The Business Case for 3D Printing Elastomers
Author: John Schober, Market Development Lead
Additive manufacturing can yield many benefits for your project, including unique designs, lower tooling costs, lead-time reduction and low-cost small-batch production (for replacement parts, for example). However, given the size of the elastomer 3D printing market compared to the overall elastomer market—$0.5 billion versus $90 billion—it's clear that many engineers working with elastomers have yet to adopt additive manufacturing.
Why? The decision to transition to 3D printing can seem complicated. It's helpful to start with high-level business considerations first before progressing to a more detailed comparison of technical factors.
Which elastomers are viable for 3D printing?
First and foremost, you must determine whether 3D printing is even commercially available for the elastomers you need. For example, 3D printing EPDM is not currently feasible on a commercial scale (although, it’s worth noting that Chromatic 3D Materials is developing EPDM for broad industrial use). The same goes for FKM, NBR, HNBR, neoprene and butyl rubber. Unlike 3D printed EPDM and the rest of the materials listed, the following elastomers are commercially available:
Thermoplastic polyurethanes
Silicone
Some TPEs
Thermoset polyurethanes
Photopolymers
You must also consider if these 3D-printed elastomers can readily meet industry standards.
3D-printed thermoset polyurethane grommets printed for automotive supplier Valeo
Prototyping, tooling or volume production?
It is also important to consider whether the printed component will be used for prototyping only, for tooling, and/or for volume production. If the printed component is only needed for prototyping, e.g. as samples solely for visualizing and handling, many different materials may be used. But the more that the printed components are expected to withstand testing and/or end-use requirements, the more the options for 3D printable elastomers are limited.
Once this is determined, it is important to answer the question of the benefit that you hope to get from 3D printing. When people think of 3D printing, the ability to realize unique designs is often highlighted. But there are also other attractive benefits including:
lower tooling costs
faster lead times
low-cost small-batch production, including in repair and replacement parts
distributed manufacturing footprint / streamlined supply chains for production environments
Of course, whether these benefits will actually be realized often requires detailed analysis of both technical and economic factors.
Technical factors to consider
| Technical Factor | Considerations |
|---|---|
| Number of different materials | Are a variety of materials required, or is more specialized equipment preferable for a single material? |
| Size of different parts | Is the print bed large enough to accommodate the range of parts that you need? |
| Mechanical properties of printed material | Can the printing process offer the required hardness, elongation, tensile strength, and compression set? < |
| Isotropic versus anisotropic | Does the printing process offer isotropic properties (properties are the same in x, y, z directions of the print)? |
| Dimensional resolution | Will you be able to achieve the requisite dimensions and tolerances? |
| Surface finish | Is the surface smooth enough, or will post processing be required? |
| Temperature and chemical resistance | Will end-use parts stand up to environmental conditions? |
| Porosity | Will porosity be detrimental to your parts' integrity? Does the printing process yield full-density parts? |
Economic factors to consider
| Economic Factor | Considerations |
|---|---|
| Equipment | What is the startup cost? Hardware costs will likely be a significant investment upfront. |
| Materials | How expensive is the raw material? Material price is a major portion of the incremental cost of each part. |
| Waste | Will any processed material be discarded? This can add significant cost to the final product, especially if raw material is expensive. |
| Print speed | How fast is the printer? Faster print speeds result in shorter processing times and therefore lower costs. |
| Support structures | Do you need to print hollow geometries? Support structures can increase cost |
| Post processing | Will machining, deburring, curing or other processes be required to get parts to their final dimensions and condition? This adds time and money. |
| Safety concerns | Will new safety protocols be required for material handling and processing? |
| Scalability | Will the process be technically feasible and economical at higher volumes? |
| Ease of use | How much training will be required for operators? |
In-House Versus Contract Manufacturing
An evaluation of whether in-house or contract 3D printing (e.g. at a service bureau or contract manufacturer) is preferable is key once you decide that 3D printing is a good fit. Contract 3D printing works best when the need for printed parts is limited or unpredictable and you need an interim or try-before-you-buy solution.
For the long term, in-house printing with your own printers is often preferable. This is usually true if there is a sustained need for printed parts or when contracted 3D printing results in lead times that are too long. Purchasing a development printer is a good way to dip your toe into in-house additive manufacturing.
There's a lot to consider when it comes to building the business case for 3D-printed elastomers. When in doubt, get in touch with a 3D printing specialist who can discuss your concerns and assist you in selecting the appropriate manufacturing method for elastomers.
Further reading
This article is the third in a series about elastomers and additive manufacturing. If you want to learn more about 3D printing with elastomers, read the previous articles, “An Introduction to Elastomers: A Type of Flexible & Durable Materials“ (Article 1) and “Elastomer Additive Manufacturing: Processes & Materials” (Article 2).