In the quirky corridors of corporate life, the clamor for innovative tools often leads to an interesting phenomenon in the workplace: the “get out of my hair money.” This concept, while not officially recognized in any business manual, plays a pivotal role in how management deals with persistent requests on topics they do not clearly understand. This is especially true when it comes to innovative and popular tech like 3D printers. Have you ever found yourself asking for a 3D printer so often that the management just handed you enough funds to buy a tabletop printer, effectively to get you to stop asking? Well, you’ve just encountered what we call “get out of my hair money.”

The Starter Printer: Your Entry-Level Sidekick
If you’ve landed funds for a sub-$10,000 desktop 3D printer, think of it as your entry ticket to the techie club—not the VIP section, but a start. For many professionals, receiving funds to purchase a sub-$10,000 desktop 3D printer often represents a compromise. Typically, these units are Fused Deposition Modeling (FDM) type printers, which are great for uncomplicated projects. These machines are good for demonstrating the viability of 3D printing technology within a company. However, they come with limitations. Desktop printers often are single headed, and they lack the capability to execute complex geometries, lack consistency in production, and lack the speed that an industrial-grade printer has.

Are FDM tabletop systems the only 3D printing technology?
While these budget-friendly printers are the interns of the 3D printing world—eager but not always up to the task for the big leagues, there are numerous other types of 3D printing technologies and materials that you should be looking into, for example:

Stereolithography (SLA):
This uses a laser to cure liquid resin into hardened plastic in a process that allows for high-resolution output. 50 plus of material choices.

Digital Light Processing (DLP):
Similar to SLA but uses a digital light projector to flash a single image of each layer all at once. 50 plus material choices

PolyJet:
Works by jetting layers of curable liquid photopolymer onto a build tray. Materials for color, clear and digital rubber like materials.

Selective Laser Sintering (SLS):
Uses a laser to sinter powdered material, binding it together to create a solid structure. Usually used in metal processes with metal power made from several metals.

Selective Absorption Fusion (SAF):
A newer technique that involves absorbing infrared light to fuse powder particles together. Materials include PA11, PA12 and others.

Industrial Fused Deposition Modeling (FDM )printers:
Industrial FDM printers have two or more material heads; one for material and one for soluble support. They include a controlled heated building environment, on site repair, materials designed for specific applications, and is designed for an industrial environment. These printers use several specialty materials.

Stepping up into additive manufacturing as a path forward
There are several uses of these technologies in a modern factory.

Product Development: Prototypes, Concept Modeling, and Surrogate Tryout Parts
3D printing has revolutionized the product development phase by allowing designers and engineers to create prototypes quickly and with fewer costs compared to traditional methods. Prototyping is perhaps the most well-known application of 3D printing. It enables rapid production of parts to test for form, fit, and function. By doing so, it allows for immediate feedback and multiple iterations without the need for expensive tooling or molds.

Concept modeling is another area where 3D printing shines. Designers can bring their ideas to life in a matter of hours, presenting physical models that can be touched and seen, rather than merely viewed on a screen. This tangible representation is invaluable for marketing teams and stakeholders to gain a clearer understanding of the product’s potential.

Moreover, in surrogate tryout parts, 3D printing assists in the automotive and aerospace industries where testing specific components in an assembly under real conditions is crucial. These parts can be used in place of more expensive, final materials to test for thermal and stress properties, thereby identifying potential issues early in the development process. These technologies, especially in an industrial setting, can handle a myriad of materials from polymers to metals, offering a versatility far beyond the capabilities of your typical hobby printer.

Manufacturing Support: Jigs and Fixtures, Drill Guides, Injection Molds, and End-of-Arm Tooling
3D printing also plays a critical role in manufacturing support, particularly in the creation of jigs and fixtures. These tools are essential for ensuring precision and efficiency in the manufacturing process. By using 3D printing, these items can be custom-made for specific tasks at a fraction of the time and cost of traditional methods.

Drill guides fabricated through 3D printing are not only quicker to produce but can also be designed with complex features that enhance their functionality and accuracy. Similarly, 3D printing of injection molds is a game-changer, particularly for low-volume production where the high cost of traditional steel molds is not justifiable.

In robotics, end-of-arm tooling (EOAT) can be specifically tailored for particular applications. Lightweight and perfectly fitting EOAT can be produced using 3D printing, enhancing the efficiency of robotic arms used in assembly lines.

Production Parts: Bridge to Production, Low Volume Production, and Spare Parts
In terms of actual production, 3D printing provides solutions such as bridge to production, where it can be used to fill in the gap between prototype development and full-scale production. This is particularly useful during the evaluation phase of a product’s market potential before companies invest in expensive tooling.

For low-volume production, 3D printing is ideal because it does not require the same upfront investments in tooling that traditional manufacturing does, making it cost-effective for small batches of products. This capability is incredibly beneficial for customized products or for industries where the demand does not justify mass production techniques.

Lastly, the production of spare parts is another area where 3D printing offers significant advantages. It enables on-demand production without the need to hold large inventories. This is particularly crucial for older machinery where parts may no longer be produced or for systems requiring rapid turnaround to prevent downtime.

The concept of “get out of my hair money” in the context of acquiring a 3D printer represents a unique intersection of innovation, compromise, and practicality in the corporate environment. While entry-level FDM tabletop printers may initially seem like a mere stopgap, they can open the door to the broader, transformative potentials of additive manufacturing. From creating prototypes and manufacturing aids to producing end-use parts, the range of applications for 3D printing continues to expand, offering significant efficiencies and creative opportunities. This initial investment, driven perhaps by a manager’s desire to quell persistent requests, can inadvertently set the stage for a deeper exploration and integration of advanced 3D printing technologies within a company, thereby enhancing its capabilities and competitive edge in the market.

If there is a technology that you’d like to learn more about, please contact us at Prototyping Solutions. We are committed to helping you find the right solution and materials for your needs.