3D Printing Services — Complete Guide
3D printing (additive manufacturing) builds parts layer by layer directly from a 3D model, eliminating the need for tooling or molds. It's the fastest path from design to physical part, making it ideal for prototypes, custom parts, and low-volume production.
This guide covers all major 3D printing technologies, materials, design guidelines, and how to choose the right process for your application.
Comparing 3D Printing Technologies
FDM (Fused Deposition Modeling)
How it works: Molten thermoplastic filament is extruded through a heated nozzle, building layers from bottom to top.
| Parameter | Value |
|---|---|
| Layer height | 0.1-0.3mm |
| Tolerance | ±0.3-0.5mm |
| Build volume | Up to 600×600×900mm (industrial) |
| Surface finish | Rough, visible layer lines |
| Material types | Thermoplastics only |
Best for: Large parts, functional prototypes, jigs, fixtures, concept models
Not for: Parts needing fine detail, smooth surfaces, or tight tolerances
SLA (Stereolithography) / DLP (Digital Light Processing)
How it works: A UV laser or projector cures liquid photopolymer resin layer by layer.
| Parameter | Value |
|---|---|
| Layer height | 0.025-0.1mm |
| Tolerance | ±0.1-0.2mm |
| Build volume | Up to 500×500×500mm |
| Surface finish | Very smooth — best surface of any 3D printing process |
Best for: High-detail prototypes, jewelry, dental/medical models, master patterns for casting
Not for: Functional parts (resins are generally less durable than thermoplastics)
SLS (Selective Laser Sintering)
How it works: A CO2 laser sinters nylon powder particles together. Unfused powder supports the part — no support structures needed.
| Parameter | Value |
|---|---|
| Layer height | 0.1-0.15mm |
| Tolerance | ±0.15-0.3mm |
| Build volume | Up to 750×550×550mm |
| Surface finish | Grainy matte, slightly porous |
Best for: Functional prototypes, living hinges, snap-fit connections, small batch production
Note: Parts are naturally porous; they absorb moisture — seal or dye for food/medical use
MJF (Multi Jet Fusion) — HP Technology
How it works: HP's process sprays fusing and detailing agents onto a powder bed, then passes an IR lamp to fuse the layers.
| Parameter | Value |
|---|---|
| Layer height | 0.08-0.1mm |
| Tolerance | ±0.2-0.3mm |
| Build volume | 380×284×380mm |
| Surface finish | Smooth matte — smoother than SLS |
Best for: Functional parts, complex geometries, colored parts (full-color MJF available)
Advantage over SLS: Faster build speed, more consistent mechanical properties, tighter tolerances
DMLS / SLM (Direct Metal Laser Sintering / Laser Melting)
How it works: A high-power laser fully melts metal powder layer by layer. Parts are near-100% dense.
| Parameter | Value |
|---|---|
| Layer height | 0.02-0.08mm |
| Tolerance | ±0.1-0.2mm |
| Build volume | Up to 400×400×400mm |
| Surface finish | Matte, slightly rough — typically needs post-machining |
Materials: Aluminum (AlSi10Mg), titanium (Ti-6Al-4V), stainless steel (316L, 17-4PH), tool steel (H13, Maraging), Inconel (718, 625), cobalt chrome
Best for: Medical implants, aerospace components, custom tooling, conformal cooling channels in molds
Not for: Large production runs — cost is 5-10× per part vs machining or casting
Technology Comparison Table
| Technology | Layer height | Tolerance | Surface | Material range | Relative cost | Best for |
|---|---|---|---|---|---|---|
| FDM | 0.1-0.3mm | ±0.3-0.5mm | Rough | Thermoplastics | $ | Large parts, jigs, functional prototypes |
| SLA/DLP | 0.025-0.1mm | ±0.1-0.2mm | Very smooth | Photopolymer resins | $$ | High detail, cosmetic prototypes, casting |
| SLS | 0.1-0.15mm | ±0.15-0.3mm | Grainy matte | Nylon-based powders | $$$ | Functional prototypes, small production |
| MJF | 0.08-0.1mm | ±0.2-0.3mm | Smooth matte | Nylon-based powders | $$$ | Functional parts, complex assemblies |
| DMLS | 0.02-0.08mm | ±0.1-0.2mm | Matte rough | Metal powders | $$$$$ | Medical, aerospace, conformal cooling |
| PolyJet | 0.016-0.03mm | ±0.1-0.15mm | Very smooth | Multi-material resin | $$$ | Multi-material prototypes, rubber-like |
Material Selection
FDM Thermoplastics
| Material | Strength | Heat resistance | Chemical resistance | Typical use |
|---|---|---|---|---|
| PLA | Moderate | Low (55°C) | Low | Concept models, educational |
| ABS | Good | Moderate (80°C) | Good | Functional prototypes, automotive |
| PETG | Good | Moderate (75°C) | Good | Food safe, durable parts |
| Nylon (PA12) | Excellent | High (150°C) | Good | Gears, hinges, functional parts |
| PC (Polycarbonate) | Excellent | High (130°C) | Good | Structural parts, tooling |
| PEI (Ultem) | Excellent | Very high (217°C) | Excellent | Aerospace, medical, high-temp |
| TPU (Flexible) | Flexible | Low (80°C) | Good | Seals, gaskets, padding |
SLS/MJF Nylon Powders
| Material | Properties | Typical use |
|---|---|---|
| PA12 (Nylon 12) | Balanced strength and flexibility | Most common for SLS/MJF |
| PA11 | More flexible than PA12 | Living hinges, snap fits |
| PA12-GF (glass filled) | Stiffer, higher HDT | Structural parts |
| TPU (flexible powder) | Rubber-like | Seals, gaskets, padding |
| PA12+PA6 blend | Higher strength | Functional parts |
| PA12-ESD | Electrostatic discharge safe | Electronics handling |
DMLS Metal Powders
| Material | Properties | Typical use |
|---|---|---|
| AlSi10Mg (Aluminum) | Lightweight, good strength | Aerospace, automotive |
| Ti-6Al-4V (Titanium) | High strength, biocompatible | Medical implants, aerospace |
| 316L Stainless | Corrosion resistant | Medical, food, marine |
| 17-4PH Stainless | High strength, heat treatable | Tooling, structural |
| Maraging Steel | Ultra-high strength | Injection mold inserts, tooling |
| Inconel 718 | High-temp, corrosion resistant | Aerospace, turbochargers |
| CoCr (Cobalt Chrome) | Wear resistant, biocompatible | Dental, orthopedic implants |
Design Guidelines
General Rules
- Minimum wall thickness: 0.5mm (resin), 0.8mm (nylon SLS), 1.0mm (FDM), 0.3mm (metal)
- Support structures: SLA and FDM need supports for overhangs >45°; SLS and MJF are self-supporting
- Hole diameters: Minimum 0.5mm (resin), 1.0mm (FDM), 0.8mm (SLS), 2.0mm (metal DMLS)
- Threads: Design for thermal-set inserts or print pilot holes and tap afterward
- Clearance for moving parts: 0.3-0.5mm gap for SLS/MJF (powder-process parts can self-clear)
By Technology
| Rule | FDM | SLA | SLS/MJF | DMLS |
|---|---|---|---|---|
| Minimum feature | 0.5mm | 0.2mm | 0.3mm | 0.2mm |
| Boss diameter (for insert) | 3× screw dia | 2.5× screw dia | 2× screw dia | 2× screw dia |
| Support needed? | >45° overhang | All overhangs | No (self-supporting) | >45° (often needed) |
| Max unsupported span | Not recommended | Not recommended | 20mm | Depends on material |
Cost Estimation
| Technology | Setup cost | Per-part cost (small) | Per-part cost (medium) | Per-part cost (large) |
|---|---|---|---|---|
| FDM | Minimal | $5-15 | $15-50 | $50-200 |
| SLA | Minimal | $10-25 | $25-80 | $80-300 |
| SLS | Moderate | $15-40 | $40-150 | $150-600 |
| MJF | Moderate | $15-30 | $30-120 | $120-500 |
| DMLS | High | $50-200 | $200-800 | $800-3,000+ |
When to Use 3D Printing vs Alternatives
| Scenario | 3D Printing | CNC Machining | Injection Molding |
|---|---|---|---|
| Prototype (1-10 pcs) | ✅ Fastest choice | OK — but slower and more expensive | ❌ Not economical |
| Small batch (10-100 pcs) | ✅ Good for complex geometries | ✅ Better for simple parts | ❌ High tooling cost |
| Production (1,000-10,000+) | ❌ Too slow per part | ❌ Too expensive per part | ✅ Cheapest per unit |
| Very complex geometry | ✅ No added cost for complexity | ❌ Cost increases with complexity | ❌ Needs complex mold |
| Tight tolerance (±0.05mm) | ❌ Cannot achieve (±0.1-0.5mm) | ✅ (±0.025mm) | ✅ (±0.05mm) |
| Large parts (500mm+) | ✅ FDM can do it | ✅ Large mills available | ❌ Molding machine limits |
| Metal parts | ✅ DMLS (expensive) | ✅ Best choice | ✅ Casting or MIM |
| Overmolding / multi-material | ❌ Limited options | ✅ Can assemble | ✅ Overmolding process |
Why MFGABC for 3D Printing?
- Multi-technology: FDM, SLA, SLS, MJF, and DMLS under one roof — we recommend the right process, not just what we have
- Materials: 20+ polymer materials + 6+ metal powder options
- Scale: From single prototypes to bridge production (100-1,000 parts)
- Post-processing: Vapor smoothing, dyeing, painting, metal polishing, heat treatment
- Quality: Dimensional inspection reports, material certificates available
- Turnaround: Standard 3-7 working days, expedited in 1-3 days for most processes
*Upload your STL or STEP files for a free 3D printing quote.*
*→ Next: [Metal Stamping Services Guide](/capabilities/metal-stamping/)*
*→ Related: [3D Printing Technologies Comparison](/blog/3d-printing-technologies-comparison/)*
*→ Related: [3D Printing vs CNC Machining](/blog/3d-printing-vs-cnc-machining/)*
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