Most designers know the feeling of seeing something – a product, a concept, another designer’s work – and immediately start thinking, “How can I do that?”
Now that 3D printing is becoming more ubiquitous in the design world, you might be wondering how a designer goes from that initial lightbulb moment to a finished 3D printed part. Read on to learn more about the lifecycle of a 3D printed design, how it differs from traditional manufacturing techniques, and how ideas are turned into reality.
The first step is one you’re probably already familiar with – ideation and initial renders. Most designs, however the prototype will be made, start on paper as rough ideas. The designer can then translate those ideas to digital renders, both 2D and 3D.
In a traditional design process, designers often rely heavily on renders because they’re extremely inexpensive and quick to create. Digital renders are great for experimenting with colours and design possibilities, but they have a major drawback: they don’t allow for problem solving the way physical prototypes do. Designers can’t hold a render in their hands and test the ergonomics of a design, or verify the colour accuracy in real life. 3D printing lets designers make renders real.
The next step after creating digital renders is preparing them for 3D printing. Stratasys PolyJet printers feature a design-to-print workflow strategy, which makes going from render to printed part straightforward and fast.
With a digital CAD model, or one designed with rendering software, designers can simply import the design using native CAD files or 3MF file format. 3MF imports complete colour and texture data, including PANTONE-verified colours, ensuring that the final 3D printed design looks exactly the way the designer intended.
Once the model design has been imported, designers use GrabCAD Print software to print and manage projects.
Unlike traditional manufacturing techniques, 3D printing doesn’t require active labour or constant supervision. Instead of spending hours crafting foam models, designers can just click “Print.” GrabCAD allows for remote monitoring, which means designers can leave the printer on overnight and come back to a finished part in the morning.
In addition to easy workflow, PolyJet Technology provides multi-colour and multi-material capabilities. Whatever the original render featured – specific colour matching, intricate surface details, realistic textures like wood or leather – 3D printing can make it real in hours.
Traditional methods for creating prototypes typically involve lengthy post-processing. Depending on the material, the model may require sanding, staining, buffing, painting, and varnishing to achieve the desired finished look. Detailed models especially may require hours of finishing time that takes away from time to correct mistakes and improve the design.
But finishing doesn’t have to take up a huge part of the design process. Parts created with PolyJet Technology come off the printer with full colours and accurate surface textures.
Often, post-processing is limited to removal of supports. PolyJet printers typically use one of two types of support: soluble and WaterJet-removable. Soluble support materials like SUP706B dissolve in a solution of caustic soda and metasilicate, while materials like SUP705 can be sprayed off parts using the WaterJet cleaning system. Both support types allow the creation of detailed, intricate geometries and interior spaces.
For designers who want to see their ideas in real life, not just on a screen, traditional options can feel limiting. Hand-modelling is labourious, but outsourcing is expensive and sometimes equally time-consuming. The process of taking render to reality is faster, simpler, and more efficient with the power of 3D printing and PolyJet Technology.
