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FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 2
Introduction
Rapid prototyping helps companies turn ideas into realistic proofs of concept, advances these
concepts to high-fidelity prototypes that look and work like final products, and guides products
through a series of validation stages toward mass production. With rapid prototyping, designers
and engineers can create prototypes directly from CAD data faster than ever before, and
execute quick and frequent revisions of their designs based on real-world testing and feedback.
In this white paper, you’ll learn how rapid prototyping fits into the product design process, its
applications, and what rapid prototyping tools are available to today’s product design teams.
FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 3
What is Rapid Prototyping?
Rapid prototyping is the group of techniques used to quickly fabricate a scale model of
a physical part or assembly using three-dimensional computer-aided design (CAD) data.
Because these parts or assemblies are usually constructed using additive techniques as
opposed to traditional subtractive methods, the phrase has become synonymous with
additive manufacturing and 3D printing.
Additive manufacturing is a natural match for prototyping. It provides almost unlimited form
freedom, doesn’t require tooling, and can produce parts with properties closely matching
various materials made with traditional manufacturing methods. 3D printing technologies have
been around since the 1980s, but their high cost and complexity mostly limited use to large
corporations, or forced smaller companies to outsource production to specialized services,
waiting weeks between iterations.
The advent of desktop and benchtop 3D printing has changed this status quo and inspired a
groundswell of adoption that shows no sign of stopping. With in-house 3D printing, engineers
and designers can quickly iterate between digital designs and physical prototypes. It is now
possible to create prototypes within a day and carry out quick iterations of design, size, shape,
or assembly based on results of real-life testing and analysis. Ultimately, rapid prototyping
helps companies get better products to market faster than their competition.
FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 4
Why Rapid Prototyping?
REALIZE AND EXPLORE CONCEPTS FASTER
Rapid prototyping elevates initial ideas to low-risk concept explorations that look like real products
in no time. It allows designers to go beyond virtual visualization, making it easier to understand the
look and feel of the design, and compare concepts side by side.
Consecutive iterations of Sutrue, an automated surgical suturing device prototyped on Formlabs SLA printers.
A good model is a 24-hour design cycle: design during work, 3D print parts overnight, clean and
test the next day, tweak the design, then repeat.
FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 5
Applications of Rapid Prototyping
Thanks to a variety of available technologies and materials, rapid prototyping with 3D printing
supports designers and engineers throughout product development, from initial concept models to
engineering, validation, and production.
CONCEPT MODELS
Concept models or proof-of-concept (POC) prototypes help product designers validate ideas
and assumptions and test a product’s viability. Physical concept models can demonstrate
an idea to stakeholders, create discussion, and drive acceptance or rejection using low-risk
concept explorations.
The key to successful concept modeling is speed; designers need to generate a wealth of ideas,
before building and evaluating physical models. At this stage, usability and quality are of less
importance and teams rely on off-the-shelf parts as much as possible.
3D printers are ideal tools to support concept modeling. They provide unmatched turnaround time
to convert a computer file into a physical prototype, allowing designers to test more concepts,
faster. In contrast with the majority of workshop and manufacturing tools, desktop 3D printers are
office-friendly, sparing the need for a dedicated space.
FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 6
Diving camera manufacturer Paralenz used
3D printing to create realistic prototypes that
endured testing 200+ meters below sea level.
FUNCTIONAL PROTOTYPES
As the product moves into the subsequent stages, details become increasingly important.
3D printing allows engineers to create high-fidelity prototypes that accurately represent the
final product. This makes it easier to verify the design, fit, function, and manufacturability
before investing in expensive tooling and moving into production, when the time and cost
to make change becomes increasingly prohibitive.
Advanced 3D printing materials can closely match the look, feel, and material characteristics
of parts produced with traditional manufacturing processes such as injection molding. Various
materials can simulate parts with fine details and textures, smooth and low-friction surfaces, rigid
and robust housings, or soft-touch and clear components. 3D printed parts can be finished with
secondary processes like sanding, polishing, painting, or electroplating to replicate any visual
attribute of a final part, as well as machined to create assemblies from multiple parts and materials.
Engineering prototypes require extensive functional testing to see how a part or assembly will
function when subjected to stresses and conditions of in-field use. 3D printing offers engineering
plastics for high-performance prototypes that can withstand thermal, chemical, and mechanical
stress. The technology also provides an efficient solution for creating custom test fixtures to
simplify functional testing and certification by gathering consistent data.
FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 8
Rapid Prototyping Tools: FDM vs. SLA vs. SLS
Over the last few years, high-resolution 3D printers have become more affordable, easier to use,
and more reliable. As a result, the technology is now accessible to more businesses, but choosing
between the various competing 3D printing solutions can be difficult.
Which technology is suitable for your particular application? What materials are available? What
equipment and training do you need to get started? How about costs and return on investment?
Now, we’ll take a closer look at the three most established technologies for 3D printing plastics
today: fused deposition modeling (FDM), stereolithography (SLA), and selective laser sintering (SLS)
FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 9
STEREOLITHOGRAPHY (SLA) SELECTIVE LASER SINTERING (SLS)
Stereolithography was the world’s first 3D printing Selective laser sintering is the most common additive
technology, invented in the early 1970s, and is still one manufacturing technology for industrial applications.
of the most popular technologies for professionals. SLS 3D printers use a high-powered laser to fuse small
SLA uses a laser to cure liquid resin into hardened plastic particles of polymer powder. The unfused powder
in a process called photopolymerization. supports the part during printing and eliminates the
SLA parts have the highest resolution and accuracy, need for dedicated support structures. This makes SLS
the clearest details, and the smoothest surface finish ideal for complex geometries, including interior features,
of all plastic 3D printing technologies, but the main undercuts, thin walls, and negative features. Parts
benefit of SLA lies in its versatility. Material manufacturers produced with SLS printing have excellent mechanical
have created innovative SLA resin formulations with characteristics, with strength resembling that of injection-
a wide range of optical, mechanical, and thermal molded parts.
properties to match those of standard, engineering, The most common material for selective laser sintering
and industrial thermoplastics. is nylon, a popular engineering thermoplastic with
SLA is a great option for highly detailed prototypes excellent mechanical properties. Nylon is lightweight,
requiring tight tolerances and smooth surfaces, such strong, and flexible, as
as molds, patterns, and functional parts. SLA is widely well as stable against impact, chemicals, heat, UV light,
used in a range of industries from engineering and water, and dirt.
product design to manufacturing, dentistry, jewelry, The combination of low cost per part, high productivity,
model making, and education. and established materials make SLS a popular choice
Request a free sample part and see the SLA among engineers for functional prototyping, and a cost-
quality firsthand. effective alternative to injection molding for limited-run or
bridge manufacturing.
FDM parts tend to have visible layer lines SLA parts have sharp edges, a smooth SLS parts have a slightly rough surface
and might show inaccuracies around surface finish, and minimal visible layer finish, but almost no visible layer lines.
complex features. This example was printed lines. This example part was printed on a This example part was printed on a
on a Stratasys uPrint industrial FDM 3D Formlabs Form 2 desktop SLA 3D printer Formlabs Fuse 1 benchtop SLS 3D printer
printer with soluble supports (machine (starting at $3,499). (starting at $9,999).
starting at $15,900).
COMPARE FDM, SLA, AND SLS TECHNOLOGIES
Each 3D printing technology has its own strengths, weaknesses, and requirements, and is suitable for different
applications and businesses. The following table summarizes some key characteristics and considerations.
Resolution
Accuracy
Surface Finish
Throughput
Complex Designs
Ease of Use
Print Volume Up to ~200 x 200 x 300 mm Up to 145 x 145 x 175 mm (desktop Up to 165 x 165 x 320 mm
(desktop 3D printers) 3D printers) (benchtop 3D printers)
Training Minor training on build setup, Plug and play. Minor training Moderate training on build setup,
machine operation, and on build setup, maintenance, maintenance, machine operation,
finishing; moderate training on machine operation, and finishing. and finishing.
maintenance.
Facility Air-conditioned environment or Desktop machines are suitable for Workshop environment with
Requirements preferably custom ventilation for an office environment. moderate space requirements
desktop machines. for benchtop systems.
Ancillary Support removal system for Post-curing station, washing Post-processing station for part
Equipment machines with soluble supports station (optionally automated), cleaning and material recovery.
(optionally automated), finishing finishing tools.
tools.
FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 11
COSTS AND RETURN ON INVESTMENT
Ultimately, you should choose the technology that makes the most sense for your business.
Prices have dropped significantly in recent years, and today, all three technologies are available in
compact, affordable systems.
Calculating costs does not end with upfront equipment costs. Material and labor costs have a
significant influence on cost per part, depending on the application and your production needs.
Equipment Costs Mid-range desktop printers Professional desktop Benchtop systems start
start at $2,000, and industrial printers start at $3,500, at $10,000, and industrial
systems are available from and large-scale industrial printers are available from
$15,000. machines are available $100,000.
from $80,000.
Material Costs $50-$150/kg for most $149-$200/L for $100/kg for nylon. SLS
standard and engineering most standard and requires no support
filaments, and $100-200/kg engineering resins. structures, and unfused
for support materials. powder can be reused,
which lowers material
costs.
Labor Needs Manual support removal Washing and post-curing Simple cleaning to remove
(can be mostly automated (both can be mostly excess powder.
for industrial systems with automated).
soluble supports). Lengthy Simple post-processing to
post-processing is required remove support marks.
for a high-quality finish.
FORMLABS WHITE PAPER: Introduction to Digital Dentistry and 3D Printer Buyer’s Guide 12
Form 2 Fuse 1
Intuitive, reliable stereolithography The industrial power of selective
for the desktop laser sintering for the benchtop