Why you can now play at home: the history and techniques of 3D printing

The early times (SLA)

The 3D printing tech field began to take shape in the early 1980s with one of the first methods called stereolithography (SLA). In 1984, a professional nerd by the name of Chuck Hull patented the SLA process, which uses ultraviolet (UV) light to cure liquid photopolymer resin in thin layers. The SLA-1, released in 1987, was the first commercial 3D printer using this technique.

Digital Light Processing (DLP)

Another technique, another cool-sounding acronym, DLP. Digital Light Processing emerged in the late 1980s as another method within the resin photopolymerization family. Like stereolithography (SLA), DLP cures liquid resin layer by layer; however, instead of using a UV laser to trace each layer’s geometry point by point, DLP employs a digital projector. This projector flashes an entire image of the layer onto the resin in one go, which generally allows for faster layer curing. The resolution in DLP is determined by the pixel size of the projected image, which can offer a precise level of detail depending on the system’s specifications. Over time, improvements in projector technology have enhanced the speed and accuracy of DLP printers, making them popular for applications that require quick turnaround and fine detailing, such as jewelry and dental components.

Material Extrusion (FDM)

When you think 3D printing, you are thinking about this method. In 1989, Scott Crump introduced Fused Deposition Modeling (FDM). This method deposits molten thermoplastic through a moving nozzle, building objects layer by layer according to a predefined path. FDM made it possible to produce robust parts from common plastics and later evolved into a technology widely used in desktop 3D printers for rapid prototyping and hobbyist projects.

Powder-Based Techniques (SLS)

Why have only three techniques when you can have more? Another key method, Selective Laser Sintering (SLS), emerged in the late 1980s and early 1990s. SLS uses a high-powered laser to fuse powdered material—such as plastics or metals—into solid objects. This process does not require additional support structures, permitting the creation of complex geometries that might be challenging with other techniques. SLS has been especially useful in industries where processing a variety of materials and intricate designs is required.

The Open-Source Movement and Democratization

A turning point for 3D printing came with the open-source movement. In 2005, the RepRap project, initiated by Dr. Adrian Bowyer, focused on creating self-replicating 3D printers (exciting and a little scary at the same time). The project's goal was to reduce costs and make the technology accessible for personal use. RepRap enabled enthusiasts and educators to develop and share their own printer designs, fueling a steady increase in low-cost, home-based 3D printers.

This democratization paved the way for companies like MakerBot, Prusa, and Creality to bring consumer-friendly machines to the market.

Today and tomorrow

As the technology advanced, more techniques and refinements emerged. Over the past decade, material improvements have enabled for newer resin types that allow for incredibly detailed parts. You can now also do metal printing with techniques that introduce even more acronyms like Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLM) and for more varied materials and colors that can be used on a single print.

Spend money now: some 3D printer options for your workshop

Below are several 3D printers—each based on a different technique—that many hobbyists use in their workshops. My dream is that one day this newsletter grows so much that I will get these for free.

Fused Deposition Modeling (FDM) Printers

• Prusa i3 MK3S+ This printer is known in many maker circles for its reliability and ease of use. It supports a range of common materials and has a strong, proven design.

• Creality Ender 3 Series The Ender 3 and its variants (such as the Ender 3 Pro or V2) are favored by hobbyists for their affordability and community support.

Resin (SLA/DLP) Printers

• Anycubic Photon Mono X A common choice among enthusiasts for its balance of resolution and print size in resin printing.

• Elegoo Mars 2 Pro Known for its consistent detail, this printer is used by those who need precise models or miniature parts.

Powder-Based (SLS) Printers

While SLS has traditionally been used in industrial settings, some desktop models are now available for small-scale projects:

• Sinterit Lisa A desktop SLS printer that uses plastic powders, suitable for those who want to experiment with a process that does not require support structures.

More

While preparing this article I used these sources that you can use as the starting point for your deep dive into the fascinating world of 3D printing.

• https://www.researchgate.net/figure/Timeline-illustrating-some-of-the-important-milestones-relating-to-3D-printing-technology_fig1_359157355

• https://reprap.org/wiki/RepRap

• https://www.prusa3d.com/category/3d-printers/

• https://www.reddit.com/r/3Dprinting/

• https://www.3dsystems.com/blog/2015/06/sla-1-national-inventors-hall-fame-museum

• I’ll stop here, I’m sure you can find many more.

😂

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