3D Printing

Summary

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Best Practices

FDM vs SLS in Healthcare Setting

There are currently two major commercial types of 3D printing fused deposition modeling (FDM) and stereolithography (SLA). FDM is the most widley used and works by extruding thermoplastic filaments, through a heated nozzle and applying the plastic layer by layer to build a models. SLA uses a laser to cure liquid resin into hardened plastic creating detailed and smooth finished results. While SLA printers can create smaller and more detialsed prints, FDM is likely the best fit to use in the healthcare setting. The main reason for this is the the printing process and uses of resin, requires proper ventilation and often the use of a respirator when working with the materials. Most spaces in a hospital do not allow for open windows or ventilation options that would make this process safe, making SLA a poor choice for this setting. If your program is located offsite, or has access to a workshop space, you may be able to make safety accommodations.

Policies & Procedures

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Sanitizing

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Account Settings & Management

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Models of Printers

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Name (template)

Brand:

Current Programs Using:

Features:

Limitations:

Default Slicer:

Cost:

Flash Forge Adventurer 4

Adventurer 4

Brand: Flashforge

Current Programs Using: Ann & Robert H Lurie Children's Hospital of Chicago

Features: Enclosed, heated bed, quick swap nozzles, flexible/removable build plate, ready out of box, filament detection sensor, touch screen UI

Limitations: Proprietary nozzles, misleading bed leveling (uses average based on 9 points, not mesh), limit opportunities for user mods/adjustments

Default Slicer: FlashPrint

Cost: $700 (April 2023)

Slicers

Slicers are programs that take 3D models and "slice" them into horizontal layers for the 3D printer to print. This is also where you will be adjusting layer height (affects detail/time of print), supports (needed to print overhangs), print speed/temperature (slight adjustments needed depending on the filament being used), and other settings. Most printers have a default slicer but some are better supported and most can be used with any printer.

Cura

The default slicer for the UltiMaker devices, but the arguable favorite in the 3D printing community. Actively being developed with updates coming out several times a year, often with industry changing advancements. Can be a bit more complex in advance settings, but nothing that isn't learnable through watching a few YouTube videos. Also has an option for community add-ons which offer several quality of life improvements.

FlashPrint

The default slicer for the Flashforge devices. Works well with these devices and can be used with other brands of printers, but nothing flashy or special that puts it above other slicers.

Modeling Software

To edit or clean up 3D models, there are several different programs one can use. Each has different levels of complexity and limitations.

Tinkercad

A web based design program that allows the user to create 3D models using predefined shapes. Shape dimensions can be modified free hand or inputting precise measurements. Users combine normal and "ghost" shapes to delete portions of objects. While it will load already created STL files, it does have a set limit on file size/triangle account. This is a great introduction into 3D modeling and a good resource to introduce to a patient to create their own project.

Blender

A free program revolving around 3D modeling and animation. A bit more in depth then other software, requiring time spend watching tutorials or simply messing around to get a feel for the process. Users can modify models on the mesh level by adjust vectors and face or use the sculpting mode for a more artistic approach. Will load most complex STL files and is a great way to combine two models into one (e.g. a lithophane and a stand).

Fusion360

Fusion 360 is a cloud-based 3D CAD program that utilizes the cloud storage for easier use in collaboration on complex projects. Another advantage of the cloud platform is that Fusion stores the entire history of the model including the changes to it. Numerous design options are available, including freeform, solid, and mesh modeling. The software is free for personal and noncommercial use, but has limitations on the number of projects stored on the cloud.

Meshmixer

While it is no longer being developed, Meshmixer provides straight forward and unique tools in editing mesh models including planner cuts, filling/hollowing models, and creating tubes. While likely not the first choice in creating models from scratch, these tools can be helpful in end stage processing.

Filament

Fused deposition modeling (FDM) printers use rolls of filament as their material source andare several different types that each have ideal usages, strengths, and limitations. Below are some of the most common types used, but advancements are made each year, so other unique products may be available/best fit for your needs.

PLA

PLA (Polylactic Acid) is the most common 3D printing material because it is easy to use and is made from renewable resources and thus, biodegradable. Some companies have PLA+ or Silk variants that mix additives into the base PLA to increase strength, smoothness, texture etc. This will often modify print temperature or other setting, so make note on what is listed on the package.

Typical Temp Range: 205±15 °C

Heated Bed: Not Required

Ventilation: Not Required

Pros: most cost effective, easiest materiel to work with

Cons: not super strong, can warp in high heat, degrades with UV exposure over time

ABS

ABS (Acrylonitrile Butadiene Styrene) is another commonly used 3D printer material. Best used for making durable parts that need to withstand higher temperatures.

Typical Temp Range: 230±10 °C

Heated Bed: 90±10 °C

Ventilation: Likely, fumes aren't toxic but do smell

Pros: strong heat/UV resistant prints, can be post process with acetone for a glossy finish

Cons: prone to warping so may require an enclosure, stinky fumes

PET (PETG)

PET (Polyethylene terephthalate) is almost a combination of the ease of use of PLA with the durability of ABS.

Typical Temp Range: 245±10 °C

Heated Bed: Not required

Ventilation: Not required

Pros: stronger then PLA, barley warps, no odor, more transparent then other materials,

Cons: harder to clean during post-processing, can get stuck to print bed, very hygroscopic so requires a dry box for storage or drying before use

TPU

TPU (Thermoplastic Polyurethane) is an elastic, oil/grease resistant, and abrasion-resistant material with a shore hardness of 95A. This materials is great for grips, cases, and other item that require more flexibility

Typical Temp Range: 220±10 °C (can depend on brand)

Heated Bed: 40±10 °C

Ventilation: Not required

Pros: elastic/soft material, low warp-age/shrinkage,

Cons: difficult to print, prone to clogging particularly with systems using a bowden extruder, difficult to post-process especially support removal, hygroscopic so requires a dry box for storage or drying before use

ASA

Acrylonitrile styrene acrylate (ASA) was developed as an alternative to ABS. With a number of additional features, like improved weather resistance and resistance to yellowing from UVs, making it an excellent choice for parts or prints meant for outdoor use.

Typical Temp Range: 250±10 °C

Heated Bed: 90±10 °C

Ventilation: Likely, fumes aren't toxic but do smell (less then ABS)

Pros: strong heat/UV resistant prints, post processed with acetone,

Cons: prone to warping so may require an enclosure, stinky fumes, hygroscopic so requires a dry box for storage or drying before use

Compatible Accessories

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Adaptive & Inclusive options

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Additional Resources

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