3D Printing Processes

Our on-demand 3D printing service allows you to create custom parts with ease. Utilizing six advanced 3D printing technologies, we transform your designs into plastic, metal, and elastomeric components. With a fleet of over 120 printers, we ensure rapid production and reliable delivery within days. Beyond a wide range of materials, we also provide various post-processing options to enhance aesthetics and improve mechanical performance.

Metal 3D Printing

Direct Metal Laser Sintering (DMLS) utilizes a fiber laser to selectively fuse atomized metal powder, layer by layer, creating fully dense metal components with high precision.

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Stereolithography (SLA)

Stereolithography (SLA) employs an ultraviolet laser to trace and solidify liquid thermoset resin layer by layer, gradually building up the final part with exceptional detail and accuracy.

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Selective Laser Sintering (SLS)

Selective laser sintering (SLS) utilizes a CO2 laser to selectively fuse nylon-based powder, building durable thermoplastic parts layer by layer.

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Multi Jet Fusion (MJF)

Multi Jet Fusion (MJF) precisely deposits fusing and detailing agents onto a nylon powder bed, where heating elements solidify thousands of layers into a fully functional part.

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PolyJet

PolyJet utilizes a jetting process that deposits tiny droplets of liquid photopolymer onto a build platform, where they are layer-cured to create detailed elastomeric parts.

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Carbon DLS

Carbon DLS utilizes digital light projection, oxygen-permeable optics, and programmable liquid resins to create plastic parts with superior mechanical properties and a high-quality surface finish.

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FDM 3D Printing Available via the AIXI Network

FDM (Fused Deposition Modeling) 3D printing creates parts by melting and extruding thermoplastics layer by layer. It is ideal for producing durable prototypes and functional components. Available materials include ABS, TPU, PEI, PETG, and more. Get an instant quote and receive FDM parts in just a few days.

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Compare 3D Printing Processes

New to our 3D printing service and unsure which additive manufacturing technology suits your design? Explore the comparison below to find the best process for your application’s needs.

  Materials Max Part Size Min Feature Size Tolerances
Metal 3D Printing Aluminum
Stainless Steel (17-4, 316L)
Titanium
Inconel
Cobalt Chrome		 9.6 in. x 9.6 in. x 13.0 in
X Line: 31.5 in. x 15.7 in. x 19.7 in.		 0.006 in. ±0.003 in
Stereolithography ABS
Polycarbonate
Polypropylene
Silicone		 29 in. x 25 in. x 21 in. 0.0025 in. ±0.002 in.
Selective Laser Sintering Nylons
Polypropylene
TPU		 19 in. x 19 in. x 17 in. 0.030 in. ±0.010 in.
Multi Jet Fusion Nylons 11.1 in. x 14.9 in. x 14.9 in. 0.020 in. ±0.012 in.
PolyJet Elastomer (30A to 95A) 19.3 in. x 15.4 in. x 7.9 in. 0.012 in. ±0.005 in.
Carbon DLS ABS
Polypropylene		 7.4 in. x 4.6 in. x 12.8 in. 0.020 in. ±0.010 in.
  Materials Max Part Size Min Feature Size Tolerances
Metal 3D Printing Aluminum
Stainless Steel (17-4, 316L)
Titanium
Inconel
Cobalt Chrome		 245mm x 245mm x 330mm
X Line: 400mm x 800mm x 500mm		 0.1524mm ±0.076mm
Stereolithography ABS
Polycarbonate
Polypropylene
Silicone		 736mm x 635mm x 533mm 0.0634mm ±0.0508mm
Selective Laser Sintering Nylons
Polypropylene
TPU		 482mm x 482mm x 431mm 0.762mm ± 0.254mm
Multi Jet Fusion Nylons 281mm x 378mm x 378mm 0.508mm ±0.305mm
PolyJet Elastomer (30A to 95A) 490mm x 391mm x 200mm 0.305mm ±0.127mm
Carbon DLS ABS
Polypropylene		 89mm x 118mm x 326mm 0.508mm ±0.254mm

3D Printing Materials

Plastic 3D Printing Materials

ABS

ABS is a versatile material known for its smooth finish, impact resistance, and durability. We provide a range of ABS-like plastics, including:

  • Accura Xtreme White 200
  • Accura Xtreme Gray
  • Accura 7820
  • WaterShed XC 11122
  • MicroFine
  • Carbon RPU 70
Learn more about ABS 3D printing.

Nylon

We provide various grades of nylons through our Selective Laser Sintering (SLS) and Multi Jet Fusion (MJF) 3D printing technologies. These powdered thermoplastics create strong parts with mechanical properties ideal for functional prototypes and end-use applications.

  • PA 12 White
  • PA 11 Black
  • PA 12 Black
  • PA 12 Mineral-Filled
  • PA 12 40% Glass-Filled
  • PA 12 40% Glass-Filled Black
Learn more about nylon 3D printing.

Polycarbonate (PC)

Polycarbonate is a versatile material that provides rigid parts with exceptional heat deflection. We offer several polycarbonate-like materials through our stereolithography (SLA) process:

  • Accura 60
  • Accura 5530
  • PerFORM (Ceramic-like Advanced High Temp)
Learn more about polycarbonate 3D printing.

Polypropylene (PP)

3D-printed polypropylene is a lightweight material known for its flexibility, durability, and resistance to chemicals.

  • Polypropylene Natural
  • Somos 9120 (PP-like Translucent White)
  • Carbon FPU 50
Learn more about polypropylene 3D printing.

Silicone

3D-printed silicone is available in various Shore-A hardnesses, offers biocompatibility, and performs well across a wide temperature range.

Learn more about silicone 3D printing.

TPU

3D-printed TPU provides rubber-like flexibility and stretchability, along with excellent abrasion and impact resistance.

Learn more about TPU 3D printing.

Digital Photopolymer

3D printing with digital photopolymer is available in various Shore A hardnesses and comes in three colors: clear/translucent, white, and black.

Learn more about digital photopolymer 3D printing.

Metal 3D Printing Materials

Aluminum

3D-printed aluminum provides excellent resistance to high temperatures and corrosion, along with a superior strength-to-weight ratio.

Learn more about aluminum 3D printing.

Cobalt Chrome

3D-printed cobalt chrome delivers a strong strength-to-weight ratio and exceptional resistance to creep and corrosion.

Learn more about cobalt chrome 3D printing.

Inconel 718 is a high-strength, corrosion-resistant nickel-chromium superalloy available in three different resolutions and can undergo various post-processing treatments.

Learn more about Inconel 3D printing.

Stainless Steel

3D-printed stainless steel is a corrosion-resistant material known for its high hardness and strength. We provide two grades of stainless steel for 3D printing:

  • Stainless Steel 17-4 PH
  • Stainless Steel 316L
Learn more about stainless steel 3D printing.

Titanium

Titanium, often referred to as a “workhorse” alloy, is a lightweight metal that combines high strength with outstanding corrosion resistance. All finished titanium parts undergo a vacuum stress relief process.

Learn more about titanium 3D printing.

Sample Quote

Check out our material feature that allows you to compare the pricing of different 3D printing processes, materials, and resolutions.

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“Excellent service at a reasonable price, and the quality of my parts is outstanding. Keep up the great work!”

3D Printing Toolkit

Receive expert design guidance to enhance your 3D-printed parts. Designing with additive manufacturing in mind can speed up production and lower overall costs.

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Surface Finish Options for 3D Prints

Unfinished Dots, or standing “nibs,” remain evident on the bottom of the part from the support structure remnants.
Natural Supported surfaces are sanded down to eliminate the support nibs.
Standard Supported surfaces are sanded, and the entire part is finely blasted for a consistent look. Note that the layers are still present.
Custom Soft-touch paint, clear part finishing, painting, masking, color matching, decals/graphic, and texture finishes are available.

Custom Finishing

Want to enhance the strength, clarity, or look of your 3D-printed parts? Select from options like microfluidic and high-resolution materials, metal plating, additional machining, and custom finishes such as painting, clear coating, and decals.

Clear Coat Clear cosmetic finish that can be applied to ABS-Like Translucent/Clear (WaterShed XC 11122) and PC-Like Translucent/Clear (Accura 60) materials.
Painting After smoothing the part with sanding and polishing, parts can be painted with automotive-grade paint. Provide a pantone color with your quote request. We also offer soft-touch painting.
Plating Electroless nickel plating can be used to achieve parts that are similar to cast aluminum or magnesium.
Dyeing Dyeing is another method for adding color to 3D prints. This is a faster option with a limited color selection, so it is a more cost-effective choice than painting.
Decaling Decaling can be used to add a logo or other graphics to boost cosmetics or function.
Polishing We can polish parts to a mirror-like finish. If this is a requirement, we ask that you provide either a drawing or image that indicates your finish expectations.
Heat Treatment Harden and strengthen metal 3D prints with multiple heat treatment options: NADCAP heat treatment, hot isostatic pressing (HIP), solution annealing, and aging.
Machining Machine metal 3D prints to achieve exceptional surface finish quality or meet tight tolerances.

Why Choose Us for Custom 3D Printing?

Exceptional Quality

Benefit from expert design feedback provided by our engineering team, who have assisted thousands of customers in bringing high-quality 3D-printed products to market. We collaborate with you to determine the best part orientation based on your specific application needs.

Extensive Material Choices

We offer a diverse range of materials, including commercial-grade thermoset resins, thermoplastics, and metal powders, across six 3D printing technologies. Our materials are suitable for a variety of applications and industries. Additionally, we provide post-processing options like heat treating, secondary machining, plating, painting, and dyeing to further improve the mechanical performance and appearance of your parts.

Production Capacity and Flexibility

With over 120 3D printing machines in our facility, we are equipped to handle both small batch orders and large production runs. No matter your timeline, we ensure you have the capacity to get your parts quickly.

What is 3D Printing?

3D printing refers to a group of additive manufacturing techniques that create parts layer by layer from a 3D digital design. Some 3D printers work by extruding filament to form parts, while others use lasers to melt or solidify raw materials such as metal or plastic powders, or liquid resins. There are various 3D printing technologies available, each offering different materials, surface finishes, costs, and production capabilities.

Advantages of 3D Printing

Creating parts layer by layer offers numerous advantages, enabling design possibilities that traditional methods such as injection molding, machining, or casting couldn’t achieve.

  • Ability to create intricate, organic shapes with minimal impact on cost
  • Combine multiple components into a single part, simplifying assembly
  • No need for expensive tooling or molds
  • Rapid production, with parts delivered in as little as 24 hours
  • Design internal features for enhanced heat transfer and fluid flow applications

Common 3D Printing Applications

Additive manufacturing is widely used for both rapid prototyping and production across industries such as aerospace, medical, automotive, and more. Common examples of parts include:

  • Prototype models for form and fit testing
  • Enclosures and protective housings
  • Medical devices and instruments
  • Snap-fit components
  • Jigs and assembly fixtures
  • Heat exchangers and sinks
  • Engine parts and components
  • Fuel injection systems
  • Surgical tools and equipment

Get an Instant 3D Printing Quote

Upload your 3D CAD file to receive an instant quote for your 3D printing design. Our quoting platform provides real-time cost estimates based on your selected material and resolution options.

If you have any questions about your quote or design, our applications engineering team is available to assist you and guide you through the entire process.

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3D Printing FAQs

The cost of 3D printing per part is influenced by various factors, such as design, material, process, and post-print operations. Post-print operations, particularly those requiring manual labor, usually make up the majority of the cost. For cost-effective end-use parts, laser powder bed sintering processes like SLS and MJF tend to be the most economical options. Visit this blog post to gain a deeper understanding of the factors that affect 3D printing costs.

When choosing a 3D printing technology, start by identifying the key design requirements such as strength, temperature resistance, water resistance, appearance, or durability. These factors will typically help you decide whether you need metal or plastic 3D printing for your project. For more guidance on selecting the right technology based on your design needs, refer to this 3D printing material selection guide.

Although all file types are eventually converted to STL (.stl) for 3D printing, it is recommended to upload files in STEP (.stp/.step), SOLIDWORKS (.sldprt), or IGES (.igs/.iges) formats. For more details on how to design files for 3D printing in .stl format, check out further guidance on .stl files.

The size of the part you can 3D print is determined by the build volume of the 3D printer being used. Thanks to advancements in large-format printing, metal parts can be printed with a maximum size of 31.5 in. x 15.7 in. x 19.7 in., while plastic parts can reach up to 29 in. x 25 in. x 21 in.

One of the key benefits of 3D printing is its speed, or the quick turnaround from design to finished part. Other advantages include design flexibility, cost efficiency, and the ability to produce high-quality parts without the need for tooling investment.

Historically, 3D printing has been used primarily for rapid prototyping. However, with improvements in post-processing techniques and the development of engineering-grade materials, it is now frequently used for producing end-use parts.