What is Additive and Subtractive Manufacturing?

Additive manufacturing processes build objects by adding material (3D printing) layer by layer, while subtractive manufacturing removes material to create parts. Though these approaches are fundamentally different, subtractive and additive manufacturing processes are often used side by side due to their overlapping range of applications.

Subtractive manufacturing is an general term for various controlled machining (CNC) and material removal processes that start with solid blocks, bars, rods of plastic, metal, or other materials that are shaped by removing material through cutting, boring, drilling, and grinding.

What is SLA 3D printing?

SLA (Stereolithography) 3D printing is the most common resin 3D printing process that has become vastly popular for its ability to produce high-accuracy, isotropic, and watertight prototypes and end-use parts in a range of advanced materials with fine features and smooth surface finish.

How big a SLA part can ABEN make?

ABEN can build SLA parts up to the size of 800*800*1000mm in one piece, subject to design suitability. We can also build parts in pieces and join them, which can often offer a lower part price.

Can SLA models be smoothed and finished after building?

SLA parts are produced with a smooth surface. However, they can be polished to enhance the surface further. It is an excellent process to produce high quality ascetical looking show, exhibition and sales models.

How does SLA technology work?

Stereolithography (SLA) or (SL) is an additive manufacturing process that creates three-dimensional objects by curing liquid photopolymer resin layer by layer using ultraviolet light. SLA is actually the oldest additive manufacturing technique and one of the most popular in industrial settings.

Is stereolithography additive or subtractive?

Early concept models and prototypes are generally more economical and faster to produce with plastic additive manufacturing processes, such as stereolithography (SLA) or selective laser sintering (SLS).

What is SLS 3D printing?

SLS (Selective Laser Sintering) is an additive manufacturing / 3D printing powder based process for rapid prototyping and production of 3D parts with complex shapes and geometries.

How does SLS 3D Printing work?

SLS 3D Printing works by spreading a thin layer of Nylon 12 powder over the build surface. A laser is used to selectively heat areas of the powder, fusing some of the particles together. The process is repeated with further layers added on top, bonding the fresh powder to the layer below. The fused areas are built up layer by layer resulting in solid plastic parts.

How big a SLS part can ABEN make?

ABEN can build SLS parts up to the size of 680*360*560mm in one piece, subject to design suitability. We can also build parts in pieces and join them, which can often offer a lower part price. Sometimes parts can be hollowed to reduce build time.

Can a thread be added to a SLS part?

Yes a tapped thread can be added directly into a SLS part but it’s very easy to add a pocket for a nut or threaded insert, etc. These are more serviceable, better life and less hassle overall.

Can I print any design?

Almost any design, some designs are better than others. For evaluation please send your CAD to ABEN Europe and we will let you know if it can be made and if any potential improvements would help the quality of the finished SLS part.

What Applications can I use SLS 3D Printing for?

It is ideal for rapid and cost-effective production of single or short run parts with complex geometries and a high-quality surface finish, yet is also ideal for run of 50, 100 or 150 parts.

SLS is great for applications such as:

• Show, Sales, Marketing and Exhibition models
• Engineering / Consumer Products
• Robotics and Assembly equipment
• Medical Devices
• Prototyping and Pre-Production testing
• Low Volume Batch Production
• An alternative to Injection Moulding, as no capital expenditure on tooling and freedom to introduce Engineering changes at no cost

Which stage of the product development is SLS used?

SLS can be used at any stage of the product development cycle, from a single concept part through to a functional prototype and is increasingly used to manufacture operational components.

Does SLS 3D Printing require support material?

No, the parts are produced while surrounded by loose powder. Therefore the loose un-melted powder acts as a supporting material. This method of 3D printing is fantastic for producing complex geometries that would otherwise be impossible with technologies that require support. SLS ENCOURAGES FREEDOM OF DESIGN FOR MANUFACTURING.

SLS parts can be stronger than SLA parts?

• Yes in general a SLS part will be stronger than a SLA part.
• Surface finish is high quality, powdery and porous until coated with sealant.
• Moving parts can be created e.g. living hinges.
• Finished part is very clean, requiring very little hand finishing. Excess powder removed by blowing or brushing

Is PA12 Nylon Food Safe?

PA12 material is certified as biocompatible and can be food safe under certain conditions. Though due to the porous nature of parts via the SLS printing method we cannot certify our materials as food safe. Please use it at your own risk.

Can I choose the Orientation of my SLS parts?

The best orientation for your part is one that reduces stepping and warping. This is chosen for you by ABEN’s expert technicians. If you require a special orientation for your part, then please send an email to ABEN Europe for review.

What is CNC?

Computer Numerical Control (CNC) is the automation of machine tools by means of computers executing pre-programmed sequences of machine control commands. This is in contrast to machines that are manually controlled by hand wheels or levers, or mechanically automated by cams alone.

In modern CNC systems, the design of a mechanical part and its manufacturing program is highly automated. The part’s mechanical dimensions are defined using computer-aided design (CAD) software and then translated into manufacturing directives by computer-aided manufacturing (CAM) software. The resulting directives are transformed (by “post processor” software) into the specific commands necessary for a particular machine to produce the component and then are loaded into the CNC machine.

Which materials are used in CNC Machining?

Almost any material can be used in a CNC machine. It really depends on the application. Common materials include metals such as aluminium, brass, copper, steel, and titanium, as well as wood, foam, fiberglass, and plastics such as polypropylene, ABS, POM, PC, Nylon, etc.

What is the difference between NC and CNC?

NC stands for Numerical Control whereas CNC stands for Computer Numerical Control. In NC Machines the programs are fed into the punch cards. But in the CNC machines, the programs are fed directly into the computer with the help of a small keyboard similar to our traditional keyboard.

What are the 5 axis on a CNC machine?

The term “5-axis” refers to the number of directions in which the cutting tool can move. On a 5-axis machining centre, the cutting tool moves across the X, Y and Z linear axes as well as rotates on the A and B axes to approach the workpiece from any direction.

What is the principle of vacuum casting?

Vacuum casting is a manufacturing process in which a liquid material is poured into a mould and allowed to solidify. Vacuum casting involves using a vacuum to remove air from the mould, which helps ensure that the object takes on the desired shape. This process is often used for casting plastics and rubber parts.

What are the advantages of vacuum casting?

Vacuum casting enables complex features to be produced, including snap fits, thin walls, living hinges, undercuts and similar features. There is also no need for draft angles, which can help to speed the prototyping process. An ideal alternative to injection moulding when the quantities are low.

What is another name for vacuum casting?

Vacuum Casting is known by different names such as Urethane casting and Polyurethane casting. This process comprises silicon moulds that help to make different components from rubber and plastic under a vacuum. This process mimics the injection molding to produce various parts of Polyurethane and cast Nylon.

Is vacuum casting cheaper than 3D printing?

3D printing is usually more cost-effective for prototypes and small-volume production. As production volume increases, the cost per part decreases, making vacuum casting the more economical choice for larger batch production, even though the mould can only be used approximately 20 times before requiring a replacement.

What is the difference between vacuum forming and vacuum casting?

Vacuum casting is typically used for prototype development and low volume production, while vacuum forming is used for mass production. Vacuum casting can be used with various materials, plastics, and composites. Vacuum forming is typically only used with plastics. Vacuum casting uses liquid plastics poured were as vacuum forming uses sheets of plastic to be formed.