How to 3D Print Faster - Without Compromising Part Quality

How to 3D Print Faster - Without Compromising Part Quality

May 23, 2018

The build time estimate is showing eight hours. You've re-oriented the part a few times and even played around with removing build supports - so what if that overhang droops a bit - but the estimate doesn't budge. What could you have done differently this time, you wonder, to get a faster print? You run through the checklist. 

Can you Compromise Design for Speed?

This design has overhanging features, sharp corners, and tiny features - everything a 3D printer is supposed to do in a single build without fuss. You're not going to sit here and print cubes all day. You have real designs that need physical realization. Changing the design of the part is out of the question.

Can you Change the Wall Thickness?

You could change the wall thickness of your part to speed up the print. Thinner walls require fewer passes with the printer head, but in turn you're sacrificing wall strength as you decrease wall density and infill. If you're 3D printing a knick-knack, wall strength won't matter as much. But you're not printing a knick-knack; you need something functional. Changing the wall thickness is a no go.

Can you increase the layer height?

Of course increasing layer height helps increase speed. But increasing the thickness of the layer affects the smaller features of your part, causing loss of accuracy and fine feature details. The time it would take you to tweak the layer height only just enough to reach a middle ground between thickness and a compromise for feature detail is time you might as well spend printing the part. Changing the layer height is simply not worth the hassle.

You just wanted to print a part and not have to wait a full workday for its completion. Before you give up, let's see how you could have printed faster if instead of trying to change your design and the way you build, you changed out your printer.

How the HSE solves for speed

Like you, we've had early days setting up a build only to come in late at night 24+ hours later to finish it up. And, like you, we wanted to print the parts we wanted, without increasing the time by tenfold. Here's how Essentium's HSE machine with FlashFuse technology speeds up 3D printing.

10X Faster:

A significant barrier to faster 3D prints boils down to the nozzle head. We developed a better high-temperature nozzle. What's unique about our nozzle is that it extrudes 10x the force of other printing nozzles. It gives users temperature control as fine as adjusting from 20 C to 600 C in roughly three seconds. The force and heat combines to deliver a significantly faster build while maintaining high accuracy.

Stronger Parts: 

In addition to speeding up the print, we strengthened bonding along the Z-axis. Typical 3D printed parts are weaker along the Z-axis, which can lead to inadequacies in part performance. We developed FlashFuse technology to heat and fuse layers more quickly and effectively without significant retracts and this helps deliver stronger parts overall.

Design And Build Without Compromise

It's par for the course to constantly tweak a design to make it more suitable for 3D printing. We see engineers spending a lot of time trying to offset cost for speed, or speed for accuracy, or accuracy for cost. It's time consuming on top of an already slow manufacturing process. It's time we broke that norm and started using 3D printing as a real manufacturing process. We've built the machine that allows engineers to do just that: manufacture without compromise. 

Learn more about our HSE platform and FlashFuse technology.


Webinar on Demand: Build Faster with HSE

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