3D Printing Techniques: A New Generation R&D Approach from Prototyping to Production

In 2009, the expiration of Stratasys’ core patent for Fused Deposition Modeling, or FDM, opened the way for open-source initiatives such as the RepRap project, as well as consumer-focused 3D printer manufacturers such as MakerBot and Ultimaker. As a result, 3D printing technologies became much more accessible to the public. Today, these printers are no longer limited to industrial environments; they are also used in many homes, workshops, laboratories, and design studios.

Between 2013 and 2015, the expiration of patents related to early 3D printing technologies such as stereolithography, SLA, and selective laser sintering, SLS, helped reduce the cost of these technologies and made them more accessible to small-scale users. Formlabs’ Form 1 printer, introduced through a Kickstarter campaign in 2012, is widely regarded as one of the first high-quality and affordable SLA printers. Today, however, this technology can be accessed at much lower cost and with a wider range of device options.

3D Printing Technologies

3D printing technologies include various methods used to create three-dimensional solid objects from a digital design. These technologies work by adding different materials layer by layer using different production methods. Today, the most commonly used 3D printing technologies include FDM, SLA, SLS, DLP, MJF, and PolyJet.

FDM — Fused Deposition Modeling

FDM, or Fused Deposition Modeling, is one of the most widely used 3D printing technologies. In this method, a thermoplastic material produced in filament form is melted and extruded through a nozzle with a fine opening. The melted material is deposited onto the build platform layer by layer. After each layer cools and solidifies, the next layer is added and the production process continues. FDM is easy to use, offers a wide variety of materials, and can produce highly durable parts depending on the selected material. Compared to other 3D printing technologies, FDM may have some disadvantages, such as lower surface quality, more visible layer lines, and the need for support structures in complex geometries. However, with the right hardware and material selection, many of these limitations have become much less significant today.

SLA — Stereolithography

SLA, or Stereolithography, is a 3D printing technology that creates objects by curing UV-sensitive liquid resin layer by layer using a UV laser. This technology allows the production of models with very high resolution and precision, nearly smooth surfaces, and highly complex details. Compared to other 3D printing methods, SLA generally has higher raw material costs, smaller build volumes, and slower printing speeds. In addition, the printed objects can be brittle, and complex geometries may require support structures that leave visible marks after printing. SLA is commonly used in molding, prototyping, dental applications, and jewelry production.

SLS — Selective Laser Sintering

SLS, or Selective Laser Sintering, is a 3D printing technology that uses a high-powered laser beam to fuse powdered polymer, metal, ceramic, or composite materials layer by layer to create solid objects. One of the greatest advantages of SLS is that it allows the production of highly complex geometries without the need for additional support structures. This is because the unsintered powder surrounding the part provides natural support during the printing process. SLS enables the production of durable and functional parts. The resulting models generally have isotropic properties. However, printing costs are relatively high. Surface quality is usually rough, and depending on the application, post-processing such as sanding or polishing may be required.

DLP — Digital Light Processing

DLP, or Digital Light Processing, is very similar to SLA. However, instead of using a laser, it uses a UV projector. In this method, an entire layer is projected onto UV-sensitive resin at once. Since each layer is produced in a single exposure, DLP can be much faster than SLA. The print quality and resolution are similar to SLA. However, DLP also shares some of SLA’s limitations, including limited material variety and the need for support structures that may leave visible marks on the final object. Today, DLP 3D printers are available at price levels accessible even to home users. DLP printers are widely used in hobbies, prototyping, dental applications, and jewelry production.

MJF — Multi Jet Fusion

MJF, or Multi Jet Fusion, is a 3D printing technology developed by HP, leveraging its expertise in two-dimensional inkjet printing technologies. Similar to SLS, this method is based on powdered raw material. Two different printing agents are applied to selected areas of the powder, and then heat is used to fuse the desired areas together. MJF offers high printing speed and enables complex geometries to be printed without support structures. The resulting parts are dense, durable, and isotropic. However, printing costs can be higher than many other 3D printing methods. With MJF, it is possible to produce functional prototypes as well as end-use parts.

PolyJet

PolyJet technology produces parts by jetting droplets of liquid photopolymer through inkjet-like print heads and curing them immediately with UV light. This technology allows different materials with different properties to be used simultaneously. The resulting models can have smooth surface quality and fine details. PolyJet also enables multi-color printing. However, printing costs are quite high. It is commonly used for realistic prototypes, certain consumer products, and medical models.

3D Printing Applications at Ones Technology

Ones Technology actively uses 3D printing technologies in its R&D, design, and production processes. In the past, the company received 3D printing services from external suppliers. Since 2018, however, Ones Technology has started adding 3D printers to its own inventory. Initially, FDM printers were used only for prototyping. Today, these printers are used in many different areas, including the production of structural parts for various products, assembly fixtures, mounting jigs required by field teams, and even different objects needed within the office. Taking into account the latest developments in FDM technology, Ones Technology continues to update its machine inventory with next-generation printers that offer higher printing speeds and better print quality. At the same time, the company continues its efforts to integrate MJF technology into its internal capabilities. This step is expected to strengthen Ones Technology’s position in terms of production speed, design flexibility, and advanced manufacturing capability.