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How to Choose an FDM 3D Printer: 12 Factors to Consider

Investing in a FFF (also known as FDM) 3D printer is an important business decision. At its core, choosing a 3D printer means the printer that fulfills the requirements of your application the most cost effectively. When looking to purchase a 3D printer, a business should be informed of the following:

  1. The business’ application’s 3D printing needs
  2. The 3D printer’s build volume
  3. The filaments needed for the business’ application
  4. Dual extruder 3D printers
  5. How a business should budget for a 3D printer
  6. The cost to operate the printer
  7. Easy to use printer

However, businesses should also become informed of a 3D printer’s quality and safety features, as these could be additional measurements of a professional 3D printer. Businesses should also be aware that 3D printing software and support from a 3D printer manufacturer can affect their 3D printing experience, learning curve, and 3D printing production.

This guide will discuss what you need to consider when determining which 3D printer is right for your business.

Step 1a: Determine Whether You Need an In-House 3D Printer or a 3D Printing Service

Some common reasons why companies need 3D printing include making manufacturing more efficient, producing customizable parts, and performing small-batch manufacturing. Read “Why Businesses Need 3d Printing” for a more comprehensive description of why businesses need 3D printing.

If your business has decided that it can benefit and implement 3D printing into its operations, it will need to decide whether to opt for an in-house 3D printer, or a 3D printing service. If your business did not need 3D printing before, it could indicate that you may not need an in-house 3D printer just yet. Your intended application or goal for 3D printing can help determine whether purchasing a 3D printer is the right option for you.

For example, if the project’s goal is to print a few parts, it may be more beneficial to outsource this task to a 3D printing service capable of producing the parts you need rather than purchasing a 3D printer.

However, if your business aims to increase production or create product models for your business then it would be better if you purchased a 3D printer. In addition, if your goal is to start a 3D printing business, then it would be necessary to purchase a 3D printer.

Step 1b: Understand Your 3D Printing Application

Understanding your 3D printing application is crucial because it will help determine which type of 3D printer and which 3D printing technology will work best for you. One way to start understanding your 3D printing application includes keeping in mind your industry and your intended use for the 3D printer.

Common industries that incorporate 3D printing into their operations include:

  1. Automotive
  2. Education
  3. Entertainment
  4. Manufacturing
  5. Medical

Common 3D printing applications include:

  1. End-use parts
  2. Jigs & Fixtures
  3. Prototyping
  4. Production
  5. Model Making

For example, KIDO Sports CO, Ltd. is a motorcycle helmet manufacturer who used 3D printing in their prototyping to edit and test new helmet designs cost-effectively before mass-producing the designs. This resulted in more accurate, customer-oriented helmets for their clients.

Read about other 3D printing applications across different industries here.

Step 2: Make Sure the 3D Printer Has the Right Build Volume for Your Application

A 3D printer’s build volume refers to the size of the parts it can produce. Different build volumes are suitable for different types of projects and applications.

A desktop 3D printer like the E2 has a single extrusion build volume of 330x240x240 mm (13×9.4×9.4 inches) and is an excellent option for projects that require smaller parts whose size will not increase over time. Desktop 3D printers are excellent options for schools and small-batch manufacturing.

The Bolton School Junior Boys use an E2 desktop 3D printer because the machine is small enough to fit on a desk, yet has a large enough build volume to produce different projects. Printing with the E2 helped students learn interdisciplinary design and production in art, design, and technology courses. Read Bolton’s 3D printing experience with the E2 here.

In comparison, a large-format 3D printer like the RMF 500 has a build volume of 500x500x500 mm (19x19x19 inches) for single and dual extruder printing.  The RMF large format 3D printer produces high-performance end-use parts with repeatability, making it an excellent option for small batch manufacturing.

There are many instances when a business needs to print a part whose size is not practical to produce on a desktop 3D printer or a large format 3D printer. Or a business may currently have projects that are smaller, but will need to produce larger parts in the near future. Looking for a 3D printer with a more flexible build volume is helpful in these situations. For example, the dual extruder 3D printers in the Pro2 Series and the Pro3 Series.

The Pro2 Series includes:

  1. Pro2 with a build volume of 305x305x305 mm (12x12x11.8 inches)
  2. Pro2 Plus 3D printer with a build volume of 305x305x605 mm (12x12x23.8 inches)

The Pro3 Series includes:

  1. Pro3 with a build volume of 300x300x300mm
  2. Pro3 Plus with a build volume of 300x300x605mm.

A 3D printer with a build volume like the printers in the Pro2 and Pro3 Series give businesses the flexibility to print parts of different sizes.

 

 

3D Printer Table

Step 3A: Make Sure the 3D Printer Processes the Filaments You Will Need

The right 3D printer for your business will be able to support the right filament for your application.

The right 3D printing filament for your application depends on a variety of factors, including the following:

  1. The type of part that will be printed
  2. How that part will be used
  3. The conditions that part will be under (for example: whether it needs to perform well in high heat, or have high strength)
  4. The desired result for what the project is trying to achieve
  5. The quality of the part needs to be (Keep in mind that price can be an indicator of the quality of the filament)

Depending on the type of work that needs to be done, a business may need a printer that can process a variety of filaments, or may only need a printer that specializes in a few types of filaments.

For example, the E2CF is an IDEX desktop 3D printer with features that make carbon fiber 3D printing easier. At the moment the E2CF is compatible with PA12 CF, which is a carbon fiber reinforced filament. A business whose 3D printing application will remain focused on producing carbon fiber printing could benefit from a 3D printer such as the E2CF.

There are printers capable of printing with a wide range of filaments. For example the E2, Pro2 Series, and Pro3 Series can process the following: PLA, ABS, HIPS, PC, TPU, TPE, NYLON, PETG, ASA, PP, PVA, Glass Fiber Infused, Carbon Fiber Infused, Metal Fill, Wood Fill. A business can benefit from purchasing a printer capable of printing a variety of filaments  in the following types of situations:

  1. Current projects require multiple filaments
  2. Parts that require a support structure during printing
  3. There is uncertainty whether future projects will require different types of filaments

Finally, ISO certifications are available for filaments. For example, biodegradable materials that offer sterilization capabilities are distinguished by the FDA. A 3D printer manufacturer that possesses ISO certifications (ISO9001, ISO14001) can indicate the quality of your filaments and printers.

Step 3B: Make Sure the 3D Printer Processes the Filaments You Will Need

When researching a printer’s filament capability confirm whether the 3D printer can support third-party filaments, because it usually affects the material’s cost and availability of various materials. A 3D printer manufacturer with an Open Filament Program (OFP) makes it easy to choose from a wide variety of filaments with the best quality and top performance for your printing needs.

An Open Filament Program is a collaboration between the manufacturer and several selected certified filament manufacturers to identify and pick top-performing filaments that are highly compatible with the 3D printer manufacturer’s printers. This ensures that materials are certified by the manufacturer.

Since filaments listed in an OFP are compatible with the 3D printer, they can be easily installed into the printer’s settings. This is much easier than buying a filament from another brand and setting it up yourself. It is a time-consuming process and the quality of the results will depend on the user’s experience.

Step 4: Learn About Dual Extruder 3D Printers

When searching for a 3D printer, you will notice that 3D printers feature either a single or dual extruder to perform single or dual extrusion printing. Some businesses may find that a 3D printer with a single extruder can perform the 3D printing project to the standards required of their application. However, most businesses may find that a dual extruder 3D printer better suits their needs. These printers perform advanced functions and processes making them an important asset in a variety of applications such as prototyping, production, manufacturing, and RnD.

Dual extruder 3D printers can also perform dual-color printing and dual material printing. Dual material printing allows you to produce parts with breakaway support in a material different than that of the part. Breakaway supports give you the freedom to create more intricate and complex designs and geometries.

Sometimes only one material is necessary to produce a part and if it is necessary to print the part with breakaway support, it is possible to print the part and breakaway support in the same filament. However, if the part and support are printed in the same material, the support may be difficult to remove or it can cause damage to the final print.

For example, if a part and its break-away support are printed in carbon fiber, the break-away support will be hard to remove.

Carbon fiber if you use its own material to support it, it will be hard to remove. Break away support saves you time and effort. It also gives you the freedom and geometry to make more things.

Step 5: Budget

There is a price range for different level printers. Pricing on a 3D printer can range from as low as  $200 to a million. Printers under $1,000 can generally satisfy the needs and requirements of hobbyists. Professional 3D printers well suited for business applications usually start at $3,000. While a business’ 3D printing needs can be met with a $3,000 professional printer, having a budget of at least $5,000 gives a business more options and flexibility when purchasing a printer.

Several factors contribute to the cost of a 3D printer, such as:

  1. The type of 3D printer
  2. The 3D printer’s build volume
  3. The quality of the 3D printer

Many options of FDM 3D printers are priced within a $5,000 budget. For example, a dual extruder 3D printer, like the Pro2 is $3,999. A desktop 3D printer with IDEX, like the E2, is $3,499.  And a desktop IDEX 3D printer for carbon fiber printing, like the E2CF, is $4,499.

When shopping for a 3D printer it is important to understand that a printer’s price is not the only cost associated with purchasing a 3D printer. 3D printers have direct and hidden costs.

Direct Costs:

  1. 3D Printer Price
  2. Materials
  3. Equipment
  4. Labor Costs

Hidden Costs:

  1. Consumables
  2. Slicing Software
  3. Training & Electrical Resources
  4. Electricity costs
  5. Machine operator

Hidden Cost Table

 

Because of direct and hidden costs, it is advisable to maintain two budgets when shopping for a 3D printer. The first budget is for the actual 3D printer. The second budget is the yearly budget for the function and maintenance of the printer. A common mistake businesses make when purchasing their first 3D printer is to spend the whole budget on the actual printer, leaving no room for maintenance or consumable costs. Consumables include replacing the filament used in 3D printing and the cost of replacing machine parts due to wear and tear during the 3D printing process. Examples of machine parts that receive a lot of wear and tear including nozzles, hotends and, Buildtak or other printing surfaces.

Depending how often a business is printing consumables can cost $1,500 a year, and this needs to be considered when budgeting for a machine.

For general purposes, a 5K-10K budget is enough for purchasing a high quality 3D printer. However, when the task is too demanding, i.e. big parts, metal parts, etc, a larger budget is necessary to accommodate the demand.

At times businesses may have different 3D printing options that fit their application needs. For example, a business may require a metal part and may initially look into SLM for direct metal 3D printing. SLM is an high cost system that uses a high powered laser that melts and fuses an expensive metal powder to build a metal part. However, indirect metal 3D printing is also capable of producing a metal part that fits the business’ needs, and a business can choose indirect metal 3D printing over CNC and SLM. For example, Metalfuse from Raise3D is a metal 3D printing system that can operate at 10% or 20% of the cost of SLM because it does not use a high powered laser or metal powder as a material. This option may not work for every business because the final 3D printed part from an indirect metal 3D printer will have less density than that of an SLM printer. Less density results in a loss of mechanical strength, but not all applications require such high mechanical strength. For example, SLM printed parts can have a density of 99% and above, and the Metalfuse achieves 97% density. 97% density can meet the requirements of most applications. Another factor to consider is the maximum size that can be built with indirect metal 3D printing. Generally, because of the debinding and sintering process, the part can not be too large. Make sure an indirect metal 3D printing option like Metalfuse can produce metal parts in the size required by the business application. Contact Raise3D to discuss if Metalfuse indirect metal 3D printer can suit your needs.

 

When choosing a 3D printer for an application, selecting the most cost-effective option gives the business flexibility to invest in more 3D printers. In general, investing in creating an in-house printing farm of several different 3D printers is advantageous to a business. The types of 3D printers included in the farm can range across the most cost-effective and the most capable. Therefore, a single printer does not need to be used for all the applications a business requires. It is possible to have several types of printers for different applications. In addition, a 3D printer may not be able to fulfill all the requirements of an application. If a business needs to invest in additional manufacturing equipment beyond a 3D printer, then choosing the most cost-effective printer will leave flexibility in the budget for other manufacturing equipment.

Printing metal parts can be used as an example to help explain this point further. If a business requires metal parts for an application, then SLM or an indirect metal 3D printing process OR CNC, like Raise3D’s Metalfuse, is necessary to produce those parts. If the business chooses Metalfuse is a much lower cost system than SLM, but a relatively higher cost by the dollar amount. However, it may not be necessary to produce the part in metal before deciding and achieving the final design of the metal parts. A business can use another 3D printer, like the Pro3 Series, to prototype the part in plastic to finalize the design before producing the part in metal. By prototyping the prototype using a more cost-effective printer for the task, like the Pro3 Series, the more cost-effective printer will lower the business’ overall expense and get to the final part quicker. Therefore, a single printer does not need to be used for all applications, and a single printer is not necessary for the same application, because different printers may be more cost-effective for different stages of production.

 

3D printing is not an instant process. Depending on the type of project, it can take over 10 hours to finish a print job. Some materials, such as resin, require post-processing, adding to a project’s timeline. Purchasing multiple 3D printers gives engineers on the team more access to a printer, meaning no one has to wait for a machine to be ready to use. This maximizes workflow and increases production, resulting in an advantage over competitors.

Investing in multiple printers saves time, and shortens a business’ production cycle. Shortening production cycles gives a business the ability to react to clients and new situations quicker. Having a slow response to urgent matters and clients can result in a loss of revenue and a loss of confidence in a company. For example, a business might be prototyping with a client who constantly updates its needs. Since the client’s needs change frequently, a business could lose the client’s confidence if it can not accommodate the new changes efficiently.

 

When the COVID-19 pandemic began, the supply chain for most businesses was impacted. It prompted many businesses to look for ways to have more control over their operations. Owning a 3D printer allows businesses to produce what they need in-house, removing the dependency and time spent waiting on a third party and shipping. During this time, businesses that owned a 3D printer had more control over their operations. However, businesses that invested in multiple 3D printers saved more time and were able to serve customers better because they eliminated the time spent waiting for a project to finish printing before beginning a new print job.

 

For example, a business with a $10,000 budget can purchase one Pro3 Plus professional 3D printer, priced at $7,249 with a build volume of 10 × 11.8 × 23.8 inch/ 255 × 300 × 605 mm. If a business does not need a printer with a larger build volume, like the Pro3 Plus, then it should leave room in the budget for operational costs, filament, and consumables like hotends.

A business can purchase:

  1. Pro3 priced at $5,249
    With a Pro3, a business can have a printer with features to improve the overall 3D printing experience.
  2. E2 priced at $3,499
    If the business is producing batches of smaller parts, then it could consider purchasing several E2IDEX 3D printers to boost productivity.
  3. E2CF, priced at $4,499.
    A business also has the option to purchase the E2CF for high strength parts in a carbon fiber enhanced composite filament.

Important Factors to Keep in Mind When Purchasing a 3D Printer

The above 5 steps guide businesses interested in purchasing 3D printers on how to break down their research for searching and budgeting for the right 3D printer. However, there are other equally important factors that businesses should give equal importance to when evaluating 3D printers.

1. Choose a High Quality 3D Printer

When purchasing a 3D printer, businesses should pay close attention to the printer’s quality. The price of a 3D printer is not the most reliable measure of a printer’s quality.

Visit the manufacturer’s website or read the buyer reviews to learn if the printer has received any industrial awards and recognition. Manufacturers of high-quality printers share the certifications, awards, and recognition their products receive on their websites.

For example, Raise3D shares on its website that the Raise3D factory is ISO certified. This means that all their products are made in factories that possess the IOS9001 and ISO14001 certifications. To put it simply, it means these printers are made with good components.

ISO9001 certification is defined as the international standard that specifies requirements for a quality management system (QMS). Organizations use the standard to demonstrate the ability to consistently provide products and services that meet customer and regulatory requirements. Companies that possess this certification are recognized for creating, implementing, and maintaining a Quality Management System.

An ISO14001 certification states that an organization is required to identify and have access to all applicable legal requirements related to its environmental aspects. ISO 14001 is an internationally agreed standard that sets out the requirements for an environmental management system. It helps organizations improve their environmental performance through more efficient use of resources and reduction of waste, gaining a competitive advantage, and the trust of stakeholders.

2A. Choose a High Quality Slicing Software

While a high-quality 3D printer is capable of producing a quality print, it executes the model based on a series of commands given to it in the printing file. The printing file makes a difference in the quality and success rate of a print. For example, if someone printed the same model using identical machines but different templates, the final printing results can have different results: a good quality print, a lower quality print, or even a failed print. Therefore, a high quality printing file is necessary for the printer to execute the model you need. Businesses that use a high quality slicing software with advanced features, and an optimized algorithm will be more likely to produce a high quality printing file.

Load the 3D model to the slicing software to begin preparing the printing file. A common choice for the code format used in the printing file is GCode. Code format, like Gcode, is the series of commands that dictates to the printer how to execute the model based on the settings in the slicing template.

Note: When exporting the 3D model, remember to make sure the chosen file format is compatible with the slicing software, and 3D printer. STL and OBJ are the two most common file types that modeling software can export and slicing software and 3D printers can import.

Examples of the settings that can be controlled in the slicing template include:
1. print speed
2. nozzle temperature
3. bed temperature
4. infill percentage
5. infill pattern
6. retraction settings
7. print order prioritization

Creating high quality instructions in the printing file during this step is critical to a print’s success rate. This is because 3D printing produces an object layer by layer, depending on the layer thickness set in the template, the file is cut into an x-amount of layers, and the number of layers equals the model height divided by the layer thickness, which is where slicing comes from. However, different printing methods finish each layer differently. FDM/FFF printing the hotend is controlled to move from one spot to another spot, drawing lines of a certain width and thickness. The thickness of these lines is the Layer Height. The width of these lines is the Nozzle Height. This line will finish the layer, and then the next layer is built on top of the existing layer. How well the slicer is able to prepare the file for printing each layer, and how well each layer is sliced is the foundation of a print having a good success rate. A good, high quality slicing software with good starting templates and open to a variety of setting adjustments to fine tune printing templates for the best results is essential for producing a high quality printing file.

ideaMaker is a free, easy-to-use slicing software developed by Raise3D. This slicer can import STL, OBJ, 3MF, and OTLP files and export GCode. In addition to processing these files, ideaMaker can process pre-existing templates, and templates uploaded to ideaMaker Library (open software template where users can contribute and download designs from different users) from other users.

An example of one of ideaMaker features is Automatic Support.

1. Automatic Support
This user-friendly slicer can automatically generate support structures and features an auto-repair tool that can highlight and correct any areas of the model that need repair. Users can edit the automatically generated supports by adding or removing supports from the part. ideaMaker also offers features to fine-tune the model before printing such as the ability to cut, duplicate, and change the file size.

ideaMaker’s advanced features allow users to customize and optimize settings for their model. Examples of its advanced features include:

  1. Modifiers
    ideaMaker’s modifiers allow users to specify settings changes within specific regions of the model. This means users do not need to use the same settings for the whole structure, and can only customize the sections that require it. For example, if a part needs to be strong within a certain area without such advanced modifiers, users may need to print the entire part solid and use additional material. However, ideaMaker’s modifiers give users the ability to specify the exact area that needs to be strong, rather than being forced to make the entire part solid and use extra material.
  2. Adding Texture
    Users can skip lengthy CAD processing and easily create different iterations of the same STL model by applying different patterns to the selected model’s surface. It works by creating a concave or convex surface on the designated model according to the values of an image’s greyscale. Users can try out an unlimited amount of images for many appearance options. This easy-to-use feature gives those still learning modeling skills the possibility of customizing the surface of a 3D printable object with a texture.

ideaMaker is compatible with filaments such as PLA, ABS, ASA, PETG, TPU, PP, and PC. There are pre-set templates for the E2CF to process PA12CF and its support material for carbon fiber printing. The E2 desktop 3D printer can also run GCode from this template. In addition to processing a wide range of filaments, ideaMaker is compatible with Raise3D’s Open Filament Program (OFP). OFP is a collaboration between Raise3D and several filament manufacturers to identify which filaments work best on Raise3D printers.

ideaMaker’s range of features makes it a useful slicing software to users of different levels of 3D printing experience. This high quality slicing software also connects to the rest of Raise3D’s suite of 3D printing software, ideaMaker Library, and RaiseCloud, resulting in a sophisticated 3D printing software ecosystem.

 

2B. Choose a 3D Printing Management Platform

RaiseCloud is a cloud-based 3D printing management platform developed by Raise3D. With RaiseCloud users can remotely operate and monitor the printer from their mobile device accessing files, webcam streams, the status of their print job, and more.

The ability to operate remotely is a valuable asset for businesses. For example, since RaiseCloud features a webcam stream of the print job, having a person on-site to monitor the print job is no longer necessary, lowering the cost of labor.

Operating remotely also gives businesses the ability to react quickly to unexpected changes. For example, COVID-19 made working remotely necessary, and businesses had to suddenly alter how they operated. Businesses that had RaiseCloud were able to continue their 3D printing operations and continue production. In comparison, businesses without a printer management software like RaiseCloud needed to spend time figuring out and setting up remote operations, causing production delays.

RaiseCloud also manages users and printing tasks while keeping teams synchronized, improving workflow management which is useful for businesses that require multiple 3D printers. For example, a business with multiple printers needs to manage the sequence of print jobs to make sure when a printing task finishes, the next task can begin without losing time. With RaiseCloud, businesses can create a queue of printing tasks, and assign these tasks to printers, making sure that time is not lost on any project.

RaiseCloud pairs with ideaMaker, completing Raise3D’s 3D printing ecosystem. The Raise3D ecosystem results in a better 3D printing experience while producing high quality prints.

3. Choose a 3D Printer with Fail Safe Features

When 3D printing, there can be certain occurrences that can cause a print to fail or to be damaged. Two common examples are if the filament runs out during printing, or if there is a power outage during printing.

  1. Filament Runs Out

If the filament runs out during printing, the part can break or snap in the middle, and can not be repaired. The print job will need to be restarted. However, professional, high quality printers will include features to alert users before the filament runs out during printing. For example, Raise3D printers feature filament run-out sensors on their extruders that can sense and alert when the filament is about to run out.

  1. Power Outage

A power outage or an accidental unplugging of the printer will cause the printing process to stop. In this situation, after power is restored, the printer will not be able to continue printing from where it left off unless it has some features that address power outages. For example, Raise3D printers feature power loss recovery, meaning the printer can pause and save its place during a power outage and resume printing when power is restored.

  1. Automatic Detection

Since some businesses want to be mindful that the 3D printers are fully enclosed, the business may want the option to pause printing if the printer’s door or lid is opened. Printers like the Pro3 Series, E2CF, and E2 provide businesses the option to enable a feature called Automatic Detection. If a business enables Automatic Detection, printing will pause if the printer’s door or lid is opened. If the business does not enable Automatic Detection, then the printer will continue printing even when the printer’s door or lid is opened.

4. Choose a 3D Printer That Offers Support From the Manufacturer

A 3D printer with support from the manufacturer or reseller (whose sales network offers good support), is easier to communicate with, and offers educational resources to learn how to use the printer is invaluable. Receiving support results in a smoother, better 3D printing experience and it shortens the learning curve enabling businesses to start printing quicker.

For example, Raise3D offers a Support Center with a Ticket System to answer your technical questions. We also provide an online demo studio where you can connect with us, and schedule presale or sale demo sessions. Our online educational resources include manuals, guides, and a learning center, RaiseAcademy. We share educational videos and live streams on Raise3D’s Youtube channel.