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In today’s manufacturing landscape, the terms “3D printing” and “additive manufacturing” are often used interchangeably. But are they truly the same? While they share similarities, there are key distinctions between the two. This blog will help you understand the relationship between 3D printing and additive manufacturing and when to use each term.

What is 3D Printing?

3D printing refers to the process of creating a three-dimensional object from a digital model, such as a CAD (Computer-Aided Design) drawing. This technology has revolutionized how objects are designed and produced. The process involves slicing the digital model into thin layers, which the 3D printer then builds up layer by layer using various materials.

Here are some of the most widely used 3D printing technologies:

• Fused Deposition Modeling (FDM): This method extrudes thermoplastic filament to build an object layer by layer.
• Selective Laser Sintering (SLS): A polymer powder is preheated to its melting point and then selectively fused together by a CO2 laser to create a solid part.
• Stereolithography (SLA): In this process, a photosensitive liquid resin is solidified using an ultraviolet laser.
• PolyJet: This technology uses liquid photopolymers and builds parts by depositing ultrafine droplets onto a build platform.

3D printing is commonly associated with small-scale, one-off productions and is often used in prototype development or by hobbyists.

What is Additive Manufacturing?

Additive manufacturing (AM) encompasses 3D printing but goes beyond just the printing process. It refers to an entire industrial manufacturing process that includes not only the creation of objects but also several other essential steps. While 3D printers play a crucial role, additive manufacturing involves a broader, more complex workflow.

The additive manufacturing process can include:

• Modeling: Developing a digital design using CAD software.
• Material Traceability: Ensuring the materials used are tracked and meet quality standards.
• Workflow Management: Coordinating the various stages of production.
• Post-Processing: Finishing techniques such as painting, polishing, or heat treatments to enhance the final product.
• Quality and Inspection Systems: Rigorous checks to ensure that the final product meets all necessary specifications.

Additive manufacturing is typically used in large-scale or industrial applications, where precision, consistency, and scalability are crucial. This workflow can look vastly different than a typical small-scale 3D printing process.

Understanding the Difference

While 3D printing is a subset of additive manufacturing, not all 3D printing is considered additive manufacturing. The key difference lies in the scope and application. 3D printing usually refers to smaller-scale operations, often at the consumer or hobbyist level. In contrast, additive manufacturing refers to a comprehensive production process used in industrial settings.

Key Takeaways:

• 3D Printing: Ideal for small-scale, prototype, or hobbyist applications.
• Additive Manufacturing: Involves a full production workflow and is used in industrial and large-scale manufacturing contexts.

When choosing which term to use, consider the context. If you’re referring to a process with multiple steps in an industrial setting, “additive manufacturing” is the appropriate term. For smaller-scale or one-off productions, “3D printing” is more accurate.

By understanding these differences, you can better navigate the evolving landscape of modern manufacturing and use the right terminology for your needs.

In resin-based 3D printing, post-processing is crucial for high-quality parts. After photopolymer resins are cured, printed objects are often covered in excess resin that must be removed before further post-processing steps. Traditionally, this is done by manually submerging the parts in isopropyl alcohol (IPA) and scrubbing them, which is both labor-intensive and risky for the overall environment.

IPA poses significant challenges in additive manufacturing due to its flammability, which increases workplace accident risks and releases volatile organic compounds (VOCs). These VOCs degrade air quality and can cause respiratory issues. Additionally, the repetitive task of scrubbing parts with IPA can lead to technician fatigue and inconsistencies in part quality.

Addressing Safety and Efficiency

To tackle these challenges, PostProcess Technologies has developed automated solutions that eliminate the need for IPA by combining innovative hardware, proprietary software, and additive-specific chemistries. They have engineered a workflow that effectively cleans excess resin while addressing safety and environmental concerns.

In this process, printed parts are placed into a DEMI system which utilizes Submersed Vortex Cavitation technology and PLM-403-SUB detergent. This system efficiently cleans the parts, removing residual resin from the printing process. However, a final rinse step is necessary to prepare parts for curing and/or additional cleaning steps.

IPA has traditionally served as the final rinse step, but it has an incredibly low flashpoint, which makes it a hazard to any facility, and as previously mentioned, some facilities and countries will not allow IPA to be used at all in their facilities.

How to Eliminate IPA from Resin Post-Processing

To completely eliminate IPA from the resin removal workflow, PostProcess has developed AUX-400-RINSE. This organic-based rinse solution can be used as a final rinse step following processing in PostProcess automated resin removal solutions.

PostProcess conducted comprehensive testing of AUX-400-RINSE, focusing on flashpoint, drying time, safety, longevity, and material compatibility. The findings revealed that AUX-400-RINSE surpasses industry safety and performance standards and also sets a new benchmark for post-processing excellence.

The full PostProcess resin removal workflow, featuring AUX-400-RINSE, streamlines operations, reduces manual labor, and ensures consistent part quality, promoting regulatory compliance and a healthier work environment.

Pioneering a Safer Future

The development of AUX-400-RINSE highlights PostProcess Technologies’ commitment to advancing industry standards through safer and more efficient solutions. Manufacturers can improve safety, enhance environmental practices, and achieve operational efficiency by adopting IPA-free resin removal methods.

AUX-400-RINSE provides a significant reduction in overall safety hazards due to the high potential for IPA fumes to spontaneously combust at low temperatures, which poses a risk of injury to employees and creates a hazard to the overall facility’s environment. Both chemistries used in PostProcess’ resin cleaning workflow provide increased safety. AUX-400-RINSE has a 21% lower vapor pressure than IPA, reducing flammability risks, and PLM-403-SUB offers a significantly higher flashpoint of 220°F / 104.4°C compared to IPA’s flashpoint of 53°F / 11°C.

If you’d like to learn more about an IPA-free post-processing resin removal workflow, download our white paper: Eliminating IPA in Resin Cleaning.

Elastomeric resins are a class of polymer materials known for their elasticity, which allows them to regain their original shape when distorted. Examples include natural rubber, polyurethane, polybutadiene, neoprene, and silicone. Consumer goods, automotive, and industrial are a few of the key industries using elastomeric resins in the market.

The number of elastomeric resins is also growing rapidly, with 45 different types and more to come in the future. However, like other 3D printed materials, elastomeric resins pose significant challenges in the post-processing step. It can be difficult to remove the uncured resin without impacting the cured resin. Solvent soaks, such as isopropyl alcohol (IPA) or tripropylene glycol monomethyl ether (TPM) can alter elastomeric properties, causing breakage, swelling, cracking, or loss of elasticity.

Introducing PostProcess Elastomeric Resin Removal Solution, PLM-501-SUB™

To address these challenges, PostProcess Technologies has created a new elastomeric resin removal solution featuring an all-new additive-specific chemistry, PLM-501-SUB. This is an organic-based resin removal solution for VAT-based 3D-printed elastomeric parts. PLM-501-SUB is specifically formulated to remove uncured resin from elastomeric materials while minimizing swelling, damage, or changes to mechanical properties.

This full-stack solution integrates hardware, software, fixtures, and proprietary chemistry to remove resin from many 3D printed plastic materials, effectively cleaning parts from elastomeric materials while minimizing overall part damage.

PLM-501-SUB is designed for use in PostProcess’ DEMI 400, X 520, 800, and 900 Series solutions. These solutions provide a completely IPA-free elastomeric resin removal system, integrated with PostProcess hardware, AUTOMAT3D software, allocated fixtures, PLM-501-SUB, and rinsing with AUX-400-RINSE.

After elastomeric parts are submerged in PLM-501-SUB, they can then be rinsed with PostProcess’ AUX-400-RINSE if a final rinse step is necessary before they are dried and/or cured.

Why Choose PLM-501-SUB?

Odorless and Organic: PLM-501-SUB™ is an odorless, organic solution with a 30% longer lifespan compared to IPA and TPM.

Enhanced Safety: It provides a safer alternative to solvent soaks like IPA, with a high flashpoint (237°F / 115°C) to significantly reduce flammability risks. Unlike IPA, it does not require explosion-proof or ATEX-certified equipment.

Efficiency and Speed: Elastomeric resin is removed within 5-7 minutes when components are submerged in PLM-501-SUB™ using a PostProcess SVC solution. This eliminates the need for manual labor and achieves superior efficiency, with 35-38% longevity in terms of resin by weight.

High-Quality Output: By integrating PLM-501-SUB™, manufacturers can protect elastomeric parts from swelling or cracking, resulting in a higher quality end-product and increased throughput production of quality parts.

Seamless Integration with PostProcess Solutions

PLM-501-SUB is designed for seamless integration with PostProcess’ DEMI 400, X 520, 800, and 900 Series solutions, providing a more efficient and safer production process.

Eliminating solvent soaks and integrating PLM-501-SUB in a PostProcess solution will prevent swelling or cracking of elastomeric parts, boosting the production throughput of high-quality end products, while eliminating safety concerns.

PLM-501-SUB is the superior solution for PostProcess systems with its ability to streamline workflows, improve part quality, and increase production efficiency.

At PostProcess, we continue to push the boundaries in the additive manufacturing industry. Our latest innovations, DEMI X 520™ for Resin Removal and DEMI X 520 for Dental Resin Removal, expand our post-processing offerings and provide the world’s only IPA-free resin removal solution.

The DEMI X 520 series elevates post-printing workflows, combining intelligent software capabilities, robust hardware features, and specially formulated chemistry to achieve optimal IPA-free resin removal for 3D printed parts. These solutions extend the PostProcess Submersed Vortex Cavitation™ portfolio and introduce brand new Axial Flow Technology™ to deliver enhanced features that provide a simple, personalized and full-stack post-processing experience.

Customizable Software for Seamless Operation

The DEMI X 520 series solutions are equipped with our AUTOMAT3D® software to seamlessly guide users through the entire processing cycle.

This AUTOMAT3D® software is completely customizable, allowing users to set their own time, temperature, and agitation for their particular application. These tailored experiences allow for a consistent, efficient, and error-free operation. Plus, users can also conveniently store recipes for future use.

The difference between the two solutions? The DEMI X 520 for Resin Removal is equipped with software designed specifically for dental resin removal. The DEMI X 520 is designed for all other resin applications, including plastic resins and elastomeric resins.

Cutting-Edge Hardware & Fixtures

The DEMI X 520 series offers cutting-edge hardware and fixtures that guarantee unparalleled consistency.

This includes:

• An automated parts lift to protect parts from over-exposure to chemicals and enhance operator safety.
• Specific resin removal fixtures designed to ensure optimal part processing, whether parts are processed directly on the build platform or in batches off-platform.
• Brand new Axial Flow Technology, to give users the ability to adjust flow and optimize performance, resulting in consistent, high-quality finished parts.

IPA-Free Chemistry

The rising safety and environmental concerns of isopropyl alcohol (IPA) in traditional post-processing methods have created a need for alternatives in the industry. At PostProcess, we strive to create solutions that are completely IPA-free.

The DEMI X 520 series uses a combination of PLM-403-SUB detergent and AUX-400-RINSE, offering a safer and more efficient alternative to IPA.

Engineered for operator well-being, this proprietary chemistry produces low odors and enhances safety for technicians with high flashpoints of PLM-403-SUB (220°F / 104.4°C) and AUX-400-RINSE (102°F / 38.8°C), significantly reducing the risk of flammability. The biocompatible PLM-403-SUB detergent also ensures seamless and quick resin removal, with most cycles completed in less than 10 minutes.

The addition of AUX-400-RINSE as the final rinse step in the workflow, eliminates any need for IPA in the resin removal process.

By combining intelligent software, cutting-edge hardware, and safer chemistry, these solutions will transform your 3D printing workflows.

Both solutions in the DEMI X 520 series ensure unparalleled consistency through validated workflows, enabling high-quality, repeatable cycles. These innovations translate into increased throughput and productivity, setting a new standard for precision and reliability in resin removal technology.

Explore the future of resin removal with the DEMI X 520 series and step into a new era of enhanced safety and streamlined resin removal.

2023 brought a wave of dynamic collaborations and innovative ventures to PostProcess Technologies. Our dedicated team has been tirelessly advancing state-of-the-art post-processing automated and intelligent solutions, transforming the landscape of the additive manufacturing sector. As we approach the year’s end, let’s delve into the noteworthy milestones that unfolded at PostProcess this past year.

Move Away from IPA: AUX-400-RINSE allows for an IPA-free Resin Removal Workflow

In May, we announced our latest rinse detergent to be used in our resin removal workflow: AUX-400-RINSE. AUX-400-RINSE is an organic-based rinse solution that replaces the IPA rinse step in the PostProcess resin removal workflow that may be required following the processing of parts in one of our full-stack automated solutions.

This is a revolutionary development for the resin removal workflow because IPA can create many challenges to additive operations. When combined with our automated and intelligent solutions, AUX-400-RINSE now creates an IPA-free workflow, allowing for a safer alternative to IPA, thanks to a high flashpoint that does not require explosion-proof or ATEX-certified equipment. It also offers improved performance, rinsing 3X as many parts per Gallon (or 3.78 L) as IPA, and improved sustainability because it is easily filtered for reuse.

Partnerships Across the Globe Help Increase the Reach of PostProcess

PostProcess has consistently recognized the significant value that channel partners bring to the additive manufacturing market. In fact, we announced 6 new partnerships in 2023:

PLM Group

PLM Group, a company rooted in the Nordic region, specializes in delivering 3D design and additive manufacturing solutions. This partnership effectively introduces PostProcess to the markets of the Nordic countries, the Baltic region, and Iceland.

CadBlu

Bringing over 25 years of industry expertise, CAD BLU has established itself as a reliable source of digital 3D printing solutions tailored to jewelry design and manufacturing. This partnership simplifies the process for customers to acquire a comprehensive solution for wax 3D printing, facilitating end-to-end digitization of the workflow from part design through 3D printing to post-processing.

Additive Solutions Group (ErPro Group Subsidiary)

As a leading service bureau in France, Erpro Group is widely recognized for its expertise in utilizing additive manufacturing for production purposes. Through its subsidiary, Additive Solutions, the company concentrates on empowering customers with comprehensive manufacturing process solutions. The collaboration with PostProcess helps their customers incorporate automated post-processing and delivers end-to-end solutions to the French market.

CDG 3D Tech

Concurrent Design Group (CDG 3D TECH), a company specializing in 3D engineering design and manufacturing brings PostProcess’s digitized post-processing solutions to customers across England, Scotland, Wales, Northern Ireland, and the Republic of Ireland.

Raplas

Headquartered in Wales, RAPLAS Technologies, a distinguished industrial manufacturing technology company, leads the way in SLA production resin systems, resin materials, and software. This collaboration establishes a well-defined workflow for large-format SLA in additive manufacturing, including the crucial post-processing step of resin removal.

Proto3000

Proto3000, a leading provider of 3D printing solutions and services, provides PostProcess solutions to dental customers throughout the United States and Canada to transform the resin removal process for dental professionals.

Bendix Commercial Vehicle Systems Revolutionizes Post-Processing with Automated FDM Support Removal 

We have published a new case study featuring Bendix Commercial Vehicle Systems, a company specializing in the development and provision of cutting-edge active safety technologies, energy management solutions, and air brake charging and control systems for heavy-duty trucks, tractors, trailers, buses, and commercial vehicles across North America.

This insightful Q&A explores the efficiency of the PostProcess Volumetric Velocity Dispersion (VVD) technology integrated into the VORSA 500™ and highlights how this technology enables Bendix substantial time savings in their FDM part finishing, leading to reduced costs for their additive manufacturing operations.

Nexus Dental Makes the Leap to Automation for Post-Processing with the DEMI 430™

Nexus Dental Lab stands at the forefront of the dental industry and is committed to transforming dental practices. They provide a range of services, including digital smile diagnostic services, dental implant restorations, crown and bridge solutions, implant guide design and production, direct print services, and Lucitone digital copy dentures.

Encountering issues in their resin post-processing workflow, they struggled with the use of IPA, which posed both environmental sustainability concerns and risks to their staff. Discover how the implementation of the PostProcess® DEMI 430™ enabled them to reduce manual labor by one-third.

You can read the full case study here

New and Improved ROI Calculator for PolyJet

In 2023, we also launched a brand new ROI tool to help determine the best PostProcess solution for your PolyJet operation. Enter basic details about your existing post-processing operations, and we’ll analyze them to illustrate the potential cost savings and productivity improvements achievable by transitioning to an automated PolyJet Support Removal solution.

Our calculator examines your current operation, taking into account labor costs, the time allocated to process each part, and the percentage of parts that experience warping or damage.
While the productivity gains may vary for each customer, many witness a return on investment within weeks, thanks to reduced cycle times and increased throughput.

You can access the ROI calculator here

‘How It Works’ Webinar Series Decodes PostProcess’ Automated & Intelligent Post-Processing Solutions

This year, our How it Works webinars examined the workflow associated with each of our revolutionary automated and intelligent post-processing solutions. Hosted by an expert from our PostProcess team, this series looked at our post-processing solutions for resin, FDM, PolyJet, and wax.

Watch the recorded webinars here.

2023 was full of exciting news here at PostProcess, and 2024 is shaping up to be just as exciting. Brace yourselves for an equally exhilarating 2024, filled with groundbreaking advancements and announcements that promise to redefine your experience with automated post-processing.

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What’s on your to-do list for your additive operation in 2023? Additive manufacturing continues to grow in popularity and become a major part of a wide variety of industries. It’s important in today’s economic climate to evaluate your overall workflow and how you can improve upon your operation for the new year.

Back in December, we released our 4th Annual Post-Processing Survey. Within the survey, we asked respondents from all over the globe about their current additive operations, including post-processing, and how they planned to advance and alter their plans in the upcoming year. Let’s look at some of the common themes to see what to evaluate in your additive manufacturing operation for 2023.

Environmental Health & Safety Are Paramount to Effective Workflows.

Environmental, health, and safety (EH&S) considerations have always been important to anyone in additive manufacturing. The safety and well-being of their operations continue to be critical to maintaining an effective facility.

57% of respondents stated they want to improve their operation’s environmental, health, and safety in 2023, with the largest concentration in the EU. Those that use DED, Vat Photopolymerization, and Powder Bed Fusion print technologies reported the highest percentage of respondents looking to improve EH&S. When reviewing by industry, the medical industry is looking to improve EH&S most, with 71% prioritizing it for 2023.

As new print technologies emerge, so do new environmental, health, and safety risks. The standard ISO 17296-2 lists seven major groups under the heading “3D printing,” which shows that operating in an additive environment is not without danger. Many risks are linked to the technology itself, as well as the risks of the raw printing material. Powdered materials used in technologies like SLS, DMLS, and SLM are finely milled and increase the risk of anoxia. Liquids like resin used in technologies, such as DLP, SLA, and CLIP print technologies, can irritate and/or burn the user if they come in direct contact with the skin.

Finish 3D Printed Parts Faster.

Traditional post-processing methods are notoriously time-consuming. For the third year in a row, our respondent’s number one post-processing concern was the time it took for them to finish parts. While material extrusion remains the print technology that reported this pain point the most often, the time to finish parts is problematic across all technologies. Post-printing can be labor and time-intensive, leading to bottlenecks that can derail the entire additive workflow if you aren’t careful.

Why does it take so long to finish parts with traditional post-processing methods? One reason is that most of these post-processing methods are taken from traditional manufacturing. They weren’t designed to work specifically for additive manufacturing, so they aren’t efficient in removing support structures or excess resin in any sort of optimized way. This leads to greater bottlenecks, part warpage, and part breakage. Automated solutions that allow for reduced manual labor and increased efficiency can ease some of these common bottlenecks.

The Growing Importance of Sustainability in Additive Manufacturing.

Another buzzword heard around the additive field is the increased emphasis on sustainability. While often lumped into environmental, health, and safety, we can say based on our respondent’s input that sustainability is an important factor to consider for any additive operation. 38% of the people we spoke with are looking to increase sustainability in 2023.

Many printing companies emphasize sustainability, with companies like EOS taking a serious stance on integrating sustainability into their overall company mission. They’ve even offered powder for 3D printing that can be reused. Stratasys also maintains a commitment to what they call Mindful Manufacturing™ and have published a Sustainability Report

We here at PostProcess also feel that this dedication to sustainability should extend through to the post-printing step in the workflow. That’s why we also are committed to continuously improving our additive-tailored solutions’ efficiencies and cutting down on material usage and waste.

As the additive market continues to grow, post-processing methods can cost companies a lot of time, money, and resources and impact the overall efficiency of an operation. That’s why it’s important to evaluate your current processes and how you can improve them.

If you’d like to learn more about our insights from our 4th Annual Post-Processing Survey, download the full report here.

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Post-processing has long been called the “dirty little secret” of additive manufacturing. But as additive manufacturing becomes more popular and additive users move into production with their additive solutions, the bottlenecks and problems become more and more apparent.

For our 4th Annual Post-Processing Survey, we asked respondents about their top post-processing challenges for each of the most popular print technologies. Here are the responses for the most popular technology used: Material Extrusion. Material extrusion includes FDM, FFF, and MEM print technologies.

The top pain points for this group remained consistent over the past three years of our survey, which indicates that while print technologies continue to advance, the traditional post-processing techniques still cause bottlenecks in the additive workflow.

Length of Time to Finish Parts

The first and most common pain point reported was the time to finish parts. Material extrusion allows for the 3D printing of complex geometries. However, these geometries then require support material to ensure the stability of the print. Often the traditional process of removing supports is cumbersome and requires a large amount of manual labor and/or soaking. Chemical baths are used to soak parts made with soluble supports. Lengthy post-processing time slows down production exponentially and can disrupt and even ruin an additive workflow if bottlenecks happen too often.

Consistency

Traditional support removal methods can lead to inconsistent results due to the manual labor required. With the need for skilled technicians to manually remove supports, parts cleaned by different technicians will be different, creating inconsistency in the final product.

Damaged Parts

Along with consistency, damaged parts are a common challenge with traditional material extrusion post-processing methods. We can look at well-known companies like Toro, who used to spend 2X as long to finish parts as they did to print parts.

Parts that are soaked to remove support material often need to be soaked for many hours at a time. With parts soaking in a caustic bath for ten or more hours, parts become saturated with chemicals or bloated, which makes them unusable.

These struggles with the length of time to finish parts, consistency, and damaged parts are common with traditional post-processing methods for not only material extrusion but all 3D print technologies. This is because traditional post-processing was pulled from other traditional manufacturing methods and wasn’t designed for additive manufacturing. With that in mind, solutions created specifically for additive manufactured parts can help ease these common post-processing concerns. Automated solutions built with additive in mind can help cut time, labor, and ultimately the cost associated with the post-printing step of additive manufacturing.

Want to learn more insights from the 2022 survey? Download the report here.