Case Studies - SD3D Printing
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Resources and Case Studies

Architecture

3D Printed Town

See the Largest 3D Printed City!

By | 3D Printing, Architecture Case Study, In the News, Rapid Prototyping | No Comments

Read about how SD3D worked with Aon to design and print a record breaking 9′ x 10.5′ model city. This giant city helped to show off the vast insurance portfolio offered by Aon to it’s clients and allowed us to test the limits of 3D printing scaled architectural models. In total this massive effort took over 200 design hours and 3000 printing hours that yielded 300 individual parts weighing a total of 66 kilograms. We assembled this record breaking model into four quadrants that could be broken down to easily transport between trade events. This project was completed within 30 days from concept to final delivery.

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Automation

Design

Taking PJ Guard From Concept to Production

By | 3D Printing, Design | No Comments

When Latrice from PJ Guard first contacted SD3D in February of 2016 she had a vision for a new product that she simply couldn’t stop thinking about. At the time, she wasn’t sure if it was going to be a marketable product or just a one-off security device for her house. Her only certainty was that it was going to solve a major security flaw in her home which would allow her to sleep soundly at night and while she was away.

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Hardware

Dual Geared Extruder

By | 3D Printing, Hardware, Hardware Case Study | No Comments

When it comes to FDM 3D printing, one of the most important pieces of hardware is the extruder. While the older Prusa based cartesian printers with moving build platforms were limited in speed mainly due to larger moving masses, new printer designs are capable of reaching much higher travel speeds without sacrificing precision. On these new FDM printer designs, the limiting factor has become the extruder responsible for positioning the filament for accurate material deposition. Read More

Punchtec 0-100C

Not all Heated Beds are Created Equal

By | 3D Printing, Hardware, Hardware Case Study | One Comment
We do a lot of research and development on 3D printing systems at SD3D in an effort to improve the quality and reliability of our machines and to help select the best 3D printer technology available for our production factory. Recently, we took six off-the-shelf desktop 3D printers and our proprietary 3DGenie FDM printer and compared the quality of the heated build plate (HBP) with respect to surface temperature gradients. Read More

Stepper Motor Cooling

By | 3D Printing, Hardware Case Study | No Comments

There are several practical reasons why you may want to cool the components inside your 3D printer. The first and most important is to make sure that your printer remains operational and free of maintenance for as long as possible. The most obvious low-hanging fruit for most 3D printers are the stepper motors responsibility for extruding and positioning the model on the x-y planes. These three motors can run so hot that they will burn you if you try to touch their surface platting during a print. While these motors are designed to run hot, there is a limit to how hot you want them to get for prolonged periods. This is where stepper motor cooling comes into play.

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IoT

The Decentralized SmartFactory

By | 3D Printing, IoT Case Study | No Comments

This case study discusses the merger of 3D Printing and IoT at the commercial scale, reflecting the data we have gathered through operations to provide estimates on production cost reductions.

As of 2019 we expect to achieve a net savings of over $400,000 per year in operational costs by implementing IoT driven energy savings and process improvements onto our 3D printing production lines in Dallas and San Diego. Implementing industrial IoT onto our production lines will allow us to offer even lower cost solutions for high volume 3D printing production, pushing additive manufacturing into new applications that are not currently economically viable.

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Materials

Flexible 3D printing Materials

Meet the Flexibles

By | 3D Printing, Education, FIlaments | One Comment
Along with the other Unique Filaments we have reviewed thus far, we have been recently working very closely with flexible materials for FDM 3D printing.  Each has benefits, and each have their own softness and flexibility.  Today we will be looking at PCTPE from taulman 3d, FlexSolid from MadeSolid, NinjaFlex by Ninjatek, and the new Cheetah by Ninjatek.  Along with overall properties, we will be giving printing settings and even a Cura profile to download.

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ABS

Complete ABS Profile Print Settings

By | 3D Printing, Cura, FIlaments, Rapid Prototyping, Software | No Comments
Through trial and error we have slowly honed in our profile settings for different 3D printing materials.   This is our second profile tutorial and today we will be taking a look at the settings and profiles that have worked for us while printing in ABS.

Further than just explaining preferred temperature settings, we will be taking an indepth look at advanced support and infill settings, as well as many other factors that go into making a clean and successful print.

ABS is quite unique to PLA for a few reasons.  The first is the difficulty to print.  Small items are quite easy, and the printer can handle ABS without any issues.  The problem arises when printing large parts.  Since ABS has a high shrinkage rate which causes warping, we will only print larger ABS jobs on our TAZ5 with our proprietary enclosure or on our fully enclosed 3DGenie. Read More