THE PRINCIPLES OF 3D PRINTING
| Romain Di Vozzo, Fablab UPSaclay, March 2022 |
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| EUGLOH GROUP WP2 |
| https://www.linkedin.com/in/romaindivozzo/ |
| romain.di-vozzo@universite-paris-saclay.fr |
| Romain Di Vozzo (Director) |
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| Fablab UPSaclay |
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| I am the director/founder of Fablab UPSaclay, and former student of both Pr Bruno Latour (philosopher) and Pr Neil Gershenfeld (fablabs « god-father »). I work on unfolding the fablab concept in its every aspects. My work is at the intersection of political arts, systemic design, publics-empowerment through design and technologies, distributed-education and networks, and innovation (what ever it means). I came to 3D printing +12 years ago when I took Fab Academy - the globally-distributed course on Design and Digital Fabrication. 3D printing is an everyday routine at Fablab UPSaclay. I have machines at home as well so my daughter is a « 3D Printing Native ». |
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About Fablabs
| Fablabs : |
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| Fablabs shape a distributed network of 2000+ digital fabrication facilities worldwide |
| Fabbers mainly agree on the fact that the 3rd digital revolution will be in fabrication |
| Fablabs offer open-access to design and digital fabrication tools |
| Technologies for the Empowerment |
| A fablab’s inventory of machines is composed of Additive and of Subtractive Machinery |
| The global fablab network offers distributed education programs : Fab Academy, Fabricademy… |
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| We say that “fablabs are one market for one person”. |
| For more infos on Fablab UPSaclay |
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| Web : https://fablabdigiscope.universite-paris-saclay.fr/ |
| Linkedin : https://www.linkedin.com/company/fablab-digiscope-lisn-upsaclay/ |
| The DU Fab Academy+ : https://www.universite-paris-saclay.fr/du-fab-academy-upsaclay |
| Check “The Morphogenesis for the Design of Design” by Neil Gershenfeld (Min 17.5) : |
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| https://www.edge.org/conversation/neil_gershenfeld-morphogenesis-for-the-design-of-design |
Turning Bits into Atoms
| From Bits to Atoms |
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| The 3D Printing Processes fit under the hat of Additive-Manufacturing. |
| Instead of removing materials from a block (of material) like in common Subtractive Manufacturing Processes, 3D Printing adds material. It supposedly produces less wastes by adding the “right” amount of material where it is required, without the need of a pre-existing solid mold. |
| It also offers more degrees of freedom in terms of conception thanks to overhang management thanks to temporary support structures. |
| But ALL OF IT is Computer-Aided, Computer-Coded, and Computer-Controlled. |
| To sum up : 3D Printing turns code into physical things. |
Important Note 1
| EUGLOH : IMPORTANT GENERAL NOTE 1 |
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| In France, the HEALTH CARE sector is now responsible for 8% of the global Greenhouse gases emissions of the country. |
| What if raw materials to fabricate medical objects were available on site together with 3D Printers ? |
| What about 3D printing meds instead of having them shipped from other countries ? |
| Meds/Pills transportation reaches 33% of the (8%) Greenhouse Gases Emissions related to health care… |
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| During COVID 19 first lockdown in march 2020, Fablab UPSaclay has been fabricating Protective Equipments for Nurses and Doctors. We were able to 3D-print 2000 parts because we had secured tens of kg of 3D Printing filament and +50sm of PETG sheets right before the industry started to close. |
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Important Note 2
| 3D PRINTING IN GENERAL |
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| 3D Printing, like many new (or so cold “new”) technologies has some advocates and lobbyists who’s interest is almost exclusively business-oriented. |
| Techno-evangelism and Marketing put together can make people think that (for example) 3D Printing Organs is already being done whereas it is not the case yet, and it might take a while before a kidney gets replaced by its 3D Printed replica. |
| “3D Printed Hearts” visible on youtube even if made from human-cells cannot “pump” yet because the cells used for 3D printing apparently don’t know how to. |
| Stay sharp intellectually, and critical. |
Important Note 3
| About the field “3D PRINTING” |
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| As a field of innovation, additive Manufacturing has a short history and a lot of news published, continuously. This page is a combination of both. |
| This page is meant to share with you as many informations as possible but is also limited by the experience we have mainly acquired in fablabs on FFF and SLA technologies. |
FROM FORMATIVE TO ADDITIVE MANUFACTURING
| From Formative Manufacturing to… |
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| Plastic Pellets in Bulk |
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| Mold (ex : rotocasting) |
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| Hundreds of Thousands Parts of Something (Plastic-Injection Mass Production) |
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| …Substractive Manufacturing to… |
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| …to Additive Manufacturing. |
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Trying to spot differences between technologies
| Formative | Subtractive | Additive |
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| Thousands of Parts of One Model from one Mold | Several Parts + Waste | Multiple/Different Parts |
| Centralized Fabrication | Decentralized Fabrication | Distributed Fabrication |
| Industrial | Semi-industrial | Desktop or Semi Industrial |
| Product is Made Far Away | Product is Regional | Object is In House |
| Producer to Reseller | Producer to Business | Producer to End-Comsummer |
| No customization | Customization | Customization |
Comparing technologies
| Comparison between 3 (co-existing) ways of Producing/Fabricating an object |
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Additive Manufacturing…Subtractive Manufacturing…Non-Humans…Humans…
| Inert Million-Years-Old Additive Geology and Subtractive Contour-Lines Made by Erosion |
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| Successive Layers of Sediment have piled-up over the centuries and were eroded. |
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| Inert Non-human-made/Extra-terrestrial Additive (and Subtractive ?) |
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| Volcanos (Olympus Mons on Mars) might definitely fit into the Additive category. |
| When lava flows out of them, material is added on a surface and volume is created. |
| Hypothesis : Repetitive patterns could even be identified. |
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| Living Non-Human-Made Additive Structure |
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| A hornets-nest is like “papier-maché”". Hornets mix wood-fibers with their saliva (binder) and add them to shape complexe architectonic structures. |
| The hexagonal shape is regular, applied to a spherical pattern, breathes, and is embedded into a bigger shape. |
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| Contemporary Human-made Layers of Food |
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| There is no doubt that a burger like this one is 99% Additive Manufacturing… |
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| Contemporary Additive Industrial Manufacturing Object |
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| This bridge has been 3D Printed and installed. Fully Additive. |
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| Contemporary Additive Non-Industrial Manufacturing Object |
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| A logo of Fablab UPSaclay 100% 3D Printed |
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Short History of Additive Manufacturing
| Key Dates of Additive Manufacturing Technologies in Chronological Order |
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| 1984 : Jean-Claude André’s and colleagues patent |
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| 1984 : Chuck Hull’s Patent (a few weeks later) |
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| 1988: First SLA-1 machine |
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| 1988: First SLS machine by DTM Inc then acquired by 3D System |
| 1990: First EOS Stereos system |
| 1992: FDM patent to Stratasys |
| 1993: Solidscape (company) was founded |
| 1995: Z Corporation obtained an exclusive license from the MIT |
| 1999: Engineered organs bring new advances to medicine |
| 2000: a 3D printed “”working kidney"" is created |
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| 2000: MCP Technologies (an established vacuum casting OEM) introduced the SLM technology |
| 2005: Z Corp. launched Spectrum Z510. It was the first high-definition color 3D Printer on the market |
| 2006: An open source project is initiated (Reprap) |
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| 2008: The first 3D printed prosthetic leg |
| 2009: FFF patents in the public domain |
| 2009: Sculpteo is created |
| 2010: Urbee is the first 3D printed prototype car presented |
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| 2010: Ultimaker (company) was founded |
| 2011: Cornell University began to build 3D food printer |
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| 2012: The first prosthetic jaw is printed and implanted |
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| 2013: “3D printing” in Obama’s State of the Union speech |
| 2015: Carbon 3D issues their revolutionary ultra-fast CLIP 3D printing machine |
| 2016: Daniel Kelly’s lab announces being able to 3D print bone |
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| 2018: The first family moves into a 3D printed house |
| ETC. |
13 Technologies Currently Available
SLA
| StereoLithography Apparatus |
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| Laser + Resin |
| A platform plunges ( Z axis) into a tank filled-in with a bath of photo-sensible liquid resin. A very discret UV laser-beam cures the liquid-resin to solidify it into a shape. Layer per layer. The object is printed “upside-down”. |
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FFF
| Fused Filament Fabrication |
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| Solid Material + Heat |
| 3 visible axis : x, y, z. A feeder. An extrusion-head (bowden or direct) is heated (around 200 C degrees). The feeder sends the solid plastic-filament (see the shore) inside the extrusion-head. The filament is heated and melted and spreads through a nozzle on the build-platform to make the shape. |
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DLP
| Digital Light Processing |
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| Uses a projector and an inactinic light instead of a UV-laser. |
| SLS (industrial) |
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| Powder + Heat |
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CLIP
| Continuous Liquid Interface Production |
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| UV-Light + Resin + Oxygen |
| Very similar to SLA but is continuous therefore a lot faster. Oxygen-injection plays an important role in this technology. |
JETTING
| MATERIAL JETTING |
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| BINDER JETTING (industrial) |
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| Powder + Binder |
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SDL
| Selective Deposition Lamination |
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| Paper + Glue + |
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WAAM
| Wire Arc Additive Manufacturing |
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CSAM
| Cold Spray Additive Manufacturing (industrial) |
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| Gas + Powder + Heat + Supersonic Nozzle |
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HYDROGELS
| BIO PRINTING (Desktop Mainly) |
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| from 0.4min to 2.09 (etc.) |
| SINGLE CELL BIO PRINTING |
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| 2min |
DMLS
| Direct Metal Laser Sintering |
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| Laser + Powder |
| image |
EBM
| Electron Beam Melting |
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| Electron Beam + Powder + Vacuum |
| image |
ACCESSING THE TECHNOLOGY
| How to Access the 3D Printing Technologies ? | Which type of machines ? |
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| Fablabs | Mainly Desktop FDM and SLA |
| Research Facilities | SLA, SLS, (sometimes) |
| Online Services | Any type of machine |
THE MACHINERY
| The Machinery I know : Cartesian, Modular, and Scalable |
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| PRUSA |
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| Desktop FFF (PRUSA) |
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| Desktop FFF Farm from prusa |
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| Desktop FFF Automated Farm from Prusa |
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| FORMLABS |
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| Desktop SLA (FORMLABS) |
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| Desktop SLA farm |
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| Desktop SLA Automated farm |
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| Semi-Industrial Grade FDM (BIG REP) |
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DEMO ON PRUSA AND/OR FORMLABS ?
SPECIAL MACHINERY AND TECHNOLOGIES
| Non-Planar 3D Printing |
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| Continuous, 45º, 3D Printing |
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| Semi-Cartesian 3D-Printers (DELTA) |
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| Multi-Material 3D Printing |
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| 5 Axis 3D Printing |
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| The Morgan |
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| HangPrinter |
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3D PRINTING FOR HEALTH
| Current HEALTH Applications for 3D Printing |
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| Dental Prosthesis |
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| Breast Reconstruction (0 to 1.22 min) |
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| Maxilo-Facial Reconstruction |
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| Real 3D Bone Implants |
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| calcium phosphate suspended into fatty acids |
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| Cranioplasty |
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| Limb and Legs Prosthetics |
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| Ear |
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| Micro-Fluidics |
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| Organs-On-A-Chip |
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| https://wyss.harvard.edu/news/first-entirely-3d-printed-organ-on-a-chip-with-integrated-sensors/ |
| Human-Skin |
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| https://www.medicaldevice-network.com/features/3d-printed-skin/ |
| Equipments (COVID 19) |
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3D PRINTING EVERYTHING !
| Other Current Applications for 3D Printing |
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| Ring |
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| Medal |
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| Engine Prototype |
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| Robot Arm |
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| Sculpture |
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| Heels |
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| Meat |
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| Space Pizza |
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| Stool |
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| Chair |
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| Sustainable Housing |
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| Less Sustainable Housing |
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| Electronics |
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| Rockets |
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CAD & SLICING & 3D PRINTING
| Computer-Controlled-Design (CAD)for 3D Printing |
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| The type of Additive Manufacturing we are look it at CANNOT be performed without computers |
| It starts with CAD (no matter what) |
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| Designing for 3D-Printing is very specific |
| Then the Design needs to be sliced to be turned into a machine-language |
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| The G-Code |
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| The 3D Printer |
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DESIGN RULES
| Design Rules for 3D Printing |
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| 3D hubs poster |
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| 3D hubs book-picture |
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FILES FORMATS
| Main CAD-Format Extensions | | :- | | :- | | .STL | https://en.wikipedia.org/wiki/STL_(file_format) | | .OBJ | https://docs.fileformat.com/3d/obj/ | | .PLY | https://en.wikipedia.org/wiki/PLY_(file_format) | | And More | https://docs.fileformat.com/3d/ |
| Technologies | Raw Materials Conditioning | Availability |
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| SLA | Liquid Resins | Common |
| FDM | Filaments on Spools | Very (very) Common |
| SLS | Powders | Industrial (Mainly) |
| JETTING | Droplets | Industrial |
| WAAM | Wires | Industrial |
| BIO PRINTING | Gels and Cells | Nor Industrial or Easy to access |
| DIRECT EXTRUSION | Pellets | Not Very Common |
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| An Expending Variety of Materials |
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| PLA |
| PVA |
| NYLON |
| WAX |
| CARBON |
| PET/PETG |
| KEVLAR |
| TPU |
| PEEK |
| ABS |
| CPE |
| MIXED |
| Mycelium |
| Metals |
| Clay |
| Concrete |
| Glass |
| ETC. |
COMMUNITIES
| 3D Printing Communities and Web Platforms |
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| They mainly emerge from companies as a mean to make the field 3D printing easer to grasp by facilitating peer-to-peer collaborations. |
| There is an incredible amount of designs available online |
| People share knowledge for machine-repair, for design optimisation or customisation |
| They also share code sequences, create software plug-ins |
| https://www.prusaprinters.org/prints |
| https://www.youmagine.com/ |
CONCLUSION
| Conclusion |
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| Design or Download a 3D file (.STL or .OBJ) |
| Find the closest 3D Printer around you (check the list below) |
| Print it |