Tuesday, 10 February 2015

Notes on the cost of 3D printing

This post sets out to address the cost of plaster 3D prints - also variously known as ZCorp, Sandstone and Colorstone. 

All 3D print technologies have different pricing parameters so the points below do not necessarily translate to other processes. Plaster printing does not need supports to be printed as the part is fully supported in the bed of plaster powder as the print progresses. Unlike the SLS process which is also powder based, all of the unused powder can be reused in the next print.  

In addition to the powder used to make the part, a greater expense in binder fluid, cleaning fluid and printheads needs to be factored into the material cost of the print. Despite this it is usual (but not universal) to charge per cubic cm (£/cc) of material used.

For many parts including most architectural massing models consideration needs to be given to whether or not a part can be hollowed out to reduce the amount of material used and ultimately to save cost.

Parts need to be cost effective for the long term success of a bureau and hollowing parts is key to this.

For many heavier 3D printed parts there are 3 possible outcomes to treating a 3D print:

  • Print solid
  • Print hollow and leave unused powder trapped inside the part
  • Print hollow and leave an opening to remove unused powder
Buildings usually sit on the earth and are consequently not viewed from the underside. This makes it possible to hollow most building massing models leaving the underside open to remove unused powder.

Hollowed 3D print

Solid models may be needed for vac forming etc and in some parts just have the wrong geometry for hollowing and need to be made solid.

Other parts can be hollowed but a hole or other opening is unwanted and then unused powder may be left trapped inside the part. Consideration needs to be given in such circumstances as to whether it would be desirable for powder to leak out if a model were broken. 

So let us take an example of a cube measuring 100 x 100 x 100mm.

  • Solid this occupies 1000cc
  • Hollowed with a 4mm wall thickness it occupies 221cc
  • Hollowed with a 3mm wall thickness it occupies 169cc
This sheds some light on those stories of horrendously expensive prices sometimes quoted (and sometimes paid) for 3D printed parts. Be careful of this when getting quotes for parts online, software is not likely to pick up on the fact you are asking to print a lump of material that could do with being hollowed. A human is usually better able to spot this kind of thing.

In the case of our 100 x 100 x 100mm cube it is worth noting that the difference in volume between the 4mm wall thickness and a 3mm wall thickness is 52cc. Which priced on a cubic cm basis could be a 23% difference in price. 

Choosing an appropriate wall thickness depends on various things. The size and strength of the part, its purpose, whether it needs to travel and even on very tight deadlines the time available to remove it from the machine and get it to the customer.

Generally we hollow parts for customers as part of our file optimisation service at Lee 3D. To do this we use Magics RP, the industry standard software for preparing models for 3D print. This allows us to hollow complex parts with a uniform thickness.

For more information about 3D printing at Lee 3D please visit www.lee3d.co.uk

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