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Ultimaker white paper Getting started with office 3D printing

Ultimaker white paper - Home | Quantum Science Co€¦ · Getting started with office 3D printing - 3 Introduction. 1. Introduction. This white paper is designed to support businesses

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Page 1: Ultimaker white paper - Home | Quantum Science Co€¦ · Getting started with office 3D printing - 3 Introduction. 1. Introduction. This white paper is designed to support businesses

Ultimaker white paper

Getting started with office 3D printing

Page 2: Ultimaker white paper - Home | Quantum Science Co€¦ · Getting started with office 3D printing - 3 Introduction. 1. Introduction. This white paper is designed to support businesses

Table of contents

1. Introduction 32. Workflow and integration 63. Setup and staffing 134. Operating 3D printers in the office 155. Conclusion 19

Getting started with office 3D printing

Page 3: Ultimaker white paper - Home | Quantum Science Co€¦ · Getting started with office 3D printing - 3 Introduction. 1. Introduction. This white paper is designed to support businesses

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1. Introduction

This white paper is designed to support businesses that are considering the potential of 3D

printing as an in-house tool.

The aim is to highlight how and why 3D printing can be more widely adopted in-house to

enable improved product development cycles and reduced cost through more agile design

and prototyping operations. This is not necessarily as intimidating, or as cost-intensive, as

might be imagined and this white paper will illustrate how to leverage these opportunities

and provide insight into how this can realistically be achieved.

The key opportunities that bringing a desktop 3D printer in-house offers include:

¥ Faster prototyping cycles

¥ Less interruption to the design process, not broken by long part lead times

outsourced to a third party

¥ The ability to carry out and evaluate more design iterations leading to a higher

quality final product

¥ Fast ROI and cost savings for the business compared with outsourcing

3D printing technologyThe manufacturing sector is currently experiencing significant disruption as advanced

technologies, including 3D printing, become more deeply embedded across a variety of

industries. Disruption, by its very nature, can be unsettling and uncomfortable for individual

organizations, but being hesitant when embracing disruptive new technology can limit

long term success. As ‘Industry 4.0’ takes hold across the world and digitalization becomes

prevalent, an agile approach to product development and manufacturing is fundamental –

and one key enabler of agility is bringing 3D printing in-house.

3D printing technology has existed for more than three decades, with a notable surge in

awareness, accessibility, and adoption in the early 2010s when 3D printing was widely

featured in the media.

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Today 3D printing has evolved into an industry in its own right – a sub-sector of the $12

trillion global manufacturing industry. The 3D printing industry has also experienced a great

deal of diversification. There are many different 3D printing process classifications, each with

advantages and disadvantages depending on their application.

The fused filament fabrication (FFF) process is the most widely adopted 3D printing process

in the world today. The process involves plastic material (typically in filament form) being

fed through a heated nozzle or extruder, which can then be deposited in thin layers to form

a part. Single or multiple extruders can be used, and these are controlled horizontally, to

deposit layers on the build platform, which has automated vertical controls, and moves after

each layer is completed.

Advantages of the FFF process are many and varied, including the easy availability

of commonly used plastic materials, such as ABS which exhibits good structural

properties, and PLA which is very easy to print in any conditions. These materials are

inexpensive and ideal for producing prototypes for testing multiple iterations of a product

without breaking the bank.

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Taking control in-houseBringing the FFF 3D printing process in-house with a desktop 3D printer has proved itself

an effective way of optimizing the product development workflow in terms of lead times,

improved product quality, and those all-important costs.

Many companies have already made the transition across a broad spectrum of industrial

sectors, including the aerospace, automotive, industrial design, engineering, architecture,

medical, and product design fields. Desktop FFF 3D printers make rapid prototyping

truly rapid, with faster turnaround times, increased numbers of product iterations to

check and test form and function, and reduced overall delivery lead times. Today’s highly

capable desktop FFF platforms can also add value for applications beyond prototyping,

such as molds, tooling and one-off and low volume end use parts, such as custom-

ized jigs and fixtures.

These benefits are universally recognized today, however, for many companies the transition

to bring 3D printing in-house with the necessary workflow integration is daunting. This white

paper aims to overcome the issues that contribute to this.

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1.Gatherrequirements

2.InitialDesign

3.Productprototype

4.Testprototype

5.Finalproductionrun

Yes

Does it meetyour needs?

No

A typical product development process

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2. Workflow and integration

There is no doubt that, perceived or real, barriers to adoption exist for many companies

when it comes to bringing 3D printing in-house. The first one that must be broken down and

overcome is not a practical one, but rather the cultural attitudes and misconceptions within

an organization that may exist around 3D printing.

This can be caused by fear of change and disruption, but standing still is no longer an

option, and remaining competitive in a digital world is essential. There are a variety of

considerations that might make a transition of this nature seem daunting – the design

software, compatibility issues, materials, the machines themselves, as well as practicalities

such as space allocation, staff training, and safety. However, when companies take

the time to break these down and address them individually, often the ‘problems’ can

become opportunities.

Integrating 3D printing into an existing work environment will require internal communi-

cation and collaboration. Management needs to figuratively buy in to the benefits it will

bring, as well as literally buy in the hardware and supporting tools and training required.

Preparation and understanding are the key here. It is highly unlikely that any organization

involved in product development today is completely unfamiliar with the concept of 3D

printing – but doing it in-house may be resisted by some. It is a transition that is much easier

to make today, and should not be feared.

Page 7: Ultimaker white paper - Home | Quantum Science Co€¦ · Getting started with office 3D printing - 3 Introduction. 1. Introduction. This white paper is designed to support businesses

Cost per part

$3

$41

$115

In-houseFFF

OutsourcedFFF

OutsourcedSLS

Project lead time

In-houseFFF

OutsourcedFFF

9 hours

6 days

7 days

OutsourcedSLS

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Time and money will need to be invested to bring 3D printing in-house, but the rewards can

be huge – in real numbers that affect a company’s bottom line positively. This chapter aims to

demonstrate how this is possible by overcoming the perceived barriers, and highlighting the

positive effect in-house 3D printing can have on a typical product development workflow.

In-house 3D printing does not necessarily change any part of this workflow (although it

can, in certain cases, negate the need for tooling). Instead it makes it more efficient, can

significantly reduce the costs and time involved, and ultimately results in higher quality

products by enabling more design iterations.

In-house or outsource?Any business that develops physical products will require prototypes at certain points in

the design cycle. Doing this requires in-house facilities or outsourcing all prototypes to

suppliers. Outsourcing prototyping needs (whether using additive processes or conventional

techniques) adds significant costs and lead times to product development cycles and can

constrain the entire workflow. This is where the transition to in-house desktop FFF 3D

printing can deliver real value.

Typical examples based on averages for a 60 cm3 prototype. In-house costs exclude labor, hardware, and other

overheads, which vary depending on circumstances.

The cost reduction per part is easily demonstrable, plus the time savings that can be

achieved through faster iterations bring comprehensive benefits to organizations that have

brought 3D printing in-house. It is this combination of time and cost savings that can bring

competitive advantages by streamlining in-house processes in a way that results in better

products, which reach their intended market faster.

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At the concept development stage of any new product, any competent designer understands

the value of holding a physical representation of their design in their hands. For consumer

products, interacting with that product physically is essential and getting market feedback

even more so. Similarly, with industrial products and components, the need to assess

form, fit and function is also vital. Early prototypes help designers to quickly and more

easily identify issues with a design, and correct them. The more iterations of a prototype

go through physical interaction, with more feedback, the more successful the design – and,

notably, the design for manufacture.

Any company that outsources the production of prototypes is at the mercy of the terms and

conditions of its service provider in terms of lead times, availability, delivery, and shipping.

Today, most 3D printing service providers offer a number of options and it is possible to pay

a premium for faster delivery. However, clients are usually looking at an absolute minimum

of one day, which can get very expensive, with the average being three to seven days for a

more economical option and for more complex parts this can extend to weeks.

Costs aside, in terms of time there is only a finite number of iterations possible when

outsourcing, particularly if companies are working to a deadline within a supply chain.

For every part, you also need to go through the hassle of finding a supplier, sharing design

files, and then invoice.

This is where an in-house 3D printer comes into its own – by providing a much more flexible

approach and enabling a more iterative design process.

A desktop FFF printer in the same office or even building allows for the production of

multiple iterations of a new product early on in the development process because the lead

time for the first prototype can literally be reduced from a week down to hours – the same

day as the design is finalized. In real terms this means that a designer or engineering team

can develop a more seamless process, where design timelines are in their control, not

dictated by a third-party supplier.

During a typical design process, it is not as if everything comes to a standstill while waiting

for the part fulfilment. Development will continue and features are often changed, which

is problematic in that it can make the prototype redundant even before the designers and

engineers have it back in their hands. In-house FFF 3D printing avoids this, making it possible

to quickly and easily 3D print cheaper prototypes in just a few hours. So decisions can be

made more quickly and based on more accurate prototypes and data.

Page 9: Ultimaker white paper - Home | Quantum Science Co€¦ · Getting started with office 3D printing - 3 Introduction. 1. Introduction. This white paper is designed to support businesses

Prioritize iterations ‘Best of both’ Prioritize speed

Tim

e sa

vin

g

Define requirements

Concept prototyping

Functional prototyping

Production

Define requirements

Concept prototyping

Functional prototyping

Production

Define requirements

Concept prototyping

Functional prototyping

Production

Tim

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Tim

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With lead times for a part reduced from days to hours, a designer has more options:

1. Reduce overall product development lead times to get a product to market faster, with

more feedback, ahead of competitors, and achieve greater market share

2. The ability to undertake many more iterations within an equal product development cycle

time to achieve a better, more thoroughly tested, higher-quality final product

3. Or, a ‘best of both worlds’ scenario, that achieves a simultaneous decrease in develop-

ment time and an increase in the number of design iterations

FFF 3D printing is a fast and, with the right 3D printer, user-friendly process that can produce

reliable and valuable early prototypes. However, the process does have its limitations and

therefore does not negate alternative processes depending on the demands of the project.

In reality, it may still make sense to outsource if alternative 3D printing processes are

more suitable for a specific application. This could be because you need a large production

run, you need a part with strength not possible using FFF, or you require an especially

smooth surface finish.

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Design and softwareProduct design, whether for an industrial or consumer market, is a discipline that demands a

varied skill set. Designing in 3D modeling software is now widespread and a prerequisite for

making the most of 3D printing. There are countless 3D modeling software options available

to designers, including the most popular professional suites such as SolidWorks, Siemens

NX, Inventor, Fusion 360, and AutoCAD, as well as freely available, tool-rich options such as

Blender and SketchUp.

Much like 3D printing processes, each software suite has its own advantages and

disadvantages, so it is not uncommon for designers to use multiple design software options,

particularly as interoperability has become less of an issue. Today, most 3D modeling

software is compatible with industry standard 3D printing file types, such as STL, 3MF, and

OBJ files, which in turn are compatible with 3D printer software, such as Ultimaker Cura.

Ultimaker have even developed plugins for specific 3D modeling suites (such as SolidWorks

and Siemens NX) that enable direct 3D printing from CAD software, as well as direct integra-

tion built in to Autodesk Fusion 360 and HP’s 3D scanning software. This hugely simplifies the

software integration process and workflow.

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Preparing a digital model for 3D printing does demand a new way of thinking about design

compared with traditional design practices – such as making sure your design files are a

suitable resolution – but it is not difficult to integrate into existing software workflows,

and training and external support is readily available. For example, you can find manuals

and video tutorials for Ultimaker Cura on the Ultimaker website.

MaterialsWhen adopting FFF 3D printing into an in-house workflow, the material options can be a

barrier to adoption due to the perception that choice is limited.

But this is far from the case, particularly when prototyping is the dominant application,

because today there are a wide range of cost-effective filament options for 3D printing that

can replicate the properties of the final parts. Indeed, today’s 3D printing filament materials

are so advanced that they are being utilized for tooling and final production applications.

The diverse range of materials available, including all of the most common types of

thermoplastics, and some advanced composite materials, should never be a barrier to

adoption for prototyping.

For general concept prototyping applications, the most common material is PLA, which has

proved to be ideal for producing fast and reliable prototypes safely. This material is ideal for

quick, basic form and fit testing. With a dual-extrusion 3D printer, such as the Ultimaker 3

or Ultimaker S5, it can be used with PVA water-soluble support material to produce

geometrically complex parts easily and with minimal post processing.

However, for more highly functional mechanical prototyping there are industrial grade

material options, including ABS, nylon, polycarbonate, copolyester, polypropylene, and

polyurethane. This provides a wide scope when prototyping applications which demand

specific material properties such as chemical resistance, durability, dimensional stability,

impact resistance, flexibility, or heat resistance.

A print before and after PVA support material is removed

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For every designer, materials are fundamental to the design and its performance. Working

with these materials directly, using in-house 3D printing, does not have to be a complicated

transition as today there are a range of tools available to help, including Ultimaker Cura

preconfigured 3D printing profiles that have been developed and tested by experts to ensure

the best results with a specific material.

Some properties of your model can even be tuned when using 3D printing software like

Ultimaker Cura, for example choosing less infill in your model for greater flexibility,

or increasing it for a more robust part. A dual-extrusion 3D printer also gives the option of

material combinations for even more possible properties.

Despite giving choice and quality close to industrial-standard manufacturing, desktop 3D

printing doesn’t have to be complex. A good way to ensure you have a smooth introduction

to 3D printing is to make sure your printer has an open filament system – which means you

can use any supplier’s material filaments.

This not only prevents you from becoming locked in to a closed system, but also enables

a greater choice of materials to suit your needs. Instead of being limited to what your

3D printer manufacturer offers, you can use filaments from specialist material suppliers,

including composite materials, with a huge variety of mechanical and aesthetic properties.

Another way to ensure great results with minimal effort is by taking advantage of

any preconfigured printing profiles in 3D printing software. In Ultimaker Cura, all of

the 3D printing parameters for a specific material are preconfigured to the Ultimaker

material profile. This simplifies the process greatly, eliminating the need to directly input

parameters, speeds up the process dramatically and provides the best print results. But

Ultimaker 3D printers also have an open filament system, so they can be used with other

manufacturers’ materials.

Chapter summary ¥ Analyze which outsourced orders you can replace with in-house 3D printing

¥ Choose compatible CAD software and train staff to design for FFF 3D printing

¥ Decide which materials you will use and understand their mechanical and

printing properties

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3. Setup and staffing

In this section, we’ll look at some of the organizational considerations to think about when

making the transition to in-house FFF 3D printing. Important issues include personnel

requirements, in terms of both training of existing staff and further recruitment to bring in

specific skills, as well as establishing buy-in across the organization. Another subject to fully

understand – and disseminate companywide – is the ecosystem around your 3D printer,

which comprises software, hardware, materials, and benefits. A 3D printer is not much use

on its own! All parts of the process should fit together efficiently to maximize its potential.

The logistics of a new in-house 3D printing setup is also important and will be covered here.

Personnel and resourcesDesigners and engineers will be familiar with designing for manufacturability (DfM); for

conventional manufacturing this has traditionally involved rules for assembly, most notably

for complex products or parts. 3D printing enables a different approach – one that frees

designers from many traditional design constraints. However, this different approach

demands a learning curve when it comes to designing for additive manufacturing (DfAM).

Training existing in-house designers and engineers on FFF 3D printing technology can be

achieved via a wide range of options available from vendors, resellers and independent third

parties. Training in this area will build on their existing skill set and if proposed in the right

way should prove to be an exciting and new opportunity.

One approach that some companies follow when setting up an in-house 3D printing initiative

is to establish a ‘taskforce’, which brings together a team of 3D printing talent (through

training or by finding staff with existing skills) that can then advocate and disseminate the

advantages of the technology throughout various other teams in the organization.

LogisticsWhen bringing 3D printing in-house, it is important to consider the physical work

environment and how you will operate the printers. Some systems are more office friendly

than others. Desktop 3D printers, by their very nature are generally considered clean

and safe for an office environment, and are quiet enough to work alongside designers.

However, if one 3D printer is serving multiple designers or teams, or multiple 3D printers are

considered necessary to service the entire operation effectively, the better option might be

to establish a central area for 3D printing which gives easy access to different departments.

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Alternatively, it could be better to install the 3D printer or printers near to other key

equipment in the workspace.

While noise is generally not a big issue for single 3D printer installations, if multiple 3D

printers are installed, it can be preferable that they are together in a separate area to reduce

the effect of the overall noise.

Other practical considerations include ventilation – but this is really only an issue for

specific materials (such as ABS) where the fumes produced, while not dangerous, can be

unpleasant without suitable mitigating measures. Ultimaker provides guidance in each

material safety data sheet.

There is no right or wrong answer when it comes to placement of 3D printers in the office.

Finding the best location within the space you have and making it work for all employees

comes down to prioritizing who will be using it the most and the space available.

Chapter summary ¥ Ask your seller about training when buying 3D printers

¥ Consider setting up a taskforce team to pioneer 3D printing

¥ Analyze available office space and where you will place 3D printers

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4. Operating 3D printers in the office

So far, this white paper has considered all of the issues around the decision-making process

and installation. But what can you expect once the 3D printers are up and running? If you

have made the right personnel and training decisions, these practical operational issues

should fall into place, but will need attention. For example, managing the use of the printers,

planned maintenance, and support with any issues that may arise with 3D printers.

Networking and security

Single 3D printer for multiple users.

It is not uncommon for a company

embracing FFF 3D printing in-house for the

first time to test the water with a single 3D

printer, which will be utilized by multiple

users across the organization. It is a sensible

approach that initially minimizes capital

expense while allowing the company to

analyze how the technology is received and

used, and monitor cost and time savings.

However, it is also not uncommon for a

single 3D printer in an environment like this

to quickly exceed expectations and be in

demand. This then poses the problem of who

gets priority on print jobs. Of course, at this

point it might be time to consider investing

in a multiple 3D printer set-up.

Multiple 3D printers for multiple users.

A cost analysis report for desktop FFF 3D

printing might demonstrate that multiple 3D

printers would benefit a multi-disciplined

organization. This can take the form of one

unit on each designer’s desk, or, to support

simpler logistics, centrally locating the units

in a dedicated space.

Whichever setup an organization opts for,

users must establish their preferred work-

able system with the 3D printers – either via

USB, SD Cards, or a network – to coordinate

print job management.

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There are multiple approaches that can be taken in this regard and the decision on the best

approach for an individual organization will lie directly with the company. The primary choice

is essentially between connectivity and security priorities. For multiple users of a single

3D printer or multiple users of multiple 3D printers it is fairly straightforward to set up a

connected network using readily available tools. One such tool is Ultimaker’s Cura Connect,

which allows multiple users to send print jobs to one or more printers via Wi-Fi. This

connectivity has significant workflow advantage in terms of accessibility and coordination

between project stakeholders.

The core feature of Cura Connect is the ability to group multiple printers together. This

enables a continuous production workflow, as jobs are automatically scheduled and

delegated to printers without the need to keep going to the printer to start each print job.

In terms of the security of such networks, Cura Connect can be made as secure as the

network it runs on, so if it is a closed network with password protection it should meet

company security standards. However, for organizations that have particularly strict security

policies and prohibit internal and external networks around IP issues, alternative measures

can be used, such as USB sticks or SD cards.

Practical operationsLike any other type of hardware, 3D printers need to be routinely maintained and cleaned

to ensure optimum performance and long lifespan. While none of the components should

be overlooked, perhaps the most vital component for FFF 3D printers in this respect is

the extruder. The extruder nozzle (or nozzles on dual models) is critical to the smooth

operation and output of the 3D printer. If not regularly monitored and cleaned, this is

the component that can cause the most issues if it becomes blocked or is operating too

close to the print bed.

Another really important component that can affect output is the build plate itself – regular

cleaning of the plate is essential for the highest quality prints, otherwise you will not be

printing onto a flat surface. Periodic calibration of the build plate will ensure consistently

accurate and reliable prints. For extra ease of use, choose a 3D printer with automatic or

‘active’ bed leveling which scans the build plate and compensates for any natural, tiny

variations in the build plate surface.

Any staff training on the use of the 3D printers should always include these day-to-day

practical issues, however, key maintenance instructions can be posted near any or all

of the 3D printers themselves as a daily reminder. As with any machinery, taking care of

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maintenance and routine cleaning will reduce issues and downtime. Most 3D printer vendors

today will also supply a dedicated resource base aimed at maintenance and troubleshooting.

Check that the manufacturer or vendor offers lifetime, fast-response support, as well as a

warranty and spare parts.

Additional toolsTo get the best from any desktop FFF 3D printer, there are a number of tools that will help

ensure smooth operations and minimize post-processing of parts. The following is an

advisory list that will serve an in-house 3D printing set up well:

Spatula or palette knife

On occasion, you might find

that your 3D print has stuck

a bit too well to your build plate, or wish to

remove a part quickly before the plate has

cooled. When this happens, a spatula or

palette knife normally solves the problem

by gently easing under the print and

carefully lifting it up.

Screwdrivers and

hex key screwdrivers

These are useful for period-

ically re-tightening the gantry screws and

the stepper motors of your 3D printer. Hex

nuts and bolts are widely used in 3D printer

assembly, so it is also a wise idea to have a

set of hex key screwdrivers and wrenches.

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Adhesion sheets

Adhesion sheets are

compatible with most

materials, and boost adhesion to the build

plate, which is an important preparation

step. They are easy to remove and can be

used multiple times. Another advantage

is that they are specially developed to

cope with high temperatures. However, it’s

important to check that the sheet is applied

correctly, as any air bubbles will mean you

won’t have a flat printing surface.

Glue stick

Covering the build plate

with soluble glue can really

improve adhesion for some materials with

minimal effort or investment. (Always check

the manufacturer’s material advice.)

Oil and grease

Sometimes, you’ll need to

lubricate the X and Y axles

of your 3D printer, just to ensure they keep

running smoothly. Usually all it takes is a

single drop of oil to resolve any issues with

dryness. For the Z trapezoidal lead screw,

grease can be a better option. Ultimaker

3D printers include both. It is important

not to use spray can lubricants, as this

affects the axle coating and can cause

damage to your printer.

Digital caliper

A digital caliper has many

applications in 3D printing,

including checking the precision of your

prints, and you can also use it to dimension

parts to replicate in CAD software.

Check if your manufacturer or vendor offers a starter kit or add-on pack, as well as what

comes in the box of your 3D printer.

Deburring tool, knife, or

cutting pliers and cutting mat

A deburring tool is great for

cleaning up modeled holes, and for remov-

ing small pieces of plastic from your printed

parts to make the end result look smoother

and cleaner. A knife and cutting pliers will

help you remove support structures.

Tweezers

Tweezers are useful to have

to hand for desktop 3D

printing. They are great for plucking any

oozing filament from the extruder nozzle

before it starts printing and are also handy

for cleaning up parts, post printing.

Chapter summary ¥ Create a maintenance schedule and train operators to perform required tasks

¥ Ensure your 3D printer comes with lifetime support

¥ Make sure your 3D printing workspace has all the tools you need

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5. Conclusion

Any company that is considering bringing desktop FFF 3D printers in-house should first be

well equipped with the necessary information and tools.

While 3D printing enthusiasts will tell you that ‘the possibilities are endless’, they can

also seem overwhelming. This is why a pragmatic approach is required when investing

in 3D printing technology – one that is based in reality, based on identifying key time and

cost saving opportunities. Essentially the mindset and culture of the entire organization

has to buy in to this, and leadership needs to be shown by the staff who will be using the

3D printers the most.

The measurable advantages of bringing desktop FFF 3D printing in-house have been outlined

here in terms of improving product quality and getting it to market faster. However, over

time, less measurable advantages also become more clear within a company as creativity is

fueled and innovation increases.

Read more 3D printing resources Compare Ultimaker 3D printers

Explore more 3D printing knowledgeLearn more from industry leaders and experts, and compare the specs of

our 3D printers, on the Ultimaker website

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About Ultimaker

Ultimaker has been in operation since 2011, and over the years has grown to become a

market-leader; creating powerful, professional, and accessible desktop 3D printers with offices

in the Netherlands, New York, and Boston, plus production facilities in Europe and the US.

Ultimaker’s team of over 300 employees continually strives to offer the highest-quality 3D

printers, software, and materials on the market to accelerate the world’s transition to local

digital manufacturing.

General inquiries: [email protected]

Find a local reseller: ultimaker.com/en/resellers