While producing a product or part, you have the option to choose from subtractive manufacturing and additive manufacturing. The conventional or subtractive manufacturing methods produce a part by removing or cutting away unnecessary materials from a block or stock.
On the other hand, additive manufacturing or 3D printing technologies produce parts by adding successive layers of material. 3D printing technologies produce a part by adding successive layers of materials based on a digital 3D model or CAD model.
But you have the option to choose from several 3D printing technologies and materials. The usage statistics posted on various websites suggest that Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA) have a larger installation base than other 3D printing technologies.
Each of these three widely-used 3D printing technologies produces functional parts or product prototypes from digital 3D files. But they differ from each other in several aspects, including filaments, resolution, dimensional accuracy, ease of use, and printing cost.
Also, each of these 3D printing technologies has its pros and cons. Hence, it becomes essential for you to understand the 3D printing technologies independently and compare them based on your project requirements. We are making it easier for you to choose from FDM, SLS, and SLA for your next project through this 3D printing technology comparison.
FDM 3D Printing Technology Overview: Process, Pros, Cons, and Applications
FDM belongs to the material extrusion category of additive manufacturing technologies. The FDM 3D printers produce strong and durable parts using production-grade thermoplastic filaments. They use the thermoplastic filament in the form of spools of materials.
These printers melt and extrude the filament through a heated nozzle. The print head deposits the semi-melted material onto the print bed by moving according to the path set by the STL file. You also have the option to choose from several materials for FDM 3D printing, including ABS, PET, PLA, PC, TPU (Flexible), and Nylon.
Most of these filaments are pure polymer. But there are a slew of FDM 3D printing filaments that are produced by modifying features of the polymer by adding additives or blends. The additives or blends produce composite filaments for FDM 3D printing by changing the core characteristics of the polymer.
FDM is a simple and fast 3D printing technology. It reduces 3D printing costs significantly by providing individuals and enterprises with access to a wide range of low-cost printing machines and materials. But engineers do not opt for FDM while producing parts with high dimensional accuracy and intricate designs.
FDM is one of the 3D printing technologies that are popular with both individuals and enterprises. Students, hobbyists, and engineers use desktop FDM 3D printers to produce parts and prototypes using various filaments.
At the same time, industrial-grade FDM 3D printers help enterprises leverage additive manufacturing technologies without investing in extra resources. FDM 3D printing technology is used mostly for producing product prototypes and proof-of-concept models without escalating printing time and cost.
SLS 3D Printing Technology Overview: Process, Pros, Cons, and Applications
SLS 3D printing technology produces parts by sintering small particles of polymer powder. The SLS printers sinter and fuse the polymer powder using a high-power laser. The unsintered powder provides support to the solid structure throughout the 3D printing process.
Hence, you are not required to use a dedicated support structure during the SLS 3D printing process. But you have to refine the part after removing it from the build chamber by performing washing, sanding, polishing, painting, and curing. The post-processing activity will remove excess powder from the 3D-printed part.
Nylon is the most commonly used material for SLS 3D printing. However, you have the option to choose from a wide range of pure and filled polyamide powders. The filled SLS 3D printing filaments are produced by altering the mechanical and thermal properties of polyamide using additives like glass fibers, carbon fibers, and aluminum.
The absence of support structure makes SLS facilitate design freedom. You can use SLS 3D printers to produce parts with additional strength and dimensional accuracy. But the parts will feature a rough surface finish. At present, SLS is used widely by enterprises and manufacturers for functional prototyping, low-volume production, and custom manufacturing.
SLA 3D Printing Technology Overview: Process, Pros, Cons, and Applications
SLA belongs to the vat photopolymerization category of 3D printing technology. It produces solid parts from digital files by curing photopolymer resin selectively. An SLA 3D printer cures a layer of resin using digital light processing (DLP) technology.
DLP technology uses UV lasers as the primary light source for curing resin. SLA, unlike SLS, requires you to provide the part with a support structure during the 3D printing process. But it allows you to use the same material for producing the part and support structure.
You have the option to choose from various forms of resin for SLS 3D printing, including standard resin, durable resin, castable resin, high-detail resin, and high-temperature resin. SLA 3D printers are effective in producing parts with a smooth surface finish and high-level accuracy.
But the parts remain sensitive to constant UV exposure. You need to paint the part with UV acrylic paint to minimize the effect of long-term exposure to UV light. SLA is used widely by enterprises from functional prototyping. However, the technology is also used by manufacturers to produce a variety of patterns, tooling, and molds.
3D Printing Technology Comparison: FDM vs. SLS vs. SLA (10 Important Differences)
You can produce a variety of solid objects or items using FDM, SLS, or SLA 3D printing technology. But each of these additive manufacturing technologies will produce the part in a different way. For instance, FDM will produce the item by melting and fusing thermoplastic, while SLS will produce the part by sintering polymer powder.
Hence, you have to invest in the right 3D printer and filament according to the precise needs of individual projects. Also, you must remember that these widely used 3D printing technologies differ from each other in multiple categories. You can refer to the 3D printing technology comparison to pick the right printing machine and material for your next project.
Operation Principle
As discussed earlier, each of these 3D printing technologies produces parts or prototypes using different operation principles. FDM produces parts by melting thermoplastic filament using an extrusion. But SLS produced parts by sintering powdered filament using a high-power laser.
At the same time, SLA produces parts through the UV curing process. The operation principles make the 3D printing technologies different from each other. The pros and cons of individual 3D printing technologies are directly linked to the underlying operating principle.
Print Volume
You have the option to choose from several desktop, benchtop, and industrial printing machines driven by FDM, SLA, and SLA technologies. Each 3D printing machine supports a specific print volume. You have to consider the print volume supported by printing machines according to the size of the part or product of the part or model to be printed.
The desktop or benchtop FDM 3D printer supports print volumes up to 300 x 300 x 600 millimeters. The benchtop industrial SLS 3D printers support print volumes up to 65 x 165 x 300 millimeters. The desktop or benchtop SLA 3D printing machines support print volumes up to 300 x 335 x 200 millimeters.
Material Options
You have the option to choose from a wide range of materials or filaments for FDM, SLS, and SLS 3D printing technologies. While using an FDM 3D printer, you have to use thermoplastic polymer produced in the form of filaments like PLA or ABS.
But you need to use powdered polymers like Nylon 11 and Nylon 12 while using an SLS 3D printer. Likewise, SLA 3D printers require you to use photocurable liquid materials and various forms of resin. Hence, material options will vary according to your choice of 3D printing technology.
Support Structure
SLS increases design freedom and dimensional accuracy by eliminating the need to use support structures. But FDM and SLA 3D printing technologies require support structures. While planning an FDM 3D printing project, you have to complement the print material with the right support material.
SLA 3D printers allow you to use the same material for both print and support. Hence, you are not required to invest in any specific support material. In addition to choosing the appropriate support material, you need to use the support structure accurately using the right techniques and tools.
Post-Processing
SLS scores over FDM and SLA in the category of post-processing. You can improve a part produced using SLS technology by performing simple post-processing activities like dusting, washing, cleaning, and painting.
But you have to focus on keeping the 3D-printed part intact while using an FDM printer by dissolving the support structure accurately. You can remove the support structure accurately only by using the right techniques and tools.
The post-processing activities in the SLA 3D printing process require more time. Based on the nature of the part, you need to store the 3D-printed item in a special container and remove the support structure using specially-designed instruments.
Tensile Strength
SLA and SLS are widely-used industrial 3D printing technologies. Hence, they are believed to produce parts and products with higher tensile strength. But several studies have highlighted the effectiveness of FDM in producing stronger parts than SLS and SLA. A part produced using FDM 3D printing machines has more than 30 MPa strength than a similar item produced using SLS or SLA 3D printers.
Ease of Use
FDM is often described as an easy-to-use and beginner-friendly 3D printing technology. You can set up, use, and maintain an FDM 3D printer with minor training. Likewise, you can operate and maintain an SLA 3D printer without requiring elaborate training. But SLS 3D printers are often operated and maintained by skilled technicians. You need moderate training to set up, operate, and maintain an SLS 3D printer efficiently and safely.
Printing Speed
FDM, SLS, and SLA differ from each other in the category of printing speed. FDM and SLA 3D printing technologies are more effective in reducing lead time than SLS. But you have to spend time on post-processing activities while using these 3D printing technologies.
SLS reduces lead time significantly by eliminating the need for time-consuming post-processing activities. But you must remember that the time required to 3D-print a part varies based on a variety of factors, including the size of the object and the type of the material. Also, the latest 3D printing machines are faster than conventional models.
Printing Cost
FDM 3D printing machines and filaments are hugely popular with students and hobbyists due to their budget-friendly nature. Many enterprises use industrial-grade FDM 3D printers to curtail production and prototyping costs significantly.
SLS 3D printers are larger and more expensive than FDM 3D printers. At present, these printing machines are used mostly by large companies in the aerospace, automotive, engineering, medical, and manufacturing industries. SLA 3D printers are less expensive than SLS 3D printers. But the high cost of resins escalates the SLA 3D printing costs drastically.
Installation Base
SLS and SLA are widely used by enterprises from various sectors for producing functional parts and product prototypes. But FDM is popular with both enterprise and individual users. Students, hobbyists, and engineers leverage FDM as a beginner-friendly and cost-effective 3D printing technology.
Hence, FDM currently has a larger installation base than SLS and SLA. The popularity of FDM is driven by the availability of low-cost 3D printing machines and filaments. It is always advisable to use popularity or installation base as a parameter while comparing 3D printing technologies.
Conclusion
FDM, SLS, and SLA 3D printing technologies make it easier for you to switch from subtractive manufacturing to additive manufacturing. But you can improve the quality of the product or prototype only by combining the right 3D printing technology and filament.
That is why; 3D printing technology comparison becomes an essential prerequisite for successful project planning. You must keep in mind the pros and cons of these 3D printing technologies while comparing FDM, SLS, and SLA.
At the same time, you must define your project needs clearly and use the requirements as the key parameter for 3D printing technology comparison. It is also a good idea to evaluate these widely-used 3D printing technologies in real-time by getting professional 3D printing services.
Leading and reputable 3D printing companies offer FDM, SLS, and SLA 3D printing services. Also, they allow you to choose from several materials and filaments. You can avail of customized 3D printing services to evaluate and compare these 3D printing technologies in real-time without incurring high printing costs.
About Aurum3D
We are amongst the major 3D printing companies in Bangalore, India. We have been providing SLS, SLA and custom FDM 3D printing services to many major industries. Please feel free to get in touch with us for your custom needs, our 3D printing solutions experts will get back to you within one business day.