Table 1.
Starting material | Method | Layer thickness (µm) | Method overview | Advantages | Disadvantages | Example of use in Ecology and Evolution | |
---|---|---|---|---|---|---|---|
Solid | Plastic filament | Fused Filament Deposition (FFD) | 300–1,000 | Plastic filament is melted and placed in layers by the print head | Common plastics, such as ABS, can be used. Chemical properties retained | Anisotropic (strength differs in Z‐axis, to X‐Y axis). Stepped surface, which lacks fine details | Thermal ecology model lizards (Watson & Francis, 2015) |
Powder | Metal | Laser melting | 20–100 | Thin layers of powder are spread over a bed which the laser selectively melts. Once solidified, a new layer of powder is spread | >99% of the metal's density can be achieved, therefore good mechanical properties | Expensive and slow, limited metals can be used, it is not suitable for reactive metals | |
Electron beam | 0.3–100 | Powdered metals are selectively melted by electron beam in a vacuum |
As for Laser melting. Reactive metals (e.g., Titanium) can be used |
Expensive, slow and limited metals can be used | |||
Plastic Metal | Laser sintering | 100–300 | The laser selectively melts powdered plastics and the model is made in the powder bed |
Common plastics can be used. Cheap for small number of objects. Chemical properties of material are retained |
Poor surface finishes and tolerances are limited | Ceramic filter holder (Lücking et al., 2015) | |
Any powder | Binder jetting | 90–200 | Powdered material is placed in layers over the build area and then glued together with a binding agent | Any powdered material can be used. Relatively fast and cheap. Color models are possible |
Produces fragile parts which need further treatment. Poor surface finish |
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Liquid | Photo‐polymer | Stereolithography (SLA) | 16–150 | A laser selectively solidifies thin layers of photopolymer. The print bed moves down to allow a new layer of polymer to form | Accurate with good surface finish that can capture fine details | Expensive and photopolymers are not stable long‐term | Model Neotropical bush‐cricket (Jonsson et al., 2017) |
Photopolymer jetting | 16–500 | Thin layers of photopolymer are jetted on to the build area. They are cured with ultraviolet light straight away | Multiple materials can be used. Can be high precision | Expensive and photopolymers are not stable long‐term |
Models of black widow spiders (Brandley et al., 2016) Mold for microfluidic devices (Kamei et al., 2015) |
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Wax | Material jetting | 13–50 | Inkjet printer heads drop hot wax on a bed, which cools and forms layers | Accurate with good surface finish. Suitable for lost wax casting | Slow process that produces fragile models | Replicating delicate dinosaur bones (Bristowe et al., 2004) |
Examples, from papers cited in the main text are provided to illustrate applications. Layer thicknesses are approximate as specific makes and models of 3D printers will vary. A guide of prices for different technology types can be found in Table 2