3D Printing Fundamentals

The buzz around 3D printing is due to its huge potential to change the way we make things, offering clear advantages over traditional methods.

• Native digital fabrication — 3D printing was one of the first manufacturing methods to be fully digital. While modern CNC milling is now entirely digital, it originally started as analog tools. Because 3D printing is digital at its core, it allows for smoother workflows and easily connects with cloud systems, artificial intelligence (AI), and other modern technologies.
• Democratized fabrication — 3D printing makes manufacturing more affordable and available to more people. 3D printers could transform the garage hobbyist into someone capable of fabricating near-net-shape parts.
• Complexity and customization as less cost — In traditional manufacturing, making complicated parts with curves or unique shapes takes more time and effort, which increases costs. But with 3D printing, complexity doesn’t add extra cost because the process is largely automated.

The Reality of Fused Filament Fabrication Printing

3D printing has huge potential, but the main technologies in this space have faced some challenges since they were first developed. One issue is that making strong, durable parts is tough because 3D printing relies on thermoplastics, which aren’t always strong enough for functional parts. Another challenge is that 3D printers have traditionally been less reliable than older manufacturing methods.

However, over the last decade, there have been significant accuracy and reliability improvements and new processes designed to yield functional parts. Overall, the outlook is very bright.

Defining key terms

Additive Manufacturing (AM) is where a part is made by adding material, and 3D printing is a subset of additive manufacturing. In 3D printing, a 3D printer makes a three-dimensional object by starting from a 3D CAD (computer-aided design) file.

• Fused Filament Fabrication (FFF) is an industry-standard 3D printing process in which thermoplastic-based filament is heated and extruded through a nozzle in discrete layers to create a part. Some FFF filaments are “filled” with microcarbon fibers, but the strength of the resultant part is similar to that of plastic.
• Carbon Fiber Reinforcement (CFR) is a 3D printing method that makes FFF parts much stronger by adding continuous fibers. A CFR printer uses two systems: one for regular FFF filament and another for long fibers. These fibers are added where needed, replacing the usual infill, and making parts up to 10 times stronger—strong enough to replace aluminum parts.

While FFF is the most common 3D printing method today, CFR improves on it by fixing the usual weaknesses in FFF parts, making them strong enough for many manufacturing uses.

Fused Filament Fabrication printers: A closer look

Fused Filament Fabrication printers are the most common 3D printing technology due to their simplicity, affordability, variety, and maturity. They exist all up and down the cost spectrum — from $200 machines that are preferred by casual users to production-grade machines that cost hundreds of thousands of dollars. As technology advances, more industries adopt it.

How a Fused Filament Fabrication 3D printer works

In this section, we’ll discuss the processes, printers, and parts of FFF. Here’s a breakdown of how an FFF printer creates a part after the initial design phase:

1. The printer software slices parts into layers and creates a toolpath, which acts as the machine’s automatic blueprint.
2. A printing system heats and extrudes material (like a glue gun) out of a nozzle, following the toolpath. It lays the first layer directly onto the print bed.
3. After completing a layer, the printer lowers its print bed one layer from the print head and starts printing the next layer. This process continues until a print job is complete.
4. After the print is complete, a user can remove the part from the print bed and use it.

Key systems in a Fused Filament Fabrication 3D printer

• Print head/extrusion system — The core part of an FFF printer where the system heats and extrudes material out of a nozzle.
• XY motion system — The system that moves the print head on the printing plane via a typical XY gantry. A precision motion system precisely controls the location of the printhead.
• Print bed — Or build plate, is the surface where an FFF part is built. It’s connected to a Z-axis system that controls its distance from the part.

Fused Filament Fabrication: The Anatomy of a 3D printed part

An FFF printer builds parts using four key elements:

• Floors and roofs: Same Floors refer to the bottom and roofs to the top of the part. Both consist of multiple layers, printed with a back-and-forth pattern that changes direction with each layer.
• Walls: Walls refer to the external “shell” outside of an FFF printed part and are commonly printed 2-4 beads thick.
• Infill: Infill is the internal structure of a part. While it’s possible to print solid parts, the clear majority of FFF-printed parts are printed with a lattice infill. 
• Support material: Support material helps with parts that have overhangs or bridges. It acts as a temporary scaffold and can be peeled away or dissolved after printing. This material is sacrificial, meaning it is removed once the part is finished.

Continuous Fiber Reinforcement: The Basics and Advantages

While FFF has impacted the 3D printing industry, it struggles with printing parts stronger than plastic. This section explores how CFR works and compares it to FFF.

A closer look at CFR

CFR enhances traditional FFF technology, enabling Markforged’s printers to reinforce FFF parts with continuous fibers. A CFR-capable machine uses two extrusion systems for two unique materials: one for FFF thermoplastic filament and another for long-strand fibers that replace the usual infill.

• CFR levels of control: Even in small amounts, continuous fibers significantly improve material strength. CFR printers offer precise control over fiber placement, distribution, and orientation, even at a layer-by-layer level.
• Conventional infill: In areas where fiber is not inserted into a part, the printer lays down conventional FFF infill.
• Continuous fibers: Where specified, a CFR-capable printer replaces conventional FFF infill with continuous fiber.

How The Digital Forge from Markforged will transform your organization

The Digital Forge is an intuitive Additive Manufacturing platform that combines the speed of agile software development with industrial manufacturing. Composed of hardware, software, and materials into a unified system, designed to fit seamlessly into your existing manufacturing processes and bridge the gap between design and functional parts.

Adopters of Digital Forge experience significant time and cost savings on parts. Through increased adoption, the platform enhances overall agility and efficiency, providing a competitive edge for your operations.

Partner with an industry leader

In conclusion, Markforged is a leading company in the 3D printing industry, offering cutting-edge materials and solutions for CFR technology, such as Onyx FR and Carbon Fiber FR. With their continuous innovation in hardware, software, and materials, Markforged is well-equipped to tackle modern manufacturing challenges and deliver exceptional value. Contact us today for more information and discover how using Markforged 3d printers transforms your business.