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.
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
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)
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
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
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 | 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 | 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 |
| 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 |
| 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 |
| 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 |
| 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+ |
| 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 |
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