What is the alternative to 3D printing?

3. Thermoforming

Thermoforming is used to shape thermoplastic sheets into specific forms. It works by softening the material through radiant heat and then using a mixture of pressure and vacuum to pull the material into shape in conformity with a pattern. The source material sheet is heated until it reaches a pliable state, above its glass transition temperature but below its liquefaction temperature. The heated sheet is placed over the male or female mold and vacuum and/or pressure is applied to force the sheet to conform to the shape of the mold. In some cases, an &#;opposite side&#; mold is used to assist in close conformity for more extreme shapes. This established forming is held in place as the material cools. Once cooled, the part is removed from the process equipment and the &#;waste&#; material of the sheet edge is trimmed off the required part.

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Thermoforming is a versatile process used in various industries to produce items such as: packaging, trays, automotive interior trim components, and some medical-device components. It involves low tooling costs in simple and hard-wearing patterns, fast production times, and the ability to create relatively complex shapes with high-quality outcomes.

This process does not relate in any way to 3D printing, being somewhat analogous to casting processes. However, it does offer a rapid and low-cost method for producing relatively precise prototype components in approximately &#;real&#; mass-production materials from a large range of available thermoplastic sheet materials. It is one of the few plastic manufacturing processes that allows continuity from one-off prototyping to true mass production without any significant change in tooling or materials.

4. CNC Machining

Computer numerical control (CNC) machining is a subtractive manufacturing process used to produce high-quality, precision parts with tight tolerances and complex geometries. A wide variety of metal, plastic, and natural materials are typically used.

CAD models are translated into machine-readable instructions using computer-aided manufacturing (CAM) software. This process creates a tool path and specifies cutter diameters and operational parameters for feed rate, cut depth, and spindle speed. The most basic CNC machines operate by moving the workpiece in three axes relative to a rotating cutter. More-complex machines also integrate cutter-alignment movements such as tilting the rotational axis. The more sophisticated end of the market can move the cutter and the workpiece in multiple axes to a maximum of 12 distinct motion classes (so far embodied in available machines).

CNC machining of various complexity and adaptability is widely available as a prototype, low-volume, and mass-production process for making simple and complex parts ranging from a custom washer to a gas-turbine combustion chamber. Virtually all product areas can and do exploit CNC machining.

Virtually any material available for mass production can be worked by CNC machining, so plastic parts can represent mass-production components more closely than most 3D printing processes can deliver. Throughput can be considerably faster than 3D printing for relatively simple parts, though production times can approach the same level for both options as part complexity rises. CNC machines of very large format are widely available, whereas 3D printing processes are generally quite limited in build envelope dimensions. &#;Height&#; in 3D printing requires a considerable increase in process times, whereas CNC machines can rapidly traverse the Z-axis to deliver taller parts faster. While metal 3D printing processes are rapidly evolving, CNC machining of metal parts retains some distinct advantages in precision and surface finish. Z resolutions in metal 3D printing are generally 0.2 mm at best, whereas CNC can operate at a better tolerance than 0.05 mm if slower processing and shallower cuts can be accepted.

To learn more, see our full guide on the CNC Process.

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3D Printing is one of the greatest achievements for Makers in recent times, but there are some issues with it.

Not everybody (myself included) can afford a 3D printer. The price tags come down every year but it´s still a very big investment.

Building a 3d Printer from scratch requires heavy development tasks to create a reliable 3D printer,which can add up to the cost of a retail model.

Kits deliver sure performance for lower price, but are still quite expensive.

In general 3D printing is a prototyping method that currently replaces older manual methodes in the maker movement.

3D printing is a process that consumes time to construct the Image-files (.stl) on a pc and printing itself consumes also a lot of time. For most projects, you have to do multiple prints to figure out slop thickness, mounting etc.

Sometimes its just quicker to do one or more mock-ups test them and correct your 3D drawings accordingly, and then have them print via an online print service.

Basic parts(f.e. Geometric shapes, spacers, lids) which can be created with 3d printing or CNC-machines can also be built with other manual techniques,that every maker can do on a very low budget.

Read the following steps to learn some usefull methodes which can substitute the all mighty 3D printer until you can afford one yourself.

This is the Poor Man´s "3d Printing" Alternatives Guide --> Head on to the next step!

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