯示出產品的材料、製造方法、公差和特定尺寸等資料；亦可用於製作2D工程圖紙及3維立體模型，可

移動、旋轉及從多角度檢視產品。

電腦輔助設計 (CAD)軟件可根據物件結構及材料，進行產品科學化分析及提供建議，有助於預測產品設計

不同環境下發生的問題。

電腦輔助設計 (CAD)圖檔包含相關立體實物的尺寸資料。透過程序把圖檔分層切割及轉化為數據資料，打

印機按照數據資料進行逐層打印出立體實物。

進行3維打印前，必須準備3維電腦輔助設計 (CAD)圖檔。檔案格式包括：

STL, OBJ, AMF, 3MF, STP, PRT, IGS

85

什麼是

3維打印技術



CAD）



3維打印技術

附錄

製作圖檔的方法

製作圖檔的方法利用電腦輔助設計 (CAD)軟件

商業或免費的電腦輔助設計 (CAD)軟件如下

逆向工程

當欠缺CAD圖檔，同時亦需要複製立體實物時，逆向工程便適合不過。

立體實物透過3維掃描器進行掃描，並將所得資料轉化數據，創建虛擬的3維圖檔，然後把3維圖檔

與立體實物掃描資料作比較，並修補CAD圖檔和實物之間的誤差。

3維掃描器通過掃描方式，收集立體實物的形狀和外觀數據資料並進行分析。

86


增材製造技術與減材製造技術的差別

SUBTRACTIVE MANUFACTURING

ADOTIVE MANUFACTURING

3維打印技術是一種增材製造技術。透過材料一層一層地添加，製造出立體實物的技術。不同的材料可使

用於不同的增材製造技術。不同的增材製造技術亦有一些共通點，如跟電腦配合使用的特定3維模型設計

軟件。

模型設計原型透過3維CAD（電腦輔助設計）程式來設計。

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什麼是

3維打印技術



CAD）



3維打印技術

附錄

後工序加工

打印打印前需檢查3維立體模型檔案 (STL)是否有誤；確定無誤後，使用電腦輔助程序進行分層切割處理，分割

成一系列的薄層，並轉換成G CODE編碼；不同類型的3維打印機，會有特定的打印指令編碼。

打印機的分析度以每層層厚微米（µm）及X-Y方向每英寸點數 (DPI)作計算。基本的3維打印機層厚大約是

100微米（µm），某些特別的3維打印機，可打印薄至16微米（µm）。激光打印機以X-Y分析度作計算，粒子

的直徑是大約50到100微米（µm）。

打印時間根據打印機類型、打印物件尺寸以及打印物件的數量作計算，打印時間可以是數個小時。

後工序加工立體模型打印完成後，將多余的材料及支撐層除去，以達致更高的精度及光潔度。某些情況亦有需要後加

工處理，例如使用化學氣化方法或拋光，令物件表面變得光滑，及噴塗上色等。

88

減材製造減材製造是傳統的製造加工技術。通過機床加工方法將原材料上多余的部分移除，從而製造出立體模型；

一般情況下會使用多於一種的機床加工方法進行加工，例如CNC銑床、磨床、車床、鑽床、甚至模具等。

89

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3維打印技術



CAD）



3維打印技術

附錄

使用增材製造的優點1. 適合複雜形狀的設計

3維打印技術適合個人化的設計，可透過修改CAD圖檔來改動設計。不需要額外工具或其他製造技術

來進行修改。工程師能夠以最具成本效益的方式，製作不同版本的單一設計。每個項目都是訂製，

滿足使用者的個人化要求。

2. 縮短原型製作時間

3維打印是一種快速的增材製造打印技術，可直接將立體實物打印出來，而不需使用額外的製造工

藝。此外，製造立體實物的過程中，無需製作模具，因此減少了模具生產和修改的時間。這是一種高

成本效益的方法，讓設計師或企業家可進行市場測試或小批量生產，甚至短時間內，將產品放在集

資網站中銷售。

3. 降低製造成本

在進行傳統製造的過程中，不管是鑄造或注塑成型，每件產品部件均需要製作一套新的模具，這是

令生產費用大幅提升的主要因素之一；為了覆蓋模具製造成本，商人一般會重復使用同一模具，去

生產不同設計的產品。

相反地，3維打印技術，每次可打印單一的立體實物，無須製作模具，有助降低成本。此外，當修改

立體設計時，無需額外的開支和時間進行模具修改，可大幅降低投資的生產成本，令製造商能夠提

高盈利。

另一方面，3維打印的製造工序小，可以減少能源消耗。而且打印的物件，可以更輕，更耐用，及使

用更少資源。亦可通過增材製造技術，將已停止生產的產品重新製作，變換成新產品，只需要2%至

25%的資源，便可製造出一個全新的產品。

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4. 降低勞動力資源

3維打印需要最少一名技術人員來操作3維打印機，該技術人員並不需要任何專業的生產技術知識，

只要3維打印機開始運作，將自動進行打印，因技術人員人數減少，勞動力資源亦相對地降低。

5. 減少材料消耗

在傳統的減材製造過程中，機床將原材料上的多余部分移除，材料浪費比率平均為90%，由於被移

除的材料不能重複使用，造成嚴重的浪費。

相反，增材製造過程是將原材料逐層的添加，除了所需打印材料以外，只有支撐結構及後期加工處

理會造成材料浪費，高達90%的材料能被充分運用。再加上大多數3維打印材料均可被回收及循環再

用，減少浪費。

3維打印

時間價錢人力材料損耗

CNC加工

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什麼是

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CAD）



3維打印技術

附錄

增材製造的缺點1. 大批量生產成本高

雖然增材製造技術有各樣好處，但面對大批量生產時，傳統製造工藝比3維打印技術更有競爭力；大

部分情況下，500至10000件將是3維打印的產量的一個轉折點，主要是取決於材料及產品設計。然

而，隨著3維打印機和原材料的價格持續下降，生產數量的範圍有望進一步提高。

2. 材料、顏色，和表面處理方法的選擇較小

儘管現今在3維打印技術擁有超過六百多種材料，當中以塑膠和金屬材料為大多數，但基本的產品

材料和顏色選擇仍然有限。然而，3維打印技術的新材料數量正在迅速增長，包括木材、金屬、複合

材料、陶瓷，甚至巧克力。

3. 產品物理性能受限制

在個別3維打印技術當中，產品的強度因應打印方向而變得不均勻。令打印物件的強度比傳統製造

的部件弱。重複性亦有待改進，在不同的打印機上製造的部件，其物理性亦可能有差異。

4. 較低的精準度

3維打印技術所製造的立體實物，精準度大約是20至100微米之間。對於產品公差沒有特別要求的使

用者，3維打印技術是很好的製造產品方法。對於產品公差要求和細緻度特別高的使用者，3維打印

技術未必能夠合乎他們的要求，難以與更高精準度的製造工藝競爭。

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1. 使用電腦輔助設計CAD軟件製作及設計3維立體模型（CAD圖檔）。

2. 將CAD圖檔格式轉換為STL（標準鑲嵌語言）格式，STL是3維打印機專用的讀取格式。

Standard Tessellation Language (STL)和3維Manufacturing Format(3MF)是通用的3維CAD檔案格式。

3. 透過電腦程序將STL圖檔轉換成數據，並輸入3維打印機。

在打印新物件前，設置所需的設備，如根據打印物件的選材，添加或填充所需的打印物料，或需要

添加支撐材料作為承托之用。

4. 開啟3維打印機，進入打印程序。

整個打印過程是全自動化，層厚可根據打印物件的尺寸、打印機型號及打印物料而調整；打印過程

可能需時幾個小時，甚至幾天，打印期間應偶爾檢查避免出錯。

5. 打印完成，從打印機中取出立體實物。

6. 打印完成後，立體實物有機會需要進行後期加工處理程序。

在精加工過程中，剩余的粉末或支撐結構應從立體實物中除去，亦有些打印材料需要加熱程序及時

間作固化。

7. 後期加工處理完成後，立體實物可被應用。

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3維打印技術

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常用的3維打印技術包括下列四種，並按照使用物料類型，分為兩大類。

熱塑性塑膠材— 固態材料

熱固性塑膠材— 液態材料

其他3維打印技術包括

MJP — 3維SYSTEMS

CJP — 3維SYSTEMS

熔積成型法 (FDM)

光固化成型法 (SLA)

POLYJET — STRATASYS

選擇性鐳射燒結 (SLS)

數位光處理 (DLP)

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介紹

熔積成型法是一種通用的增材製造技術，用於製作立體實物，如立體模型或手辨等。打印機可選用不同物

性的線材及可溶性支撐線材作打印，通過加熱線材和擠壓出熔融物料，逐層反復地鋪設在工作平台上，以

建立出立體實物。因專利問題，FDM亦被稱為熔絲製造 (Fused Filament Fabrication FFF)。

歷史

熔積成型法於1988年由S. Scott Crump開發。

於1989年，Crump獲得FDM技術的專利，並創立了Stratasys。自1991年起Stratasys開始出售FDM打

印機。

2004年，RepRap項目發明了一部自製的3維FDM打印機。

FDM打印程序

線材通過系統（驅動輪）進入發熱器，熔化成熔融狀態並儲存在噴頭內，噴頭按照電腦軟件預定的打印路

徑，擠壓出熔融材料在工作平台上，噴頭沿水準x和y方向移動，而工作平台則沿垂直z方向移動，當完成

第一層的打印路徑後，材料會逐漸冷卻和固化，成為下一層材料的基礎，噴頭再按照打印路徑反復進行堆

叠，直至整件立體實物打印完成。

根據打印物件的形狀，打印過程中有可能會用到支撐物料，作為承托之用。例如打印物件的斜度大於45

度，就必需加入支撐物料；打印完成後，可利用清洗方法將支撐物料清除或溶解。

熔積成型法(FDM)熔積成型法 (FDM)

塑膠線材

支撐線材

打印噴頭

3維打印件

支撐線材

托盤

加工平枱

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製造線材方法

利用擠出機製造線材，將原材料放進料槽，通過發熱帶將原料加熱至玻璃化轉變溫度 (Tg)，並以螺杆旋轉

所產生的壓力和剪切力將原料均勻混合，再通過模芯擠出成為線材；線材通過水槽進行冷卻，被拉輥拉

扯，然後被捲繞機收納成捲材及切斷。

材料類型

固體熱塑性塑料根據材料的熱變形溫度 (HDT)分為三大類。

一般熱塑性塑膠材

一般的熱塑性塑膠材的定義為其熱變形溫度在100攝氏度以下。

PLA、ABS、PA12 & ASA是常用的塑料。

FDM材料

線材線材

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PLA是一種可再生塑膠材料，是一種低成本快速打印原型的材料選擇。

特性

快速打印

拉伸強度高及高剛性

低熔點

多種不同顏色選項

性能測試方法英制公制

熱變形溫度 (HDT) @66 psi ASTM D648 127°F 53°C


玻璃化轉變溫度 (Tg) DMA (SSYS) 145°F 63°C

比重 ASTM D792 1.264 g/cc


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ABS是真正的生產級熱塑性塑膠材料。

特性

物理性能良好及耐用，能保持高強度和穩定性

多種不同的顏色，包括象牙色、白色、黑色等等

應用

防靜電部件




玻璃化轉變溫度 (Tg) DSC (SSYS) 226°F 108°C

比重 ASTM D792 1.04

Rockwell硬度 ASTM D785 109.5

耐燃等級 UL94 HB (0.09”, 2.50mm)

ABSPLUSABSPLUS

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ABS（半透明）ABS（半透明）

ABS（半透明）適合打印透光的部件。

特性

強度比標準ABS的優勝

半透明性質

原色和其他顏色

應用

汽車、航空和醫療設備


熱變形溫度 (HDT) @66 psi, 0.125” unannealed ASTM D648 188°F 86°C




Rockwell硬度 ASTM D785 R108

耐燃等級 UL 94 HB (0.059”, 1.5 mm)

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ABS-M30ABS-M30

特性

與標準ABS相比，ABS M30：

強度高出25%至70%

拉伸、衝擊和抗彎曲強度更強

層與層之間的接合力更強

更耐用，表面光滑

多種顏色包括原色、白色和黑色等等

應用

概念建模、功能原模、製造工具零

件和高品質可使用部件







耐燃等級 UL94 HB (0.09”, 2.50 mm)

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ABS-M30IABS-M30I

特性

可用gamma或EtO滅菌

高物理強度

生物相容性，符合 ISO 10993和USP Class VI

應用

醫療、製藥和食品包裝行業







耐燃等級 UL 94 HB (0.06”, 1.5 mm)

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特性

生產級熱塑性塑料

高物理強度及抗紫外線UV

多種防褪色顏色，包括白色、象牙色和黑色等等

應用

功能測試樣板及戶外應用的實際產

品部件






Rockwell硬度 ASTM D785 (Scale R, 73°F) 82

耐燃等級 UL94 HB

ASAASA

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NYLON 12 (PA12)NYLON 12 (PA12)

特性

高耐衝擊強度

高精準度

後期加工處理後約82至95度

工程塑料

工程塑料的定義為其熱變形溫度介乎100至150攝氏度之間。

例如：PC/ABS，PC，TPU及TPE。

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PC/ABSPC/ABS

特性

優良的耐衝擊強度

高強度和耐熱度

優良的表面光潔度

應用

概念模型、功能原模、製造工具和生產

零件

汽車、電子、電信應用和製造工業設備








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POLYCARBONATE (PC)

POLYCARBONATE (PC)

真正的工業用熱塑性塑膠材料

特性

優良的機械性能和耐熱性

高拉伸和抗彎曲強度

精硬度、耐用性和穩定性適合製作強度高的功能測試樣板

應用

內部組件、汽車製造、太空航天、

醫療設備和其他行業

可承受高強度功能測試的部件、樣

板、工具和夾具








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特性

環保，質地柔軟，高回彈性

打印流暢、高彈性、成型性良好，奶白色

性能 Shore

硬度 87 A

eFlex (TPU)eFlex (TPU)

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ELASTIC（熱塑性彈性體TPE）

ELASTIC（熱塑性彈性體TPE）

特性

打印流暢、高彈性

奶白色

性能 Shore

硬度 85 A

高性能工程塑料

高性能工程塑料的定義為其熱變形溫度高於150攝氏度。

例如：ULTEM

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特性

全面性的機械、化學和耐熱性能

FST評級（防火、防煙和防毒）

高堅硬度

應用

ULTEM 9085適合太空航天科技、汽

車和軍事應用





Rockwell硬度 ASTM D785 —

耐燃等級 UL94 V–0 (1.5 mm, 3 mm)

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特性

高強度和耐熱性

相比於任何FDM熱塑性塑料線材，ULTEM 1010的耐熱性、

耐化學性和拉伸強度均較優勝

食品接觸和生物相容性的認證，包括NSP 51和 ISO 10993/

USP Class VI

應用

汽車、航空航天、醫療和食品生產

行業，以及高壓滅菌消毒的醫療設

備






Rockwell硬度 ASTM D785 109

耐燃等級 UL94 V0 (1.5 mm), V0,

5VA (3 mm)


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熱塑性線材的優點線材

1. 生產級熱塑性塑膠材

跟傳統注塑成型的塑膠部件一樣，擁有同樣強度、穩定性和耐用性

熔積成型法打印的物件，擁有優異和工程級的機械性能。這是唯一使用生產級熱塑性塑料的3

維打印技術。可製作具備機械性能、耐熱性能和化學性能的功能測驗制品、概念性制品或最終

制成品。

2. 優良的物理性能

重複性

穩定及可預計的材料特性，可達到重複測試的結果

適用於DDM（直接數位化製造）

適用於不同的行業

無毒物

適合在低溫環境使用

3. 材料和顏色類型多樣化

相對其他3維打印技術，材料類型和顏色選擇更多

4. 耐用和穩定

物理及環境方面，均能夠保持的穩定形狀和物性

保持穩定幾何形狀和機械性能，能承受嚴苛的環境

5. 經濟

最優惠的3維打印材料

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實際案例應用

實際案例

行業醫療

應用醫療廢棄物回收箱內蓋頁

材料 TPE

打印時間小於兩小時

產品要求短時間內製作不同設計的蓋頁，驗證設計可行性內蓋頁物料需合乎產品性能的要求省卻開模費用，減省成本

FDM的特性

打印材料線材

材料類型 PLA、ABS、PC、TPE、TPU

線材直徑 1.75毫米或2.85毫米

打印速度標準

打印精準度 0.15毫米至0.20毫米

打印要求製造、維修保養和材料採購的成本低能夠打印大尺寸產品（取決於打印材料）可能需要支撐線材多種線材顏色的選擇打印材料可以回收重用

產品表面粗糙（相對於其他3維打印技術），可能需要後期加工處理適合打印結構相對簡單的產品

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使用FDM的優點1. 低生產成本

更方便，更容易打印出原型

簡化的成本來源

維修成本低

2. 干淨、簡單和人性化的技術

容易使用

不需技術人員駐守，打印時會燈號顯示

打印過程簡單，方便使用

可溶性支撐結構，方便用水清除

設備配合使用者

安靜，機身細小，適合在任何辦公環境使用

無需修改設備

3. 打印物價俱備耐用性及高穩定性

4. 打印時間快— 相對傳統製造方法

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介紹

選擇性鐳射燒結 (SLS)是一種使用鐳射激光，直接熔解及分層燒結固體粉末材料的增材製造技術。

以下兩種是從SLS延伸出來的技術

Selective Laser Melting選擇性鐳射熔化 (SLM)使用鐳射激光束直接熔化及分層燒結金屬粉末的製造技術。

Electron beam melting電子束熔煉法 (EBM)使用鐳射激光燒結金屬粉末，在真空狀態下製造完全均勻的金屬

部件，此技術可使用高含氧量的金屬。

歷史

1979年，R.F.Housholder遞交了選擇性鐳射燒結專利的申請，但他沒有將選擇性鐳射燒結技術用作商業用

途。

在80年代，The University of Texas Austin分校機械工程系得到SLS的專利，UT的學生是第一個想出使用鐳射

激光將粉末顆粒熔化在一起的人，並且用此技術製造出立體實物。

在1986年建造的第一台選擇性鐳射燒結打印機。通過一層一層燒結或熔化粉末來製造原型。

選擇性鐳射燒結(SLS)選擇性鐳射燒結 (SLS)

3維打印件

激光素描系統

加工粉末

激光

鋪粉輪

粉末傳送系統

粉末傳送平枱加工平枱

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The University of Texas System基於發明提交了第一個與選擇性鐳射燒結相關的專利，並於1987年發布，定義

了選擇性鐳射燒結打印過程。

第一家選擇性鐳射燒結公司(NOVA Automation)成立，於1989年成為Desk Top Manufacturing (DTM) Corporation。

DTM是第一所UT Austin學生和教職員創立的公司。

在1989年建造了第二台選擇性鐳射燒結打印機。

DTM於1992年推出第一批選擇性鐳射燒結打印機，稱為SinterStation，並成功商業化。

自二十世紀起，選擇性鐳射燒結廣泛應用於生產堅固耐用的模具、原型和零件。

2001年，3維Systems收購了DTM。

過程

固體粉末材料存放在加工平台的熱室內，頂部表層的粉末溫度保持在材料燒結點以下。鐳射激光聚焦成

微光束，按打印物件的平面截面面積進行照射；粉末被激光照射下升溫至高於燒結溫度，粉末粒子燒結在

一起，當表層完全燒結後，打印平台向下稍微移動，另一傳送粉末的粉末室亦稍微向上移動，輥子會將新

的粉末傳送及鋪平在加工平台的最表層；重複以上過程，直至最後一層截面燒結完成及打印物件的程序

結束。最後取出完成後的立體實物及清除未燒結的粉末。

SLS材料

SLS塑料粉末

SLS最常用的材料是PA 12。PA12若配合添加物料，可改變顏色，強度，柔韌性和剛性等物理性能；提升打

印物件耐用性、強度、耐磨性及延展性能。熱固性光敏聚合物粉末有3種顏色可供選擇，包括黑色，白色

和灰色，但沒有透明或半透明。

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特性

優良的機械性能，高溫下保持優异的機械性能和

抗蠕變特性

優异的剛性

尺寸穩定性，確保高精度打印尺寸和複雜表面還原

吸水率低、易於加工

淡黃色

應用

生產用的部件首辦和成品部件，具

備高強度、高尺寸精度、熱變形溫

度高等多項性能。

汽車進氣管連結部件

性能公制

熱變形溫度 (HDT) @1.8 MPa 97.8°C

FS6028PA PA6尼龍粉末

FS6028PA PA6尼龍粉末

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特性

由可再生原料（蓖麻油）製成

彈性和高耐衝擊強度

拉伸斷裂強度高

優良的耐化學性（特別是烴類，醛類，酮類，礦物鹼和

鹽類，醇類，燃料和洗滌劑以及油和油脂）

符合以下驗證標準

符合DIN EN ISO 10993–5的細胞毒性

定義在directive 2007/47/EC（醫療設備）

沒有進行任何特定醫療設備中使用PA11的臨床

醫學研究，歐洲藥品質量管理局 (EDQM)或其他政

府機構在醫療設備中也未獲得使用批准

不適用於身體矯形，矯形鞋墊或足弓支撐，手術

導管和工具，治療口罩和牙科模型以外的任何醫

療產品應用

不能植入人體30天以上，不能取代上表皮或眼睛

表層多於30天以上

白色和黑色

應用

帶有機械負載功能首辦的和長期移動

的部件

相關撞擊的汽車行業內部部件

薄壁及格子結構的中小型部件

性能測試方法公制

熱變形溫度 (HDT) @1.8 MPa ISO 75-1/-2 46°C


PA11 PA1101 PA1102

PA11 PA1101 PA1102

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PA12 PA2105

PA12 PA 2200/2201

PA12 PA2105

PA12 PA 2200/2201

特性

高準確度

高表面品質

可選顏色

淺膚色

應用

牙科模型

特性

高強度和剛度

抗化學性

高選擇性和細節解析度

適合各種表面處理（如電鍍、爐搪瓷、振動研磨，著色、粘

合、粉末噴塗、植絨）

根據EN ISO 10993-1和USP/VI/121°C的生物相容性

PA 22200批准符合歐盟塑料指令2002/72/EC的食品接觸，

除了酒精食品

PA 22201批准符合FDA, 21CRF, §177.1500 9(b)的食品接

觸，除了酒精食品

應用

最高品質塑膠功能部件

醫療部件義肢或可動連接部件

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PA12 PA3200 GF

PA 2210 FR特性

阻燃

沒有鹵素

剛度比未填充的PA 12高

結晶度高、耐熱、均聚物

一般抗化學性，耐油脂，耐油性

驗收標準

JAR 25（航空）

UL 94（電氣和電子產品）

應用

飛機和航空航天，汽車部件，電氣

和電子設備和電器中的塑料部件

特性

低摩擦系數

高剛性

高機械耐磨性

良好的熱負荷能力

表面質量優異

高尺寸準確度和細節解析度

應用

汽車發動機區域內的最終部件

衝壓模具

任何特殊需要高剛性，高熱變形溫

度和耐磨應用

PA12 PA3200 GF

PA 2210 FR

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特性

提高導電率

高剛度

最高的強度和硬度

重量輕

應用

代替金屬

汽車應用的氣動部件

耐機械應力部件



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特性

熱穩定

一般耐化學腐蝕，水解穩定

SLS塑膠聚合物材料中性能最好

拉伸強度 (95 MPa)及楊氏彈性模數 (4400 MPa)，比PA12和

PA11高出100%

出色的耐高溫性能

溫度範圍在180°C（機械動態），240°C（機械靜態）和

260°C（電氣）

高耐磨性

出色的抗化學性

最佳的防火，防煙，防毒的性能

耐水解性好

潛在的生物相容性及可消毒

應用

高要求的應用於醫療、航空航天或

汽車工業

醫療用途中代替不銹鋼和鈦

適當的金屬替代品，其重量輕，耐

火性在航空航天和汽車工業中最為

常用

PEEK EOS HP3PEEK EOS HP3

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特性

強度，耐磨損，彈性好

Shore A 88

原色

TPU X92A-2改良自TPU X92A-1加強打印細節度；白色，有

助染色

應用

成衣業，鞋類和運動業，管道，密

封件，義肢和更多的應用

性能測試方法數值

維卡軟化溫度VST A ISO 306 ISO 306 90°C

Shore A硬度 — 88

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特性

相對TPU X92A，強度更高，但彈性降低

Shore A 97

白色

TPU X97A-1 WT擁有接近PA的物性，而耐磨損能力增強

應用

成衣業，鞋類和運動業，管道，密

封件，義肢和更多的應用

性能測試方法數值

維卡軟化溫度VST A ISO 306 ISO 306 90°C

Shore A硬度 — 97



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使用SLS材料的好處1. 更多材料選擇

除了熱塑性粉末，金屬粉末、陶瓷粉末、石英粉末也可以選擇作為燒結材料

設計自由度大。未燒結的粉末將用作為支撐結構，從而製作出複雜形狀的立體實物，亦無須使

用額外的支撐物料。

無須支撐結構。可以直接生產具有複雜形狀的原型和零件。

2. 高材料使用率

未燒結的粉末可以重複使用，而不會浪費材料。

3. 高生產準確度

可以產生複雜幾何形狀設計。原型的準確度高達 ± 0.05mm。

4. 廣泛應用範圍

材料種類繁多。燒結零件可用於不同生產目的，如結構和功能測試、金屬成型、鑄造精確的蠟

芯和砂芯。

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實際案例應用

行業醫療

應用 3維機器人假肢裝置 (Ekso Bionics)

材料 PA12 + CG

產品要求根據身體形狀生產

承載能力要求高

靈活修改設計

縮短生產時間

行業製造業

應用工業機械臂安全殼 (AIRSKIN)

材料 TPU

產品要求減少製作模具成本增加機器手臂數量提高生產率保護工人的安全

實際案例

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行業鞋業

應用跑鞋鞋墊 (Under Armour Architech)

材料 TPU

產品要求仿真技術。分析運動學、動力學和材料性質的數據，以創建鞋墊的最佳緩衝結構

複雜形狀，不適合注塑成型承受最高的訓練實力。增強穩定性，減震能力。適合體重訓練，避

免受傷

SLS特性

打刷材料液態光敏樹脂

物料類型 PA66，PA12，PA12 + GF，PA12 + CF，PEEK，TPU，金屬和石膏粉

打印速度比FDM快

準確度 0.05–0.15 mm

要求使用高功率鐳射激光、技術難度高，製造保養成本高

無須支撐結構

可重複使用的打印材料

產品表面粗糙，比FDM優勝

能夠打印具有複雜的形狀和結構的產品

能夠直接或間接地打印金屬材料在燒結零件上。比其他3維打印技

術有較高的強度

可能需要後期處理拋光、着色

使用SLS的好處

SLS的生產成本比SLA低，SLS可單次打印大量物件。

不需要支撐材料來生產出有突出和不支撐結構設計的立體實物，粉末本身能用作支撐。

可以選用多種材料進行打印。

可打印出設計複雜的立體實物。

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介紹

光固化成型法 (SLA)透過光聚合作用製作模型、原型、幾何圖形和生產部件的3維打印技術。電腦控制器操

控紫外線鐳射光光束，將承載容器中的光敏聚合物表層固化。此技術是3維打印歷史中最悠久的方法，至

今仍然被廣泛使用。

SLA打印機包含獨特設計的光固化裝置，將液態光敏聚合物轉化成固態的立體實物。

歷史

SLA是第一個理論化的的增材製造技術。在70年代，Hideo Kodama博士通過使用紫外線光固化光敏聚

合物，發明了光固化成形法的打印方法。光固化成形法在1986年獲得專利。該方法由3維Systems, Inc.獲得

專利。指出紫外光可以逐層固化液態光敏聚合物，以製造出立體實物。

光固化成型法(SLA)光固化成型法 (SLA)

DIAGRAM OF SLA PRINTING PROCESS

升降台

激光光源

激光朿

加工平枱

材料缸

液態光敏樹脂表層

液態光敏樹脂

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過程

整個加工平台放進注滿液態光敏樹脂的半透明水箱內，表層薄薄的液態光敏樹脂暴露於加工平台之上。

SLA打印機擁有兩組電流計，分別是X軸及Y軸，用於將模型設計分解多層截面，及轉換成一系列由點和線

組成的座標，然後把紫外線鐳射光束迅速地沿着截面座標照射，液態光敏樹脂產生光固化反應，形成打印

物件的單一固態截面層。

完成單一固態截面層後，加工平台會被降低，新一層的液態光敏樹脂會暴露於加工平台之上，將整個過程

不斷重複，直至完成打印所需的打印物件，將浸泡在液態光敏樹脂的打印物件取出及清潔，並把物件放在

紫外線烤爐內進一步固化，最後清除支撐結構及後加工工序處理。

SLA材料

液態光敏樹脂

材料類型

SLA的打印材料是液態光敏樹脂。它是熱固性塑料樹脂，其物性可接近ABS, PP, PC and TPU（稱為類ABS、類

PP、類PC塑料和類TPU塑料），樹脂容易破裂（永久性變形和破壞）；基本顏色為白色、透明或半透明樹脂。

液態光敏樹脂液態光敏樹脂

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ACCURA XTREMEACCURA XTREME

特性

類ABS

堅固耐用

功能性組裝

短期生產零件

白色


熱變形溫度 (HDT) @66 psi ASTM D 648 55–58°C


特性

堅固耐用

抗破損和功能性組裝部件

非常適合卡扣，裝配和要求嚴格的應用

理想的真空鑄造材料

灰色


熱變形溫度 (HDT) @66 psi ASTM D 648 62°C


ACCURA 55ACCURA 55

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特性

堅固耐用

抗破損和功能性組裝部件

適合卡扣，裝配和要求嚴格的應用

理想的真空鑄造材料

白色






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特性

最高剛度

耐熱耐磨

抗化學性

適用於風洞模型，夾具

耐高溫

藍色


熱變形溫度 (HDT)@ 66 psi UV固化後處理 ASTM D 648 65–66°C

熱變形溫度 (HDT)@ 264 ps UV固化後處理 ASTM D 648 65°C

熱變形溫度 (HDT)@ 66 psi UV +熱流化（120°C） ASTM D 648 267–284°C

ACCURA BLUESTONE

ACCURA BLUESTONE

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VISIJET SL FLEXVISIJET SL FLEX

ACCURA 25ACCURA 25

特性

類PP

柔性塑料卡扣裝配真空鑄造耐用的功能首辦白色




特性

類PP的外觀

高柔韌性，穩定性和保持形狀

高功能分析度和準確度

卡扣裝配

聚氨酯鑄造的主要塑料

不透明的白色

應用

汽車零件和儀表板


熱變形溫度 @ 0.45 MPa ASTM D648 61°C

熱變形溫度 @ 1.82 MPa ASTM D648 53°C

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ACCURA 60

ACCURA CLEARVUE

ACCURA 60

ACCURA CLEARVUE

特性

類PC╱類ABS

堅固耐用

透明

特性

類PC╱類ABS

堅韌

耐濕性

UPS Class VI

應用

燈、瓶子和透明組件

應用

燈、瓶子和透明組件




測試方法測試方法美國公制

熱變形溫度 (HDT) @66 psi ASTM D 648 115°F 46°C

熱變形溫度 (HDT) @264 psi ASTM D 648 106°F 41°C

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ACCURA PEAKACCURA PEAK

特性

類PC╱類ABS

耐高溫

高硬度和剛度

耐濕性


熱變形溫度 (HDT) @66 psi；UV固化後處理 ASTM D 648 78°C

熱變形溫度 (HDT) @264 psi；UV固化後處理 ASTM D 648 59°C

熱變形溫度 (HDT) @66 psi；120°C熱焙 ASTM D 648 153°C

熱變形溫度 (HDT) @264 psi；120°C熱焙 ASTM D 648 124°C

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GODART 8558GODART 8558

特性

類TPU

優良的柔性和韌性

耐折彎性強

Shore D 30

原色（淡黃色）

應用

鞋類和體育產業、管道、密封件、義肢和更多

的應用

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SLA材料的好處1. 單一材料的選擇

材料性能類似ABS，PP，PC和TPU

2. 生產效率高

更快和更穩定

3. 良好的產品外觀

高品質的表面較光滑，透光率高

4. 高成型準確度

能夠生產複雜的幾何設計

原型準確度為 ± 0.02mm

5. 廣泛應用範圍

世界上約60%的快速成型機都是運行SLA打印技術的

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實例實例

應用

行業消費產品

應用炊具

工藝 SLA

等級類ABS（硬）+類TPU（軟）

產品要求光澤 ABS性能（硬）+ shoe D 30（軟）

行業電子產品

應用打印機部件

工藝 SLA

等級類ABS（硬）

產品要求剛性和表面光潔度 ABS性能（硬）

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行業醫療產品

應用氧氣面罩

工藝 SLA

等級類ABS（硬）

產品要求剛性和輕便透光率> 80%

行業消費產品

應用食品容器蓋+密封墊片

工藝 SLA + MJP

等級類ABS（硬）+類TPU（軟）

產品要求光澤度 ABS性能（硬）+ shoe A 30（軟）

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SLA特性打印材料液態光敏樹脂

材料類型較少物料類型，必須是液態光敏樹脂

打印速度快

準確度準確度高達± 0.02 mm

要求設備、保養和材料的成本比FDM高

材料有毒及對皮膚和呼吸系統有害。操作人員需要配備防護手

套，工作環境亦需要保持空氣流通

可能需要支撐結構。打印出的立體實物與支撐結構是同一種材料

所打印的，因此需要人手去除支撐結構

打印材料不能回收

產品可以打印光滑的表面，但可能打印出材料不均勻的產品

能夠打印具有復雜形狀和結構的產品

有限的強度、剛度和耐熱性

不適合長期存放

使用SLA的好處產品表面是平滑及有光澤。

SLA適合同時打印多個不同精確度的物件及高精確度的大型物件。表面解析度及完整性都能保持着

高品質。

SLA 3維打印機利用鐳射光束逐點將液態光敏樹脂固化，打印件的精確度比DLP 3維打印更精確。

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數位光處理(DLP)

液態光敏樹脂

激光光源透鏡

反射鏡

升降台馬達

加工平枱

介紹

DLP是使用光將液態光敏樹脂固化的打印技術，利用投影方法將3維電腦輔助設計軟件建立的模型打印成立體實物，每次投影一整層截面在液態光敏樹脂上並固化。打印方式與SLA相類似，主要區別是光源，DLP

利用傳統的弧光燈作為光源。

歷史

Texas Instruments的Larry Hornbeck博士於1987年發明了一種稱為數位微鏡器件 (DMD)的半導體晶片，稱為DLP晶片。DLP用投影機和使用DMD中矩陣中佈置的數字微鏡打印。每個鏡子代表圖像中的像素。第一台基於DLP的投影儀於1997年由Digital Projection Ltd推出。

過程

整個加工平台放進注滿液態光敏樹脂的半透明水箱內，當加工平台被淹沒，打印機底部的數位紫外光投影儀，會通過水箱底部把一整層截面投影在加工平台上，並將液態光敏樹脂固化在加工平台上，完成後加工平台升起，讓一層新的液態光敏樹脂流入打印物件的下方，整個過程不斷重複，逐層截面投影，直至已

完成所需的物件，最後把物件從水箱內取出。

數位光處理 (DLP)

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E-DENT 400

E-DENT 400

材料類型

SLA的打印材料是液態光敏樹脂。它是熱固性塑料樹脂，其物性可接近ABS, PP, PC and TPU（稱為類ABS、類

PP、類PC塑料和類TPU塑料），樹脂容易破裂（永久性變形和破壞）；基本顏色為白色、透明或半透明樹脂。

特性

生物兼容Class IIa和FDA批准的解決方案

精確細膩的表面光潔度

可以打印全冠或多單元橋樑

允許顏色分層和陰影

應用

牙科

液態光敏樹脂液態光敏樹脂

DLP材料

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E-MODEL FLEX SERIES

ABS 3SP TOUGH

E-MODEL FLEX SERIES

ABS 3SP TOUGH

特性

高準確度

最終使用材料，斷裂伸長率高

穩定性高

低收縮和低捲曲

粘度低

橙色、深灰色和綠色

特性

非常堅固的類ABS

適用於高品質產品

穩定可靠的生產質量適用於最終用途零件

能承受高壓力

能夠在不減低其卓越表面質量的前提下

快速打印

應用

航空航天、娛樂、汽車、消費品、教育、醫療設

備、製造業

應用

航空航天、動畫娛樂、建築與藝術、汽車、消

費和包裝物品、牙科、教育、電子、製造、正

畸、體育用品、玩具

需要彈性的物品和組裝應用


熱變形溫度 (HDT) @1.82 MPa ASTM D648 49.5°C

性能公制

熱變形溫度 (HDT) @1.82 MPa 60°C

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E-TOOL 3SPE-TOOL 3SP

E-CLEAR 3SPE-CLEAR 3SP

特性

堅固，堅韌，防水，高清晰度

剛性和耐用性

清晰，不會隨着年齡變黃

低翹曲和生物相容性

防水，高濕度

用於外觀模型，具有最少的精加工，堅韌和功

能性原型，以及RTV模式

特性

用於小批量生產或在原型設計階段創建模具

更快，更具成本效益

不需要限制最少的注塑數量

良好的強度和斷裂伸長率

應用

娛樂、消費品、教育、醫療設備、製造業

應用

航空航天、汽車、消費品、製造業、體育用

品、玩具等

性能公制


性能公制


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ABS FLEX

EC3000

ABS FLEX

EC3000

特性

ABS樣

堅韌穩定

能承受高壓力

能夠高速構建

ABS Flex黑色，ABS Flex淺灰色，ABS Flex白色

應用

特性

比任何基於聚合物的材料多3倍的蠟

清晰細節，表面光滑

實現卓越的表面質量

在倦怠期間物料膨脹可忽略不計

適用於製造無孔隙鑄件

應用

航空航天、動畫娛樂、建築藝術、汽車、消費

品、教育、電子、製造、體育用品、玩具

適合需要彈性的物品和組裝應用

生產質量最終使用部件

應用

珠寶、製造

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實例實例

應用

行業鞋類製造業

應用限定3維打印運動鞋（Adidas和Carbon）

工藝 DLP

材料 TPU

產品要求複雜形狀，不適合注塑成型

增強穩定性，減震能力

適用於最高強度，重量訓練，避免受傷

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DLP特性材料液態光敏樹脂

材料類型很少的材料類型，必須是液態光敏樹脂

打印速度打印速度比SLA快

準確度準確度高達± 0.02 m

要求設備，保養和材料成本比SLA低

材料有毒及對皮膚和呼吸系統有害。操作人員需要配備防護手

套，工作環境亦需要保持空氣流通

可能需要支撐結構

打印材料不能回收重用

產品光滑，表面準確度高

有限的強度，剛度和耐熱性

不能長期保存

適合生產模型、玩具和珠寶，可用於製造具有低強度要求的原型

使用DLP的好處 DLP適於打印單一物件，快速打印標準精度要求的物件。打印的立體實物尺寸將影響其表面精確度

DLP 3維打印機速度基本上比SLA 3維打印機打印速度快，原因是DLP是一整層截出面投影，取代鐳射

光束照射一點的打印方式。

DLP 3維打印機價格較SLA 3維打印機便宜

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結論隨着3維打印技術的進步，3維打印技術和流程將會在未來繼續發展。3維打印行業不斷創新設備、材料和

過程。可根據例如預算，設計或功能等因素，正確地選擇適當的3維打印過程和合適的材料。

3維打印可用於製造不同的立體實物，並逐步取代傳統的製造方法。增材製造技術將在不久的將來得到拓

展。

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對比表

熔積成型法 (FDM) 選擇性鐳射燒結 (SLS) 光固化成型法 (SLA) 數位光處理 (DLP)

材料熱塑性塑膠材 SLS塑料粉末液態光敏樹脂液態光敏樹脂

材料類型最多很多標準標準

強度高優越標準標準

最大尺寸（毫米） 400 x 400 x 400 300 x 300 x 300 300 x 300 x 300 300 x 300 x 200

外觀標準好優越優越

表面紋理粗糙

可拋光略粗糙

可拋光光滑

閃亮光滑

閃亮

顏色最多

不透明和半透明所有

顏色

一般

黑色

灰色

白色（不透明）

很多

幾乎無限

不透明

半透明

很多

支撐結構需要不需要需要需要

機械性能可變

強

堅韌

耐用

強

靈活強

脆

新型柔性化合物

強

脆

新型柔性化合物

機械故障逐漸變形直到斷裂逐漸變形直到斷裂幾乎沒有變形直到

突然斷裂幾乎沒有變形直到

突然斷裂

耐磨性可變優越可變可變

打印速度低標準高最高

後期處理拋光

繪畫

密封

平滑

拋光

平滑

上漆

染色

繪畫

拋光（很少需要）

繪畫拋光（很少需要）

繪畫

食物兼容性於微空隙洩漏是的只有特殊的樹脂只有特殊的樹脂

化學品的相容性由於微空隙洩漏高度耐性未定義未定義

成本便宜

打印機：便宜

材料：便宜

最貴

打印機：嚴重地昂貴

材料：便宜

貴

打印機：比較便宜

樹脂：可能很昂貴

貴

打印機：比較便宜

樹脂：可能很昂貴

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CAD）



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附錄

引用https://www.sculpteo.com/blog/2015/12/09/3d-printing-technologies-sls-sla/

https://www.sculpteo.com/blog/2016/12/14/the-history-of–3d-printing–3d-printing-technologies-from-the–80s-to-today/

https://www.creativemechanisms.com/blog/additive-manufacturing-vs-subtractive-manufacturing

http://documents.irevues.inist.fr/bitstream/handle/2042/57294/68452.pdf?sequence=1

https://www.techopedia.com/definition/2063/computer-aided-design-cad

https://www.sculpteo.com/en/glossary/cad-definition-en/

http://www.cs.cmu.edu/~rapidproto/students.03/rarevalo/project2/Process.html

http://www.stratasys.com/3d-printers/technologies/fdm-technology

http://www.stratasys.com/materials/fdm

http://www.luvocom.de/en/products/luvocom–3f-made-for-fused-filament-fabrication/

https://formlabs.com/blog/3d-printing-technology-comparison-sla-dlp/

https://www.3dsystems.com/on-demand-manufacturing/stereolithography-sla/materials

Design And Produced By: EDICO Financial Press Services Limited設計及製作：鉅京財經印刷服務有限公司

Hong Kong Head Office 香港總公司China Offices 中國辦事處Dongguan 東莞 Chongqing 重慶 Guangzhou 廣州 Shanghai 上海Tianjin 天津 Changchun 長春 Qingdao 青島 Wuhan 武漢

Milton Plastics Ltd 萬通塑料有限公司

TECHNICAL HANDBOOKPRINTING


三維打印技術手冊


3D

3D

萬通集團成員

Hong Kong Head Office 香港總公司China Offices 中國辦事處Dongguan 東莞

Chongqing 重慶 Guangzhou 廣州 Shanghai 上海 Tianjin 天津

Changchun 長春 Qingdao 青島 Wuhan 武漢

Milton Plastics Ltd 萬通塑料有限公司TECHNICAL HANDBOOK

PLASTICS INDUSTRY

PRINTING

FDM


三維打印技術手冊塑料行业


3D

3D

DLP/SLA

SLS

三維打印技術手冊塑

料行業

3D PRIN

TING

TECHN

ICAL HAN

DBOOK PLASTICS IN

DUSTRY

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