3D Printing Custom Made

How FDM Works

FDM is the most widely used and cost-effective 3D printing method. The process uses thermoplastic filament that is heated and extruded through a nozzle layer by layer. Thanks to the high availability of the technology, parts are produced quickly and at low cost, making it ideal for functional prototypes and end parts.

Advantages of FDM Printing

• Cost-effectiveness - the most economical method for producing thermoplastic parts
• Wide range of materials including ABS, PETG, nylon and special polymers
• Functional prototypes with good mechanical properties
• Ability to print large parts up to 1000 x 610 x 610 mm
• Low operating costs and easy maintenance
• Fast delivery time within a few days

Disadvantages

• Surface quality - visible layers and lines, surface cannot be smoothed to detail
• For larger series, the price per piece does not decrease as with injection molding
• Interlayer strength - parts are weaker in the vertical direction (between layers) than horizontally

How SLM Works

Selective Laser Melting (SLM), also known as DMLS (Direct Metal Laser Sintering), is a metal 3D printing technology. It uses a high-power laser to completely melt metal powder layer by layer. The result is fully functional metal parts with density up to 99.9% and mechanical properties comparable to traditionally manufactured metals.

Advantages of SLM Printing

• Complex geometry - advanced CAD techniques like topology optimization enable production of lightweight parts
• Parts can be produced quickly with full material density while maintaining high strength
• High precision and repeatability for serial production
• Possibility of continuous production cycles

Disadvantages

• Internal stress - SLM is a high-temperature process, printed parts often end up with internal stress
• Cost - SLM machines are designed for high-volume industrial use, therefore expensive

How MJF Works

Multi Jet Fusion (MJF) is a technology developed by HP. Unlike laser, it uses special agents (fusing and detailing) that are applied to nylon powder and then heated with infrared light. The result is parts with uniform properties in all directions and a smooth surface without visible layers.

Advantages of MJF Printing

• Strength and durability - parts with high mechanical resistance and stability for end parts
• Scalability - ability to produce custom parts at industrial scale
• Efficiency - good price-quality ratio for functional parts
• Surface and detail - MJF has resolution up to 0.070 x 0.070 mm and layers enable high speed

Disadvantages

• Material limitations - MJF offers PA12 (black and gray), PA11 and PA12 with glass beads, color options are limited
• For larger series, the price per piece does not decrease as with molding

How PolyJet Works

PolyJet is a 3D printing technology that creates parts by jetting thousands of photopolymer droplets and instantly curing them with UV light. It is one of the fastest and most precise 3D printing technologies with very smooth surface. It allows combining multiple materials and colors in one print.

Advantages of PolyJet Printing

• Geometry - ability to create detailed prototypes with different material properties, excellent aesthetics
• Material selection - PolyJet offers more than 1000 Pantone verified colors and material combinations
• Complex geometry - high level of detail and complex geometry without assembly
• Rubber-like flexibility - some materials can simulate rubber and soft material properties
• Fast turnaround - PolyJet 3D can create complex and multi-material parts in one operation

Disadvantages

• Lifespan - photopolymers degrade over time and most resins are not resistant to both impact and heat
• For larger series, the price per piece does not decrease as with molding

How SLS Works

Selective Laser Sintering (SLS) is a 3D printing technology that uses a laser to gradually sinter powder material (most commonly nylon). The laser automatically follows the shape according to the 3D model and layer by layer joins powder particles into a solid structure. The result is durable functional parts with good mechanical properties.

Advantages of SLS Printing

• Speed - lead time is shorter for faster design iterations
• Precision - SLS technology achieves tolerance of ±0.25 mm or ±0.3% of part length
• Scalability - SLS can create one part or component as easily as dozens of pieces
• No supports - parts do not need support structures, enabling printing of complex geometries
• Flexibility - nylon is a durable material with high resistance to impact, chemicals and UV radiation

Disadvantages

• Material limitations - currently mainly nylon materials are available (PA12, PA11)
• For larger series, the price per piece does not decrease as with molding

How Binder Jetting Works

Binder Jetting creates 3D objects by applying liquid binder to a layer of powder material layer by layer. It is known for its speed, ability to print various materials such as metals, sand and ceramics. This technology is ideal for large series and complex shapes without the need for supports.

Advantages of Binder Jetting

• Scalability - suitable for simultaneous production of multiple molds or serial production with great flexibility
• No supports - parts are printed in a powder bed, no additional support structures needed
• Cost-effectiveness - suitable for large-scale production with low cost per piece
• Material flexibility - wide selection of materials including metals, sands and ceramics
• Surface - good surface quality after post-processing

Disadvantages

• Lower strength - parts may require additional strengthening or infiltration to improve mechanical properties
• Surface finish - may require additional sandblasting and sintering

Materials and Applications

Large format 3D printing uses various technologies and materials for production of large parts. Suitable for concept models, rapid prototyping and functional custom parts.

What is Metal 3D Printing?

Metal 3D printing is an additive manufacturing technology that produces metal parts directly from metal powder. The most common technologies include DMLS (Direct Metal Laser Sintering), SLM (Selective Laser Melting) and Binder Jetting for metals. These processes use laser or binder to create fully functional metal parts with complex geometries.

Why Choose Metal 3D Printing?

• Excellent surface quality and mechanical properties comparable to traditional metals
• Ability to produce complex geometries that cannot be made by conventional methods
• Fast delivery times - DMLS/SLM parts typically in 4-7 days, Binder Jetting in 7-15 days
• Wide selection of metal materials including aluminum, Titaniumium and stainless steel

What is CNC Turning

CNC turning, also known as CNC lathe machining or computer-controlled turning, is a subtractive manufacturing process used to create precise parts with rotational symmetry. It uses a rotating tool to precisely remove material from a solid workpiece, similar to how a potter shapes clay on a potter's wheel.

Ideal for parts with circular cross-section, it offers high precision and repeatable production of components from various materials such as metals and plastics. It often performs multiple operations such as facing, turning, grooving, and threading, reducing the need for additional machining steps.

CNC turning enables efficient production of precise parts from various materials. Thanks to its ability to process complex geometries and automation, it is a foundation of modern manufacturing.

CNC Lathe

A CNC lathe is a workstation equipped with a rotating spindle that holds the workpiece (material being machined). Cutting tools are mounted on a turret that can move along various axes (typically X and Z) to remove material and create the desired shape.

The CNC control unit translates digital program (usually created using CAM software) into precise movements of the spindle and cutting tool.

CNC Turning Process

• Workpiece Setup: Raw material (bar stock, tube, etc.) is secured in the lathe chuck or between centers.
• Programming: CNC program defines the tool path, specifies cutting tool movements along axes to achieve the desired shape.
• Machining: CNC program runs, controlling spindle speed, feed rate (how fast the tool moves), and tool path to remove material from the workpiece.
• Part Removal: Upon completion, the finished part is removed and the process can repeat for the next piece.

Key Features of CNC Turning

• Rotational Focus: Excels in producing parts with circular cross-section, such as shafts, knobs, and gears.
• Computer-Controlled Precision: Program controls tool movements, ensuring consistent and precise results for high-volume production.
• Material Versatility: Can work with a wide range of materials including metals, plastics, and even some composites.
• Multiple Operations: Modern CNC lathes can perform various operations such as facing, turning, grooving, and threading, reducing the need for additional machining steps.

Advantages of CNC Turning

• Fast Lead Times: Enables rapid part production, especially compared to manual machining methods. Advantageous for prototyping, small batch production, or situations requiring quick part delivery.
• High-Volume Production: Excels in efficient production of large quantities of identical parts with consistent precision. Ideal for manufacturing a wide range of components such as fasteners, bearings, and machine parts.
• Cost-Effectiveness for Specific Parts: For certain parts, especially those with rotational symmetry, it can be more cost-effective than other machining processes like milling. High production speed and minimal material waste contribute to economic advantage.
• Material Versatility: Can work with a wide range of materials including metals, plastics, and even some composites. This flexibility enables production of parts with optimal properties for their specific applications.

Challenges of CNC Turning

• Initial costs for machines and tools
• Complex programming for intricate parts
• Limitations for non-rotational features
• Safety considerations due to rotating machinery and sharp tools

Vacuum Plating

Physical deposition that uses argon in a vacuum chamber to bombard the target material, causing its atoms to separate and adhere to the conductive workpiece, creating a uniform, smooth metallic surface layer. Applicable to a wide range of materials including metals, plastics, composites, ceramics, and glass. Most commonly used for aluminum, followed by silver and copper.

Electropolishing

Electrochemical process that immerses the workpiece in an electrolytic solution, causing ionization of its atoms and their removal from the surface by electric current, effectively eliminating fine burrs and increasing gloss.

Hydro Transfer Printing

Technique using water pressure to transfer color patterns from transfer film to the surface of a three-dimensional product. Applicable to all hard materials and paintable materials, most commonly used for injection molded parts and metal components.

Powder Coating

Dry finishing technique for applying a durable layer to the surface. Unlike traditional liquid paint, which uses solvents that evaporate during drying, powder coating uses dry powder that is electrostatically charged. Powder Coating offers a much more chip-resistant finish compared to traditional paint.

What is CNC Milling

CNC milling, also known as CNC machining by milling or computer-controlled milling, is a subtractive manufacturing process used to create precise parts with complex geometries. Unlike turning, where the workpiece rotates, in milling the cutting tool rotates and the workpiece remains static or moves along various axes.

CNC milling is ideal for creating complex 3D shapes, pockets, grooves, and surface features. It offers high precision and repeatable production of components from various materials such as metals, plastics, and composites.

CNC Milling Machine

A CNC milling machine is a workstation equipped with a rotating spindle with a cutting tool and a work table that holds the workpiece. The machine can move along multiple axes (typically 3, 4, or 5 axes) to create complex shapes and features.

The CNC controller translates the digital program (usually created using CAM software) into precise movements of the spindle and work table to achieve the desired shape.

CNC Milling Process

• Workpiece Setup: Raw material (block, sheet, etc.) is secured on the milling machine work table using a vise, clamps, or vacuum table.
• Programming: The CNC program defines the tool path, specifying the movements of the cutting tool along the axes to achieve the desired shape.
• Machining: The CNC program is executed, controlling spindle speed, feed rate, and tool path to remove material from the workpiece.
• Part Removal: After completion, the finished part is removed and the process can be repeated for the next piece.

Key Features of CNC Milling

• Complex Geometries: Excels in producing parts with complex 3D shapes, pockets, grooves, and surface features.
• Computer-Controlled Precision: The program controls tool movements, ensuring consistent and accurate results for high-volume production.
• Material Versatility: Can work with a wide range of materials including metals, plastics, and composites.
• Multiple Axes: Modern CNC milling machines can work with 3, 4, or 5 axes to create very complex shapes.

Advantages of CNC Milling

• Fast Lead Times: Enables rapid part production, especially compared to manual machining methods. Advantageous for prototyping, low-volume production, or situations requiring fast part delivery.
• High-Volume Production: Excels in efficiently producing large quantities of identical parts with consistent precision.
• Cost-Effectiveness for Specific Parts: For certain parts, it can be more cost-effective than other manufacturing processes.
• Material Versatility: Can work with a wide range of materials including metals, plastics, and composites.

Challenges of CNC Milling

• Initial costs for machines and tools
• Complex programming for complex parts
• Need for qualified operators
• Safety considerations due to rotating tools

Vacuum Plating

Physical deposition that uses argon in a vacuum chamber to bombard the target material, causing its atoms to separate and adhere to the conductive workpiece, creating a uniform, smooth metallic surface layer. Applicable to a wide range of materials including metals, plastics, composites, ceramics, and glass. Most commonly used for aluminum, followed by silver and copper.

Electropolishing

Electrochemical process that immerses the workpiece in an electrolytic solution, causing ionization of its atoms and their removal from the surface by electric current, effectively eliminating fine burrs and increasing gloss.

Hydro Transfer Printing

Technique using water pressure to transfer color patterns from transfer film to the surface of a three-dimensional product. Applicable to all hard materials and paintable materials, most commonly used for injection molded parts and metal components.

Powder Coating

Dry finishing technique for applying a durable layer to the surface. Unlike traditional liquid paint, which uses solvents that evaporate during drying, powder coating uses dry powder that is electrostatically charged. Powder Coating offers a much more chip-resistant finish compared to traditional paint.

What is Rapid Investment Casting

Investment casting is also known as "lost wax casting" or "precision casting". In this process, a wax pattern must be produced for each casting and gating system - i.e., the design is consumable. This process offers good value for money to the end user. Good surface quality, complex geometry, and casting features are achievable without the need for extensive machining or other manufacturing/finishing work to create a usable end product.

Historically, the reluctance of designers or customers to consider the investment casting process for a new part design considered low-volume, short lead-time, or prototype was due to the long lead times and high costs required to produce initial tooling. Depending on part complexity, the tooling process alone can take 8 to 20 weeks and cost $50,000 to $100,000 USD or more.

Advantages of 3D Printed Patterns

By using stereolithographic 3D printed parts as consumable patterns for investment casting without the need for tooling, the actual turnaround time can be reduced to 2 to 3 weeks, and potentially an entire production run can be built for less than a wax tool would cost. The SLA 3D printed part is used as a replacement for the wax pattern in the investment casting process, eliminating the need for tooling for low-volume wax patterns.

Traditionally, low-volume and prototype orders tended to make the investment casting process less efficient due to high tooling costs and long lead times for wax pattern tools. SLA 3D printed patterns for investment casting overcome this age-old problem and open the door for much smaller quantity orders of investment cast parts that begin to make economic sense for manufacturers.

When to Use Rapid Investment Casting

• Low-Volume and Prototype Orders: Mold costs can be avoided when there is low demand for cast products such as automotive manifolds, impellers, pump housings, brackets, covers, etc.
• Out-of-Stock Spare Parts: For parts that are sold out and have lost their supply channels, you can use rapid casting to obtain replacement parts at a lower cost.
• Instead of Metal 3D Printing: Investment casting offers great freedom in shape design and can be a high-quality and cheaper alternative to metal printing.
• Urgent Orders: When demand for metal castings is urgent, metal casting products can be obtained within 2-3 weeks.
• Prototype Verification in Trial Production Phase: A more economical method for quickly obtaining prototypes during trial production phase to verify the product and facilitate multiple iterations.

Advantages of Rapid Investment Casting

• Shorter Time: Compared to traditional casting, it takes less time. For small series of metal parts, production time can even be comparable to metal printing.
• High Quality: The quality of castings produced with wax molds can achieve or approach production-level quality and can be directly used for product-level parts.
• Good Economics: Eliminates costs for small series molds and quickly reduces costs for low-volume production.
• Material Variety: Various grades of stainless steel and aluminum alloys can be cast according to material requirements.
• High Degree of Geometric Freedom: Close to the dimensional freedom of metal printing, can produce highly complex product parts, replacing some metal printing needs.

Rapid Investment Casting Process

1. First, the investment casting pattern is designed in a 3D CAD system and saved as STL, which is then uploaded to an SLA machine where it is produced within a few hours from photosensitive resin.
2. Each investment casting pattern component is sealed and checked for leaks after leaving the SLA machine and removing supports. It is recommended that leak checking also be completed at the foundry after gating system assembly, before first dipping.
3. Once the assembly reaches the foundry, the investment casting patterns are attached to a central wax rod with gates, called a sprue.
4. The shell mold is created by dipping (investing) the cluster into very fine ceramic slurry. The first layer, the face coat, allows reproduction of finely detailed features.
5. After the first layer, the shell is covered with fine ceramic refractory grain similar to sand. After drying, the process of dipping the shell mold into slurry and layering sand is repeated (with coarser grains) to achieve the desired shell thickness.
6. After the shell mold dries, it is usually quickly fired in a furnace to sinter the mold and remove the investment casting pattern from the shell.
7. The mold is preheated before pouring molten metal.
8. The ceramic shell is removed from the solid metal by mechanical vibration, chemical cleaning, or water blasting depending on the specific metal used.
9. The original parts are now cut from the sprue and gate and ground smooth, so they are ready for further processes.

What is Vacuum Casting

Vacuum Casting, also known as silicone molding or urethane casting, is a technology that combines silicone molds and a 3D printed master pattern to create small series of high-quality parts in a short time. Each cast part precisely replicates the color, texture, and geometry of the original master model. These parts are suitable for form and function testing, marketing purposes, concept verification, high-quality prototypes, etc.

Vacuum Casting is also widely used for customizing end parts. It is an ideal choice for creating flawless prototypes and plastic parts ranging from 10 to 1000 pieces.

Why Choose Vacuum Casting

• Rapid Production: Vacuum cast parts can be produced within 7-12 business days depending on complexity and quantity.
• Material Flexibility: Wide selection of materials including ABS-like, PP-like, PC-like (transparent), rubber materials, and high-temperature variants. Maximum part dimensions up to 1500x1000 mm.
• Cost-Effectiveness: Vacuum Casting is a cost-effective method for creating small series of high-quality plastic parts. Ideal for prototypes or low-volume end parts where injection molding would be too expensive.

Custom Molding Services

• Flexible Materials: Rubber and silicone materials with hardness ranging from 30 to 90 Shore A.
• Rigid Materials: Hard plastics with assembly accuracy up to ±0.1 mm.
• Vacuum Casting of Transparent Parts: Support for manufacturing transparent and translucent parts with vacuum casting, also provides surface finishing services such as frosting.
• Vacuum Casting of Two-Color Parts: High-temperature vulcanization and molding processes form the required shapes from raw materials, ensuring long-lasting colors that will not fade.

Why Vacuum Casting Instead of 3D Printing?

Vacuum Casting can produce high-quality and robust parts with physical properties comparable to injection molding and structurally better than 3D printed parts.

Why Vacuum Casting Instead of Injection Molding?

Compared to injection molding, vacuum casting is cheaper and faster for small series. Silicone molds are produced much faster than metal molds for injection molding - they can be created by 3D printing, CNC machining, or manually, which significantly reduces lead times.

Frequently Asked Questions

• What is the minimum order quantity? There is no minimum quantity set. We offer one-time prototypes as well as low-volume production. Vacuum Casting is more cost-effective at quantities of approximately 5 pieces or more.
• Can I keep the mold? Vacuum casting molds have a short lifespan, typically around 20 casts. After production is complete, we dispose of them. If you wish to keep the 3D printed or CNC machined master model, contact us directly.
• What industries is vacuum casting suitable for? Vacuum Casting is widely used in industries such as aerospace, automotive, home appliances, toys, and medical devices. It is particularly suitable for trial production of small series samples during the development phase of new products.

What is Painting

Painting is a surface treatment that covers products and semi-finished goods that have passed inspection. Spray paint plays a role in rust prevention, corrosion protection, beautification, and marking.

Preparatory Procedures

Before painting, preparatory procedures must be performed, such as support removal, rough sanding, fine sanding, etc., to ensure good adhesion and that the color matches drawing requirements.

Advantages of Painting

• Protection against rust and corrosion
• Aesthetic surface beautification
• Marking and identification options
• Wide range of colors and surface finishes
• Increased product durability

Painting Process

• Support Removal: Surface preparation by removing print supports
• Rough Sanding: Basic surface smoothing
• Fine Sanding: Final preparation for painting
• Paint Application: Color application per specification
• Quality Control: Verification of compliance with drawing requirements

What is Plating

Process using the principle of electrolysis to apply a metal film to the surface of a product (metal or other material). It serves to prevent metal oxidation (rust), improve wear resistance, increase electrical conductivity, improve light reflection, increase corrosion resistance, and increase aesthetic value.

Advantages of Plating

• Prevention of metal oxidation (rust protection)
• Improvement of wear resistance
• Increase of electrical conductivity
• Better light reflection
• Increase of corrosion resistance
• Increase of aesthetic value

What is Silk Screening

Simply provide the project documentation and we can perform a custom silk screening process on products. Printing methods are flexible and diverse, various types of inks have strong adhesion, are suitable for long-term exposure, and make outdoor advertisements stand out.

Advantages of Silk Screening

• Flexible and diverse printing methods
• Strong adhesion of various ink types
• Suitable for long-term exposure
• Prominent results for outdoor advertisements
• Ability to print on various materials
• Weather resistance

Silk Screening Process

• Template Preparation: Creating a screen with the required pattern
• Ink Preparation: Selection of suitable ink type for the given material
• Printing: Pushing ink through the screen onto the product surface
• Drying: Curing the ink to ensure durability
• Quality Control: Verification of print accuracy and quality

Ink Types

• UV Inks: Fast curing under UV light
• Solvent Inks: High durability and adhesion
• Water-Based Inks: Eco-friendly option
• Plastisol Inks: For textile applications

What is Laser Marking

Laser Marking uses a focused laser beam to create permanent marking on the material surface. It can create text, logos, barcodes, serial numbers, and other graphic elements with high precision.

Advantages of Laser Marking

• High precision and fine details
• Fast processing
• Environmentally friendly technology without consumables
• Permanent and indelible marking
• Ability to mark on various materials (metals, plastics, glass)
• Non-contact process - no surface damage

Types of Laser Marking

• CO2 Laser: Suitable for organic materials (wood, plastic, paper)
• Fiber Laser: Ideal for metals and some plastics
• UV Laser: For sensitive materials and fine details
• Green Laser: For highly reflective materials

Marking Options

• Text Characters: Alphanumeric characters, serial numbers
• Symbols: Logos, icons, certification marks
• Patterns: Graphic elements and decorations
• Barcodes: 1D and 2D codes, QR codes
• Data Matrix: Industrial identification