August 8, 2024
32 minutes read
In the field of modern manufacturing technology, there has been a considerable focus on both high-speed Fused Filament Fabrication (FFF) 3D printing and injection molding.
While both 3D printing and injection molding technologies can be used for batch production, what are the differences in their working principles and manufacturing processes? In terms of production efficiency and speed, what are their respective advantages and disadvantages? Regarding cost and investment, which technology offers a higher return on investment between these two? What are the similarities and differences in material selection and application scope between them? From the perspective of technological development and future trends, how might 3D printing and injection molding technologies evolve and impact the manufacturing industry.
This article aims to provide a comprehensive comparison between high-speed FFF 3D printing and injection molding. It will explore their differences in principles, design freedom, material selection, manufacturing efficiency, costs, and potential applications, offering readers a deep insight into these two technologies.
Injection molding is a traditional industrial manufacturing technique with a straightforward manufacturing principle: plastic pellets are placed in the hopper of the injection molding machine and heated by the rotation of the screw and the outer wall of the barrel to make the plastic molten. Then this molten plastic will be conveyed at a very high pressure through a rotating screw into the closed space of the sealed mold, and the shape of this space is the desired final product shape. After waiting for cooling and solidification, the mold is removed, and the final solid parts can be obtained.
Currently, over 80% of durable plastic products in the market are manufactured through injection molding. The process of injection molding is similar to that of making ice cream. For example, you can mix and stir ingredients like cream, chocolate, and milk, then pour the mixture directly into molds and place it in the freezer. After some time, the ice cream mixture will solidify completely. Upon removing the mold, you get ice cream in a certain shape. Injection molding follows a similar principle, but after the material cools and solidifies in the mold, it requires cleaning and post-processing for final production.
High-speed FFF 3D printing is an additive manufacturing technology that builds parts by melting a heated filament and extruding it from an extruder head, then depositing it layer by layer according to a route previously established by slicing software. The entire 3D printing production process is similar to building bricks layer by layer. Because the entire build process starts from scratch, FFF high-speed 3D printing technology offers a high degree of manufacturing flexibility. The difference in the fundamentals of these two technologies ultimately leads to differences in applications and costs as well.
High-speed FFF 3D printing offers greater flexibility, allowing for the easy creation of complex geometric structures without being constrained by the traditional mold design and molding processes associated with injection molding. Additionally, high-speed FFF 3D printing technology excels at producing parts with intricate geometric features such as internal cavities, channels, honeycomb-like structures, and more. This makes it particularly well-suited for flexible customization in manufacturing. Thanks to its inherent flexibility, high speed FFF 3D printing also enables designers to frequently iterate on designs, achieving relatively ideal production requirements at lower costs. This makes it suitable for flexible and customized production.
The term “slicing” refers to converting a digital 3D model into instructions for 3D printers, as the slicing program literally “slices” the 3D model into layers. Raise3D provides its own slicing software, called ideaMaker, which supports the custom adjustment of printing parameters, and the system can also optimize the parameters automatically. ideaMaker uses algorithms to compute the slicing parameters for layer height, infill structure, and support structure. By adapting parameters accordingly, the filament consumption and printing time both decrease while surface quality is maintained. Boolean tools are integrated into ideaMaker to help users carve, split, and combine models. In addition, ideaMaker makes it easy to create different textures for printed models to increase design possibilities. It is worth mentioning that ideaMaker supports variable settings for selected areas of the print model to help users achieve specific product performance.
Learn more about Raise3D ideaMaker:
https://www.raise3d.com/ideamaker/
In contrast, the freedom of design of parts produced by injection molding is mainly limited by the processing mold. Firstly, the complexity of the part design needs to be taken into account, as structures such as screws, helixes, micro holes, small grooves, multi-cavities, sliders, etc. are more difficult for mold design as they may require more complex machining steps or special mold configurations. In addition, engineers need to pay attention to wall thickness, gate location, draft angles, avoiding sharp edges, and undercuts. At the same time, factors such as material flow and shrinkage in the mold should be considered during the injection molding process, as these will affect the final product.
For example, complex injection-molded parts often have contours that are more intricate, implying more walls. This places higher demands on shrinkage and uniformity margins in injection molding. Any uneven shrinkage can result in issues such as warping or indentation. Additionally, mold design must also consider demolding issues to prevent problems like sticking molds, air bubbles, tearing, stretching, or deformation.
Desiring more intricate mold designs implies incurring higher costs. Due to the extended preparatory work in the early stages of injection molding, making adjustments after the completion of mold production will lengthen the entire production cycle and significantly increase costs.
Injection molding typically boasts a fast production speed. In the presence of a fully prepared mold, plastic material can be rapidly injected into each mold, followed by a relatively short period for cooling, hardening, and demolding. The majority of injection molding cycles typically require only a few seconds to a few minutes. Due to its fast molding speed and high repeatability, injection molding is highly suitable for large-scale mass production.
However, it should be noted that the fabrication of injection molds may require a considerable amount of time. This process includes mold design, prototype fabrication, processing and assembly, mold trial, adjustments, and corrections before entering the formal production phase. Therefore, the characteristics of high initial costs, extended lead times, and elevated costs associated with design changes are crucial considerations for manufacturers when choosing a technological route. Combining the advantages and disadvantages of injection molding, it is better suited for large-scale production rather than small batches.
The FFF high-speed 3D printer manufactures products through a layer-by-layer deposition process, resulting in a relatively slower production speed compared to injection molding. However, due to the absence of mold fabrication, the overall production process for FFF high-speed 3D printing is shorter, with fewer preparation steps and increased flexibility in the manufacturing process. Therefore, FFF high-speed 3D printing excels in the aspects of customization and small-batch production.
The typical printing speed of a standard FFF 3D printer ranges from 50 mm/s to 150 mm/s. Raise3D, a manufacturer with a focus on production, has introduced Hyper FFF® technology, specifically designed to enhance the efficiency and performance of 3D printers. This technology aims to increase the output of FFF printing without compromising the quality of printed components.
The Raise3D Pro3 HS Series is capable of printing at standard speed at 300 mm/s. Even with Hyper Core series high-performance materials, it can still reach average speeds of 200-300mm/s, elevating users’ 3D printing capabilities to a new level. Compared to the existing Raise3D Pro3 Series, the Pro3 HS Series reduces printing time by 30% to 70%, depending on the size of the model.
Learn more about Raise3D Hyper FFF® technology
Learn more about Raise3D Pro3 HS series
In addition, for high-speed FFF 3D printing batch production, the overall production speed is also related to 3D printing task management. Efficient multitasking capabilities can, to some extent, improve production efficiency and reduce personnel management pressure. For batch production printing tasks, Raise3D provides RaiseCloud, which is a web-based 3D printing management platform that allows remote control, monitoring, and reporting of the entire printing production progress of the team at a glance. In addition to controlling workflow, monitoring filament data, users can also remotely modify parameters, increasing production flexibility.
Learn more about Raise3D RaiseCloud:
https://cloud.raise3d.com/raise3d.html
The current global market for injection molded plastics is approximately $300 billion. Injection molding manufacturing is widely used in various industries such as automotive parts manufacturing, mechanical equipment, electronic communication equipment, medical equipment, toys, food processing, footwear manufacturing, household appliances and so on.
Material selection is a crucial consideration in the manufacturing process. Injection molding technology predominantly utilizes melted plastic granules as the raw material, with commonly-used materials including, but not limited to, ABS, polypropylene (PP), polyethylene (PE), polycarbonate (PC), polyamide (PA), and polystyrene (PS), among others. These materials typically exhibit outstanding strength, hardness, wear resistance, and chemical stability, making them widely employed in various engineering and manufacturing applications, including automotive components, electronic enclosures, packaging materials, and more.
In contrast, the range of material applications for FFF 3D printing is more extensive, allowing for the fulfillment of several different types of project requirements. Common high-speed FFF printing materials include PLA, ABS, ASA, PETG, and others, which are very common in the market and relatively cost-effective. High-speed FFF 3D printing technology also supports the use of composite materials, such as carbon fiber-reinforced materials, to enhance part strength and achieve lightweighting. Additionally, some materials with high-temperature resistance and resistance to chemical corrosion can be used for specialized applications under specific conditions.
It is worth noting that high-speed FFF 3D printing also supports some flexible materials, such as TPU, elastic PLA, etc., which can be used for manufacturing insoles, medical models, elastic components, and more. In addition, certain biocompatible high-polymer materials, such as biocompatible PLA, PCL, etc., can be utilized in the production of medical instruments, implants, or biomimetic structures. These materials, however, can be difficult to apply under the temperature and pressure conditions found in traditional injection molding.
Raise3D provides a series of high-speed materials for Hyper FFF printing technology, including Hyper Speed and Hyper Core series. The Hyper Speed series, developed for high-speed FFF printing, features high flowability, optimized molecular weight, easy printability and excellent surface finish, as well as excellent interlayer bonding, and is represented by the Hyper Speed PLA and Hyper Speed ABS filaments. The Hyper Core series features tailored fiber distribution to provide a smooth surface, excellent interlayer bonding and less nozzle wear, and is represented by Hyper Core ABS CF15, Hyper Core PPA CF25 and Hyper Core PPA GF25.
Learn more about Raise3D Hyper Speed Filaments:
https://www.raise3d.com/filaments/raise3d-high-speed-filament/
Due to differences in technical principles, there is a cost difference between high-speed FFF 3D printing and injection molding. The cost differences are primarily reflected in equipment costs, material costs, electricity costs, labor costs, time costs, and maintenance costs. In the case of injection molding, the main costs typically include expensive mold manufacturing costs and substantial electricity costs, especially in large-scale production scenarios. Due to the high modification costs, once mold production has started, injection molding is not suitable for prototype development. The material costs of injection molding are relatively low, and the overall costs decrease further with an increase in production scale. In summary, the total investment cost of injection molding is higher and is more suitable for large-scale production.
The primary costs of high-speed FFF 3D printing include the initial investment in purchasing the equipment and expenses with the equivalent of the raw material, the filament. High-speed FFF 3D printing offers a wide range of material choices, including metals, composite materials, engineering plastics, and ceramics. While the material costs of high-speed FFF 3D printing are slightly higher compared to traditional injection molding, they are relatively reasonable for small-batch production or prototype validation. Additionally, the initial investment cost for high-speed FFF 3D printing equipment is generally more cost-effective when compared to traditional manufacturing equipment such as injection molding machines.
Through a practical case study, we can gain a clearer understanding of the cost difference between high-speed FFF 3D printing and injection molding technologies in addressing batch production.
Taking the example of small-batch production (0-1000 sets) of a cleaning tray for battery cores as an illustration, each tray is composed of 7 parts. The production of these 7 parts using the Raise3D high-speed FFF 3D printer requires a total of 21 hours.
The production costs of 3D printing primarily include the average equipment depreciation of the 3D printer, material costs, energy consumption and consumable costs, as well as labor costs. Among these, labor amortization costs decrease as the quantity of printed items increases. As evident from the above case, the costs of injection molding decrease with an increase in production volume. Injection molding entails significant upfront investment in tooling costs. However, with an increase in production volume, the mold costs are also amortized to a lower level. From the data in the above case, it can be observed that when production reaches 1000 units, the production costs account for only one-thousandth of the initial costs. In contrast, 3D printing costs consistently remain at a relatively low level. For order quantities below 200 units, the economic advantages of high-speed FFF 3D printing are even more pronounced.
In addition to the cost benefits and high production efficiency brought about by large-scale production, injection molding typically features high precision and low surface roughness. This is attributed to the precision machining of the molds, resulting in a smooth mold surface, and the mold’s accuracy often determines the final dimensions and shape of the components. Furthermore, injection molding injects the raw material into the mold in a single step, reducing the need for part connections or assembly processes, which contributes to ensuring precision. The control system of the injection molding machine can also regulate the temperature, pressure, and injection speed, ensuring that the parts meet production requirements.
However, not all injection-molded parts have high requirements for the surface quality and precision of the product. For example, injection-molded parts such as some packaging plastics, internal structural components, prototype parts, and some low-cost products (such as disposable items, cheap toys, etc.) typically only need to meet basic structural requirements, with lower demands on quality and precision.
The accuracy of high-speed FFF 3D printers is typically influenced by several factors, including layer height, printing speed, and printing temperature. To address factors that may affect printing accuracy, Raise3D employs methods such as product design and software optimization to enhance and optimize printing precision. Firstly, Raise3D’s ideaMaker provides customizable parameter templates, allowing users to optimize printing accuracy by adjusting parameters such as layer height, wall thickness, infill percentage, printing speed, nozzle temperature, printing bed temperature, and support structures.
Additionally, Raise3D achieves high-precision 3D printing through hardware optimization. Taking the Raise3D Pro3 HS series as an example, the XYZ-axis stepper precision of the Raise3D Pro3 HS series reaches 0.78125, 0.78125 and 0.078125 microns respectively. The nozzle diameter options include 0.2/0.4 (default)/0.6/0.8/1.0mm, catering to different product requirements.
The Raise3D Pro3 HS series is equipped with a tried and tested all-metal frame that establishes a specific motion system that enables the machine to achieve smooth movement and precise positioning, thus optimizing print accuracy. The newly added closed-loop stepper motor enables closed-loop control, increasing the electronic control precision, thereby stabilizing the motion accuracy of the extruder without losing steps. The optimized drive system, combined with precise positioning, ensures more accurate 3D printing. Moreover, the metal printing bed provides an even distribution of heat, enabling higher quality 3D printing. The new printing build plate can provide a more uniform magnetic adhesion, reducing model warping.
Injection molding is typically employed for high-volume, high-efficiency, high-precision, and consistent applications, such as large-scale production of relatively simple structural components. Injection molding technology has found widespread applications in industries such as automotive parts manufacturing, electronics, household appliances, medical equipment, and more. In large-scale production, injection molding often boasts lower production costs as the expenses associated with mold fabrication can be distributed across a large quantity of products.
High-speed FFF 3D printing offers greater design freedom, allowing for the realization of complex geometric shapes and internal structures. This makes it well-suited for prototype production, facilitating rapid testing of design concepts and product development. High-speed FFF 3D printing is also suitable for small-batch production, enabling the manufacture of intricate, customized components in a short period, which is economically advantageous.
Furthermore, High-speed FFF 3D printing exhibits outstanding material compatibility, supporting a variety of high-performance composite materials, including carbon fiber-reinforced composites, metal-filled composites, ceramic-filled composites, and more. Therefore, for production applications requiring high strength and performance materials, FFF 3D printing is an ideal choice. For example, lightweight high-strength components in the aerospace and automotive industries, skeletal substitutes and prosthetics in medical devices, intricate structural components in industrial manufacturing, various tooling fixtures, high-performance electronic enclosures, conductive components in electronics, as well as corrosion-resistant high-strength components in marine and maritime engineering.
On the other hand, as mentioned in the previous material section, high-speed FFF 3D printing also supports flexible materials such as TPU, elastic PLA, and biocompatible materials such as biocompatible PLA and PCL. These materials have unique applications in various scenarios.
From a comprehensive point of view, high-speed FFF 3D printing and injection molding play different roles in manufacturing due to their respective characteristics. High-speed FFF 3D printing is more suitable for areas such as prototype production and small-batch manufacturing. It offers a shorter production and delivery cycle, and the manufacturing process is more flexible. On the other hand, injection molding is better suited for the large-scale production of final parts, with a larger overall delivery volume and a relatively longer delivery cycle. These two technologies do not compete but rather complement each other. Rational application of both technologies in the production process can significantly shorten the overall production cycle, improve production efficiency and reduce production costs.
