Process guide

Additive manufacturing enables the layer-by-layer production of three-dimensional components. New materials open up a wide range of possibilities, from flame-retardant plastics to innovative metal materials such as pure copper or Zamak 5 (zinc). However, conventional manufacturing processes are also suitable for some projects. The PROTIQ Marketplace offers users an overview of established and new processes as well as transparent price comparisons.

Guide to process selection

Additive manufacturing is subject to rapid and continuous development, opening up new possibilities and potential year after year. In the field of available plastic materials, for example, new materials enable the production of components with flame-retardant and ESD-dissipating properties.

Innovative metal materials such as pure copper or the series material Zamak 5 (zinc) also open up new opportunities for current-carrying applications or direct series production in combination with zinc die-casting.

However, this dynamic development is making it increasingly difficult for users to maintain an overview and to evaluate and utilise new potential. This is where the PROTIQ Marketplace provides support with a broad portfolio of established and new manufacturing processes as well as a direct comparison. Everything in one place, transparent and also directly comparable in price.

The right manufacturing process for every application

It goes without saying that it is extremely important to always consider and evaluate additive manufacturing in the context of traditional manufacturing processes. Only when an individual application with additive manufacturing processes proves to be economically advantageous compared to other manufacturing methods is a sensible implementation possible. This is usually the case for small and medium quantities or complex component geometries.

Simple geometries and simple shapes can often be produced by turning and milling. This is particularly the case when very high demands are placed on tolerances and precision.

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For applications with particularly high quantities, on the other hand, manufacturing processes from the moulding sector are particularly suitable. For plastics, plastic injection moulding is used, which has long been established as the standard across all industries. Maximum quantities of several million parts are not uncommon here. Metal components in large quantities are usually manufactured using the zinc or aluminium die-casting process. The principle and quantities are similar to those in the plastics sector.

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Vacuum casting forms an intermediate link between additive manufacturing and large-scale production in plastic injection moulding. It is suitable for the production of small quantities up to medium-sized series. The process represents an opportunity to multiply the advantages of additively manufactured individual parts or small series to higher quantities. In addition, the 3D-printed geometry of a component can be combined with the advantages of a very wide range of possible material properties.

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Additive manufacturing processes

In general, additive manufacturing processes are categorised according to the technology used and the form of the starting material. A distinction is made between three main areas: solid, liquid and powdered starting materials.

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The best-known and most widespread fused deposition modelling process (FDM, also known as the FFF process) is primarily used in the private and low-cost sector. It is based on the melting of a solid plastic filament, which is deposited locally through a fine nozzle. This process is cost-effective, but has a low component strength and level of detail. Due to its limited productivity, it is more suitable for small quantities and components without high quality requirements.

Liquid resin and powder-based processes are primarily used for additive manufacturing with industrial requirements. Resin-based additive processes, such as stereolithography (SLA), enable the production of components with outstanding detail and surface quality. The components are produced from liquid, photoreactive synthetic resin and cured layer by layer using a precise UV light source.

Although these components were previously mainly used for prototypes due to their low strength and mouldability, thanks to newly developed resins it is now also possible to produce highly resilient series components, e.g. using the CLIP process or hot lithography.

New innovative additive manufacturing processes combine the advantages of precise resin 3D printing with the production of highly detailed components made of technical ceramics, pure quartz glass or high-strength metal components. In a two-stage process, a so-called green body is first built up from resin, in which high proportions of ceramic, silicates or metal particles are mixed. The polymer is then completely removed from this body in a thermal firing process, leaving behind a high-precision component made of pure technical ceramic (LCM), genuine quartz glass (LGM) or filigree stainless steel (LMM).

Powder-based processes dominate the industrial additive manufacturing of mechanically stressed structural components. The high component strengths that can be achieved, together with good surface quality and a high degree of design freedom, form an ideal combination here. The processes are also highly productive.

Two processes dominate the market in the additive, powder-bed-based production of plastic components: selective laser sintering (SLS) and multi-jet fusion (MJF). In both processes, the components are produced from fine plastic powder, which is melted locally using a powerful light source (laser or steel). During the printing process, the components are surrounded by non-melted powder, meaning that support structures are not required. This enables high productivity as well as the realisation of finer details, higher strengths and greater complexity. The parts are particularly suitable for mechanically stressed components and can also be used for series applications.

The very similar process of selective laser melting (SLM), also known as laser powder bed fusion (L-PBF), is used to produce even more resilient metal components. Similar to the SLS process, fine powder - in this case metal powder - is fused together using a powerful laser. The variety of materials available ranges from high-strength steels and light metals such as aluminium and titanium to special materials such as zinc and copper. The fields of application in the additive metal sector are diverse, as the material properties of the components are comparable with conventional manufacturing processes. Typical areas of application for components made using this process include lightweight construction in the automotive and aerospace sectors, individual components in mechanical engineering and complex heating and moulding tools.

Process guide

Guide to process selection

The right manufacturing process for every application

Additive manufacturing processes

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