You can 3D print that, but should you?
Nowadays, there are many different types of manufacturing processes. Some of these include casting, forming (forging and sheet metal deforming), machining (CNC), joining (welding and soldering), mechanical fastening (bolting and riveting), and additive manufacturing (3D printing).
Many factors must be considered when choosing a method of manufacturing. These considerations are cost, speed, material, and applicability to the part being created - to name a few.
It's all about choosing the right tool for the job. You know what I mean if you've tried to use a hammer to put in a screw. It doesn't work as you would think. It doesn't work at all. For example, 3D printed plastics are fantastic, but you wouldn't use them to create a new type of frying pan. Technically, you could print a frying pan, but it obviously would not work as intended.
3D Printing Benefits
3D printing is an excellent method for producing prototypes, replacement parts, low production count parts, and parts with unique geometry. Geometries impossible with other manufacturing methods are often possible with additive manufacturing. These include hollow cavities within solid components, parts within parts, and print-in-place mechanisms.
3D printing can be run as "Print on demand, " reducing inventory storage and less need for bulk production (except when resin printing, which saves time when printing multiple copies). You might have an item you sell very few of or may only need occasionally. There's no need to have the parts manufactured and stored when you can print them when needed.
Additive manufacturing can produce strong and lightweight parts. In traditional manufacturing, aluminum is often used for parts and requires a lot of weight and bulk for strength or simply to make the manufacturing process more economical. 3D printing can sometimes make that same part with a hollow interior, producing a part strong enough for the job but weighing much less.
These are just a few of the benefits of 3D printing. However, there are instances when 3D printing is not the best method of producing parts.
3D Printing Construction Limitations
Although there are many different types of additive manufacturing, this article focuses on the most common method of 3D printing: Fused Deposition Modeling (FDM). FDM uses thermoplastic polymers that are deposited in layers along a predetermined path.
The first limitation of FDM is material. Obviously, this is limited to thermoplastics (filaments) that can be melted at reasonable temperatures and cooled at the correct rate to produce a bead of material without it being too runny or too thick. Common materials include PLA, ABS, PETG, ASA, TPU, and Nylon (PA). Each has specific properties for strength, temperature resistance, impact strength, chemical resistance, flexibility, etc.
FDM places the thermoplastic material in layers, so each layer has a natural texture. Matte material can minimize this appearance. When the layers are printed thin enough, they are barely visible but still there. Sometimes this provides a nice texture that often adds to the aesthetic of the part.
The semi-matte finish of the carbon fiber nylon helps minimize the layer lines, however, they are still visible.
Color options are also limited for the filament. However, there are many colors available. If you need to match your part to a specific color, you're out of luck unless you have a filament manufacturer make one specifically for you.
3D printers have a specific build volume or size they can print. Many of the popular printers have a 300x300x300mm build volume. More significant parts require a larger print surface and substantially increase the machine's cost.
Part tolerances also vary from machine to machine. More expensive printers have better printing tolerances, but these are not as consistent as injection molds simply because of their moving parts.
Print size, tolerances, and material choices may limit your product capability.
FDM printing also has limitations for part geometry. These drawbacks include difficulty with large overhangs, small features, and requirements for smooth surfaces. Large overhangs require printed support structures, which can be problematic in certain circumstances.
Material limitations for thermoplastics also have to be considered. Obviously, heat is one of the big problems for high-temperature applications as that would melt or weaken the material. Strength can be an issue for small parts or features. Food safety is another consideration because of material toxicity and the fact that FDM can produce small pockets that can harbor bacteria.
3D Printing Manufacturing Limitations
As great as 3D printing is, it still has manufacturing limitations. Cost is one of those limitations. Injection molding is popular for mass-producing parts due to its price per part when producing many parts. However, it has a higher setup cost.
3D printing can cost more per part to produce but can often save money on the development/prototype side of things. You can probably save money by buying the injection molded part if a part is commonly available.
Additive manufacturing is getting quicker as the technology advances, but it is much slower than the speed of injection molding parts. 3D printing is probably not the solution if you aim for high production numbers.
Quality and consistency are often higher for injection molded parts. 3D printing is sometimes fussy when it comes to consistency in produced parts. Quality control has to be monitored, and you will have a higher failure rate in some circumstances.
3D printing can often require post-processing parts. Post-processing means removing supports, trimming rough edges, smoothing surfaces, or other processes to finish the piece.
Conclusion
It all comes down to using the right tool for the job. There are advantages and disadvantages to every type of manufacturing. 3D printing can be outstanding for unique one-off parts, prototyping, and low-volume production. However, consider whether the production method will produce a suitable product.