3D printing has changed the way we make things, but not all 3D printing technologies are the same. Two of the most common methods are Fused Deposition Modeling (FDM) and Stereolithography (SLA).
In this guide, we’ll compare FDM vs SLA in simple terms so you can choose the right one for your needs.
What is FDM?
Fused Deposition Modeling (FDM), also called Fused Filament Fabrication (FFF), is the most common type of 3D printing. FDM is one of the first types of 3D printing, invented by Scott Crump, a founder of Stratasys.
FDM printers come in different sizes and can use a variety of materials. Prices range from $5,000 to $500,000, depending on the machine’s capabilities.
Common materials include plastics like ABS, ASA, and PLA. Some advanced printers can also use stronger materials, such as carbon-filled plastics and nylon, for more durable prints.
How Does FDM Work?
It works a lot like a hot glue gun. A spool of plastic filament is heated until it melts. The melted plastic is pushed through a nozzle to create a thin layer on the build platform, moving side to side (X and Y axes).
The plastic cools and hardens quickly. Once a layer is done, the platform moves down, and more melted plastic is added on top, building the object layer by layer (Z axis).
What is SLA?
Stereolithography (SLA) 3D printing started in the 1980s and quickly became popular with manufacturers and product companies.
Unlike FDM, which uses filament, SLA printers use photopolymers– a special liquid that hardens when exposed to light.
Instead of a nozzle, SLA printers use a laser to turn the liquid resin into a solid part through a process called photopolymerization.
This printing method allows you to create high-resolution parts that are strong, waterproof, and consistent in all directions. Photopolymers are different from thermoplastics because they permanently harden when cured.
Just like FDM printers, SLA printers come in different sizes, material options, and price ranges.
How Does SLA Work?
The SLA process starts with a platform submerged in liquid resin. A laser, controlled by precise mirrors, shines onto the resin, hardening it layer by layer to form the part.
The first layers printed are support structures, which keep the part attached to the platform and provide stability. As the laser cures each layer, a recoater blade spreads fresh resin over the surface, ensuring the build continues smoothly.
The part is created from the bottom up, one layer at a time.
Properties Comparison Table Between FDM vs SLA
The table below shows common differences between SLA and FDM and how they compare.
Propiedad | FDM | SLA |
Print resolution | 50 to 500 Micron | 25 to 300 Micron |
Typical maximum print volume | 36" x 36" x 24" | 29” x 25” x 21” |
Wide range of material colors | Yes | No |
Minimum feature size | 1 mm | 100 Micron (.1 mm) |
Isotropic material properties | No | Yes |
Minimum recommended wall thickness | 1.5 mm | 0.5 mm |
Parts need support structures | Yes | Yes |
FDM vs SLA Comparisons
Below is a detailed comparison between FDM and SLA.
Technology
FDM and SLA work in different ways. FDM is simpler– you can set one up with basic technical skills. It melts plastic and lets it cool to form a part. SLA, on the other hand, uses a laser to harden liquid resin, requiring specialized knowledge and tools.
Materiales
SLA printers use liquid resin, which is often specific to each printer and comes in limited colors. FDM printers use plastic filaments available in many colors, including reinforced options like carbon fiber. Most FDM printers can use materials from different suppliers, so they are more flexible.
Print Volume
FDM printers come in various sizes, from small desktop units to large industrial machines that can print parts up to a cubic meter. SLA printers are generally smaller because they need to store liquid resin inside the machine.
Printing Speed
Regarding FDM vs SLA speed, 3D printing is quicker than traditional methods, but speed isn’t always the most important factor. SLA prints detailed parts with smooth surfaces but can take longer, especially for big prints.
FDM is faster because you can use bigger nozzles (0.6mm, 1mm, 2mm), but this makes the surface rougher. You need to choose between speed and quality based on your needs.
Strength & Durability
Prototypes go through heavy testing, so they need to be strong. You need to know FDM vs SLA strength to choose which one to use. FDM materials are tougher than SLA. ASA resists UV rays, so it’s great for outdoor tools. Nylon is durable for automotive parts.
SLA parts can break or wear out in tough conditions. When choosing between SLA and FDM, think about where your parts will be used. They need to work in real life, not just look good in a lab.
A 3D-printed FDM carabiner can hold 500kg, proving its strength.
Precision & Quality
Precision depends on your design needs. If you plan to use injection molding, SLA is a good choice. But for industrial parts that need strength, FDM works better.
Factory tools, for example, need to function well, not just look perfect. Choose the right 3D printing method based on your product’s purpose.
Acabado superficial
SLA produces smoother parts with fine details, while FDM prints have visible layer lines that often need extra finishing, like sanding or vapor smoothing.
Coste
SLA is more expensive because it uses specialized materials and a high-precision laser. An entry-level SLA printer costs around $1295, while you can get an FDM printer for as low as $200.
Applications & Industries
3D printing is becoming more common in different industries. Over 70% of businesses are finding new ways to use it, and more manufacturers are using it for full production. Here are some of the industries:
Aeroespacial
The aerospace industry is leading in 3D printing. However, because planes and spacecraft need strong, durable materials, some types of 3D printing, like SLA, don’t work well in harsh environments.
FDM printing, which uses strong thermoplastics, is commonly used for making prototypes and airplane interior parts. One big benefit of FDM is that it creates lightweight parts, which is important in aerospace.
Automoción
The car industry often uses strong plastics like ABS and PP. Since these materials need to handle tough conditions, FDM printing is the most popular. It’s used for prototyping, making tools, and producing small batches of parts.
Some car parts, like reflectors and lighting components, need clear materials, which is where SLA printing is useful.
Productos de consumo
Companies that make everyday products need to bring new ideas to market quickly. 3D printing helps by allowing them to test designs fast.
Many products use both types of 3D printing. For example, a handheld device might have an FDM-printed plastic shell with a soft SLA-printed grip. SLA printing is often chosen for making high-detail prototypes.
Sanidad
Healthcare uses 3D printing for medical tools, training models, and custom dental or hearing aid products. Medical devices need to be sterilized, so they must be printed with heat-resistant materials. Both SLA and FDM offer suitable materials, but you need to choose carefully.
For high-detail models, like those used in medical training, SLA printing is best. Dental products mainly use SLA, while hearing aids can be made with either method.
Education
Many schools and universities use 3D printing for student projects and research. Nearly every university has a makerspace, and more high schools are starting to use 3D printers.
Students and researchers prefer FDM because it’s affordable and easy to use. SLA printing requires more post-processing, so it is less convenient for beginners. However, FDM is expected to improve with better materials in the future.
FDM 3D Printing: Pros and Cons
Pros of FDM Printers
FDM printers use many types of plastics. They can print larger objects than SLA printers. They are useful for prototypes and small production runs.
New filaments offer more strength, chemical resistance, and low friction. Some, like carbon fiber blends, make lightweight but strong parts. FDM is great for functional parts like car components and aerospace tools. High-end models print with fine layers for a smoother finish.
Cons of FDM Printers
FDM prints often show layer lines, so you may need sanding or polishing for a smooth surface. Temperature changes can also cause warping or layer separation. Since FDM printers have many moving parts, any small issue can ruin a print. You need to check the settings and materials carefully before printing.
SLA 3D Printing: Pros and Cons
Pros of SLA Printers
SLA printers create super smooth, highly detailed prints– perfect for prototypes, jewelry, and intricate designs. They are also more precise than FDM because they don’t shrink or expand with heat. They are great for small and accurate parts.
Cons of SLA Printers
SLA prints can be fragile, so they aren’t great for parts that need strength. Stronger resins exist, but they’re still weaker than FDM materials like nylon. SLA printing is also more expensive, and printers have smaller build areas, so they are less useful for large or high-volume jobs.
FDM Considerations
FDM is a low-cost 3D printing method using common plastics like ABS, PLA, and PETG. Unlike SLA, which requires expensive liquid resin and extra equipment, FDM only needs the printer. Many filaments come in different colors, so no painting is needed.
FDM saves material with infill, creating hollow parts with a strong lattice inside instead of solid plastic. This lowers cost and speeds up printing.
FDM parts are durable, especially with ABS or nylon. Unlike SLA, which can become brittle over time, FDM prints last longer. However, parts can break along layer lines, so you must consider how force is applied when designing.
FDM prints have visible layer lines and may need post-processing for a smooth finish. Cooling plastic can also cause warping, especially with sharp corners or overhangs.
SLA Considerations
SLA prints in very thin layers– starting at 0.004 inches (0.102mm)-- which means you’ll see fewer layer lines compared to FDM printing, which usually starts at 0.008 inches (0.2mm).
The UV laser in SLA printers is extremely precise, like using a fine-tipped pen. It can create tiny details as small as the thickness of a sheet of printer paper. This makes SLA perfect for detailed parts like microfluidics or miniatures for tabletop games.
However, SLA parts don’t last long. They are mainly used for prototypes or single-use items. Because the material is cured with UV light, the parts can be brittle and will break down over time, especially when exposed to more UV rays. They may also turn yellow or become weaker.
In most cases, SLA parts start to degrade within 8 to 12 months.
When to Choose SLA Over FDM
High Quality 3D Printed Parts
Choose SLA if you need smooth, detailed, and accurate prints. While it’s pricier and needs post-processing, it offers professional results that FDM can’t match.
SLA is best for precise parts like dental models and jewelry. It uses a laser to harden liquid resin, ensuring tight tolerances. FDM, which melts plastic, can have slight inconsistencies. SLA prints come out smooth, ideal for prototypes and medical devices. FDM prints show layer lines and need sanding.
SLA excels at small, intricate details like thin walls and sharp edges. FDM may blur fine features due to melted plastic.
Fully Dense 3D Printed Parts
SLA prints are fully dense and leak-proof. FDM prints can have tiny gaps, so they are less reliable for holding liquids or handling pressure. SLA produces truly clear prints, while FDM’s air gaps make prints look cloudy.
SLA prints are equally strong in all directions. FDM prints are weaker in the vertical (Z) direction.
Temperature-Resistant 3D Printed Parts
SLA prints won’t melt, that’s why they are ideal for high-temperature uses like engine testing. FDM materials soften under heat. SLA prints withstand sterilization– they are great for medical tools and surgical guides.
SLA creates strong, heat-resistant molds and tools at a lower cost than metal or CNC alternatives.
Alternatives to SLA and FDM
SLA and FDM aren’t your only choices for 3D printing. PolyJet and Carbon DLS might also work well for your needs.
PolyJet Printing
PolyJet works by spraying tiny drops of liquid photopolymer layer by layer, which instantly hardens under UV light. It creates 3D pixels (called voxels) that combine flexible and rigid materials, known as digital materials.
Each layer is 30 microns thick, helping produce detailed and accurate parts. PolyJet prints come in different hardness levels and are reasonably priced. You can even create prototypes with overmolded parts.
Carbon DLS Printing
Carbon DLS uses CLIP (Continuous Liquid Interface Production) to shape parts with light and oxygen. A UV light shines through an oxygen-permeable window into a resin tank. As UV images are projected, the resin hardens, and the build platform lifts the part. This method is fast and creates strong, durable parts.
Conclusión
Now you know the key differences between FDM and SLA 3D printing. If you want low-cost, strong parts and easy setup, use FDM. But if you need smooth surfaces and fine details, go with SLA.
En DEK, we make your ideas real. We have reliable FDM and SLA 3D printing services, and we’re here to help you get it done right. Send us your files, we’ll take care of the rest with professional, on-time service.
Preguntas frecuentes
What is the main difference between FDM and SLA?
FDM melts and pushes out plastic to build a 3D object layer by layer. SLA uses a UV light to harden liquid resin into solid layers.
Which technology is more cost-effective, FDM or SLA?
FDM is usually cheaper because its materials and machines cost less. But the total cost depends on what you’re making and the materials you need.
Which technology is better for creating highly detailed parts?
SLA is better for detailed parts because it can create smoother surfaces and finer details.
Drilling is one of the most common processes in manufacturing. With so many types available, it’s important to choose the right one for the job. This guide will walk you through the 21 types of drill bits used in part manufacturing.
What are Drill Bits?
A drill bit is a tool that you attach to a drill to make holes in different materials. Most drill bits are round and have sharp tips to cut through surfaces. They come in different sizes and shapes to create various types of holes.
Components of A Drill Bit
Even though drill bits come in different types, they all have similar parts. Here are the main parts of a drill bit.
Body: The main section between the shank and the tip.
Point: The sharp, cone-shaped tip that does the cutting.
Shank: The end that fits into the drill.
Tang: The outermost part of the shank that connects to the drill’s spindle.
Flutes: Spiral or straight grooves along the body that help with cutting, remove debris, and allow coolant to flow.
Land (or Margin): The raised edges next to the flutes.
Body Clearance: A slightly thinner part of the body that reduces friction when drilling.
Web: The section between the flutes.
Neck: The small part that connects the shank to the body.
21 Types of Drill Bits Used in Part Manufacturing
In this section, we discuss the different types of drill bits and uses.
Brad-Point Drill Bit
Best for: Drilling precise holes in wood
This drill bit has a sharp point in the center to keep it steady while you drill. It also has wide grooves to remove dust and chips, keeping the hole clean. It’s great for making neat holes in wood, like when installing cabinet handles.
Twist Drill Bit
Best for: General-purpose drilling in wood, plastic, and light metal
This is the most common drill bit. It has a spiral design that removes dust while drilling, which is why it is easy to create an accurate hole quickly.
Pocket Hole Drill Bit
Best for: Drilling angled holes for screws
This bit is made for drilling slanted holes, also called pocket holes, to join pieces of wood together. It helps secure screws at an angle, similar to nailing wood at a 45-degree angle.
Screwdriver Drill Bit
Best for: Driving and loosening screws
These bits turn your drill into a screwdriver. They come in different shapes to fit various screw types. They are useful for building, repairs, and furniture assembly.
Masonry Drill Bit
Best for: Drilling into brick, concrete, and mortar
These bits are used with hammer drills to break through tough materials. They are commonly used by plumbers and electricians when working on walls.
Rivet Drill Bit
Best for: Drilling rivet holes in thin metal sheets
These bits make holes for rivets, which are fasteners used to hold metal pieces together permanently.
Glass Drill Bit
Best for: Drilling through non-tempered and ceramic glass
These bits have a special tip that drills into glass without cracking it. You need to drill slowly and apply light pressure to avoid breaking the glass.
Drill Saw Bit
Best for: Cutting irregular holes in wood and metal
This bit can drill down and also cut sideways. This is useful for widening holes or creating unusual shapes.
Annular Cutter Drill Bit
Best for: Cutting circular holes in metal while keeping the core intact
Similar to a hole saw, this bit cuts clean holes in metal and leaves a neat core.
Spade Drill Bit
Best for: Drilling large holes in wood
These flat bits have a sharp center point and are often used by electricians to make holes for running cables.
Installer Drill Bit
Best for: Drilling through walls and installing wiring
These long bits (up to 18 inches) can drill through walls, and they have a hole at the tip to help pull wires through.
Step Drill Bit
Best for: Drilling holes of different sizes in sheet metal
These bits have a stepped design that lets you drill various hole sizes without changing bits.
Adjustable Wood Drill Bit
Best for: Drilling different hole sizes in wood
You can change the size of the hole without switching bits. But these wear out faster than regular drill bits.
Auger Drill Bit
Best for: Drilling deep holes in wood
These long bits have a screw tip to help pull them through wood, making deep drilling easier.
Tile Drill Bit
Best for: Drilling through tiles
Similar to a glass drill bit, these have carbide tips to cut through tile without cracking it. Check the packaging to make sure the bit works for your tile type.
Plug Cutter Drill Bit
Best for: Cutting wood plugs to hide screws
Used in woodworking, these bits create wooden plugs to cover screws and make projects look neat.
Countersink Drill Bit
Best for: Creating recessed holes for screws
These bits make a small cone-shaped space so screw heads sit flush with the wood surface.
Self-Feed Drill Bit
Best for: Cutting precise circular holes in wood
These bits have a screw tip to pull them through wood, but they don’t remove sawdust, so you’ll need to stop and clean as you drill
Forstner Drill Bit
Best for: Cutting flat-bottomed holes in wood
These bits make smooth, precise holes for dowels and other woodworking projects.
Coring Drill Bit
Best for: Drilling large holes in brick, concrete, and masonry
You use a coring drill bit to cut smooth, clean holes in tough materials like brick, concrete, and tile. It removes a solid core. It makes installation easier for pipes, ducts, and wires. Water can help cool the bit for smoother drilling.
Hole Saw Drill Bit
Best for: Drilling large holes while keeping the core intact
These bits have a round cutting blade and are used for making big holes in wood, metal, tile, and plastic.
Materials Used in Making Drill Bits
Drill bits are made from different materials, which affects how strong, hard, and heat-resistant the drill bit is. Below are the most common materials used to make drill bits and what they are best for.
High-Speed Steel (HSS)
These drill bits are made from a mix of tungsten, chromium, carbon, and vanadium. They are strong, durable, and resistant to heat and wear. Since they can drill at high speeds, they are called High-Speed Steel. You can use them to drill metal and hardwood.
Tungsten Carbide
Tungsten carbide is extremely hard and durable. Because of its high cost, it is usually only used on the tips of drill bits. These bits can drill almost any material.
Acero al carbono
Carbon steel drill bits come in two types:
Low-carbon steel drill bits: Best for soft materials like wood and plastic. They are not very durable and lose their sharpness quickly.
High-carbon steel drill bits: These are stronger because they go through a heat-treatment process. They can drill through hardwood, metals, and plastic, but they can become dull if they overheat.
Polycrystalline Diamond (PCD)
These drill bits are made with diamond particles bonded to tungsten carbide. They are the hardest type of drill bit and can cut through any material. However, they are very expensive, so they are mostly used for industrial purposes.
Cobalt Steel Alloy
These drill bits contain 5-8% cobalt. They are hard, heat-resistant, and a bit brittle. They are great for drilling acero inoxidable and other tough metals.
Coatings Used on Drill Bits
Drill bits often have special coatings to make them stronger, last longer, and work better on different materials. Here are some common coatings and what they do:
Óxido negro
This is the most affordable coating. It helps protect the drill bit from rust, makes it stronger, and reduces friction. It also helps the bit hold onto drilling lubricants better. Black oxide works well for drilling iron and steel, but you shouldn’t use it for aluminum, magnesium, or similar materials.
Bronze Oxide
This coating helps make the drill bit stronger and more heat-resistant. It is often used to identify cobalt steel drill bits or combined with black oxide for high-quality, high-speed steel bits.
Titanium Nitride (TiN)
This is a more expensive coating that makes the drill bit harder and more heat-resistant. It helps the bit last longer and drill faster, especially in tough materials. TiN-coated bits work well for iron, steel, aluminum, magnesium, and other metals. They also provide the same benefits as black and bronze oxide coatings.
How to Select the Right Drill Bit?
There are many types of drill bits, and here’s how to make the right choice.
1. Choose the Right Material
Drill bits are made from different materials, and each one is best for certain jobs. High-speed steel (HSS) works well for wood, aluminum, PVC, and fiberglass. Cobalt drill bits are very hard and great for drilling tough metals. They also release heat quickly.
2. Consider the Coating
Coatings improve a drill bit’s performance and durability. Titanium nitride (TiN) coating makes HSS drill bits harder, so they can drill tougher materials. If you’re working with hard materials, look for coated drill bits.
3. Match the Drill Bit to the Material
Different materials need different drill bits. Use twist drill bits, step drill bits, or straight flute drill bits for metals. Then, use auger bits or spade bits for wood. Always check if the drill bit is meant for the material you are working with.
4. Consider the Drill Bit Shape and Size
Some important features to check:
Thickness (Webbing): A thicker drill bit is stronger and less likely to break. Heavy-duty bits are more durable.
Length: Short drill bits are more precise and stable. If you need a long drill bit, choose one with a short flute length (about twice the drill diameter).
Drill Point Angle:
- 118° angle: Best for softer materials like mild steel and aluminum.
- 135° angle: Better for harder materials.
Helix Angle (Spiral Angle):
- 10-29°: Works well for hard materials like aluminum, providing better chip removal.
- 19-49°: General-purpose angle for most drilling applications.
- 27-45°: Best for very hard materials like stainless steel, requiring less force.
5. Pick the Right Size
Use a drill bit size chart to find the exact size you need. Drill bits come in different size systems, such as:
- Fractional Inch
- Wire Gauge and Letter Sizes
- Metric Sizes
Understanding Drill Bit Angles
The angle of a drill bit is the angle between its tip and cutting edge. There are two common drill bit angles: 118° and 135°.
A 118° drill bit is sharper and cuts quickly. As mentioned earlier, it works best for soft materials. A 135° drill bit has a flatter tip, so it is better for drilling into hard materials like masonry.
When drilling metal, you’ll find drill bits with different angles, such as 90°, 120°, 135°, 140°, and 145°. The right angle depends on the type of metal and the drill bit material.
General rule: the harder the metal, the larger the angle (flatter tip) you should use.
Understanding Drill Bit Shanks
The shank is the part of the drill bit that fits into the drill’s chuck. There are different types of shanks, and you need to choose one that matches your drill’s chuck:
Hex Shank: Has six sides and is used in screw guns or electric screwdrivers, especially those with a hammer mode.
SDS Max Shank: Has grooves that lock into the chuck of hammer drills and some regular drills. It’s used for heavy-duty drilling.
SDS Plus Shank: Another grooved type, mainly used for masonry drill bits.
Straight Shank: A smooth, round shank that works with drills that have keyed or keyless chucks, usually holding bits between 10-13 mm.
Threaded Shank: Has a thread that screws into a hand-held drill. Since these drills don’t have a chuck, they are more compact and great for working in tight spaces. Some threaded shank bits are also made for grinders instead of power drills.
You can buy drill bits with these shank types individually or in sets, including mixed sets with different shanks.
Conclusión
Choosing the right drill bit is important for getting the job done right. With so many types available, it helps to know which one works best for your needs.
If you need high-quality drill bits for your manufacturing needs, contact DEK. We have a wide range of durable and precise drill bits for any job. Check out DEK today and get a free quote.
Preguntas frecuentes
What drill bit stays sharp the longest?
Titanium drill bits stay sharp longer than most other drill bits. But if you need to sharpen them, you have to recoat them, which can be a big drawback.
Which drill bit is best for metal?
Cobalt drill bits work best for metal, like stainless steel and aluminum. But you should also think about the size and length of the bit before choosing one.
Why do bits overheat in CNC machines?
Drill bits overheat in CNC machines when there is too much friction. This can happen if you run the machine too fast, use the wrong speed, or don’t use enough coolant. Dull bits and too much pressure can also cause overheating. To avoid this, use the right speed, keep the bit sharp, and make sure there is enough cooling.
When you work with metals, you need to understand their basic properties. One of the most important ones is density—how heavy something is for its size.
If you’re using lead, you should know why it’s so heavy and how that affects your project. In this blog, you’ll learn more about the density of lead and how it compares to other metals.
What is the Density of Lead?
Lead is a very heavy metal, and its chemical symbol is Pb. It has an atomic number of 82, which means each atom is big and heavy. At room temperature, lead has a density of about 11.35 grams per cubic centimeter or 0.420 per cubic inch.
That’s more than eleven times heavier than water for the same size. Lead is so dense because its atoms are large and packed closely together. This makes it one of the heaviest common metals you’ll work with.
Importance of Knowing the Density of Lead
First, it helps you decide if lead is the right material for your project. In many jobs, like building parts, the weight and size really matter.
Second, it helps when you’re reusing or recycling lead. You need to know the density to figure out the correct volume and weight. That way, you can measure things more accurately and avoid waste.
How to Measure the Density of Lead?
You can measure the density of lead in a few different ways:
Archimede’s Principle
Drop the lead into water and see how much water it pushes out. That tells you the volume of the lead. Then, use the lead’s weight and the amount of water it moved to figure out the density.
Using a Pycnometer
A pycnometer is a special tool that helps you measure volume very accurately. Weigh the lead, measure its volume with the pycnometer, and then calculate the density.
Using X-ray Diffraction
This is a high-tech method. It looks at the tiny structure inside the lead with X-rays. This gives you a very accurate density, especially if the piece of lead is really small or has a strange shape.
How to Calculate Relative Density of Lead?
You can find the relative density of lead by comparing its density to the density of water.
Use this formula:
Relative Density = Density of Lead ÷ Density of Water
Water has a density of about 1 gram per cubic centimeter (g/cm³) at 4°C. Lead has a density of about 11.35 g/cm³. So, the math looks like this:
11.35 ÷ 1 = 11.35
This means lead is 11.35 times heavier than water for the same amount of space.
Factors Affecting Lead Density
A few things can change how dense lead is. Here’s what you should know:
Temperature: When you heat up lead, its atoms spread out. This makes it take up more space, so the density goes down.
Pressure: If you squeeze lead really hard (with a lot of pressure), its atoms get pushed closer together. This makes the density go up a little.
Alloys and Impurities: Pure lead has a steady, known density. But if you combine it with other metals or it has impurities, the density can change.
Applications of Lead Based on Density
Because lead is very heavy for its size, you can use it in lots of ways:
Blocking Radiation
Plomo is great at stopping harmful rays like X-rays and gamma rays. That’s why it’s used in hospitals, labs, and nuclear plants to keep people safe from radiation.
Soundproofing
Since lead is so dense, it helps block sound. You can use it in walls, floors, and doors to keep noise out. It’s perfect for recording studios or noisy factories.
Counterweights and Ballasts
Lead is heavy but doesn’t take up much space. That makes it great for things like elevator weights, ship ballasts, and even diving belts that help you sink underwater.
Bullets and Fishing Weights
Lead is heavy and easy to shape. That’s why it’s often used to make bullets and fishing weights. They stay on track and work well because of the weight.
Comparing Lead’s Density to Other Metals
Lead is heavier than many other common metals. Here’s how lead compares to some of them:
- Aluminum is much lighter than lead, with a density of 2.70 g/cm³. This makes aluminum perfect for things like airplanes and cars, where you need to keep weight low.
- Iron is denser than aluminum but lighter than lead, with a density of 7.87 g/cm³.
- Copper is heavier than iron but lighter than lead, with a density of 8.96 g/cm³. It’s commonly used for electrical wires because of its conductivity.
- Gold is much denser than lead, with a density of 19.32 g/cm³. That’s why gold is so valuable and used in jewelry and electronics.
- Zinc is much lighter than lead, with a density of 7.14 g/cm³. It’s often used for coating metals to prevent rust.
Conclusión
Knowing how dense lead is helps you use it safely and effectively in different jobs. Lead is heavy, easy to shape, and resistant to rust. DEK is dedicated to making CNC-machined parts that go beyond expectations. We deliver high-quality, reliable parts, so contact us today to learn how our precision machining can help you get the best results for your projects involving lead.
PREGUNTAS FRECUENTES
Is lead heavier than steel?
Yes, lead is heavier than steel when the volumes are the same. Lead has a density of 11.35 g/cm³, while steel is denser at 7.85 g/cm³. So, for the same amount of space, lead weighs more than steel
What is the density of lead vs gold?
Lead is less dense than gold. Lead has a density of 11.35 grams per cubic centimeter (g/cm³), while gold is much denser at 19.32 g/cm³. This means gold is heavier than lead for the same volume.
Is lead a dense metal?
Yes, lead is a dense metal. It is much denser than many other common metals.
What is the density of lead per cubic inch?
The density of lead is about 0.420 pounds per cubic inch (lb/in³).
If you’re making machined parts and trying to choose between CNC machining and 3D printing, it’s good to know how each process works. In this blog, let’s talk about the comparison between CNC machining vs 3D printing.
What is the Difference Between Subtractive and Additive Manufacturing?
CNC machining is subtractive; you cut the material from a solid block to make a part. It’s been around for a long time and works well for both prototypes and final parts.
3D printing is additive; you build parts layer by layer using plastic, metal, or rubber-like material. It’s newer and was mainly used for quick manufacturing of custom parts and prototypes, but now it’s also good for small to medium production, especially if the part is complex.
Keep reading further to get more details about the difference between CNC and 3D printing.
¿Qué es el mecanizado CNC?
Mecanizado CNC is short for Computer Numerical Control machining. As mentioned above, it is a way to make parts by cutting material away from a solid block. A computer controls the tools, so you get very accurate and detailed parts. You can use it to make one part, like a prototype, or a lot of the same parts for mass production.
This method started back in the 1950s at MIT and changed how people make things because it made the process faster and more exact.
The process starts with designing your part using CAD software. Then, you turn that design into instructions using CAM software. These instructions, called G-code, tell the machine what to do. The CNC machine reads the G-code and uses sharp tools to cut the part from a solid block. It moves in different directions to make detailed shapes, and motors help it cut very accurately.
Common CNC Machines and Their Functions
Below, we discuss the most common ones and how they work.
CNC Mills: These machines use spinning tools to cut and shape materials like metal or plastic. If you need to make detailed parts with complex shapes, this is the machine for you. It’s often used when you need high precision.
CNC Lathes: Lathes spin the material while a tool shapes it. They’re great for making round items like bolts or shafts. You’ll find them used a lot in car and airplane parts.
CNC Drills: These machines are used to make holes with exact sizes and positions. They’re often used along with other machines when you’re making parts that need perfect holes.
CNC Grinders: Grinders use rough wheels to smooth out metal surfaces. If you’re working on parts that need a shiny or smooth finish, like tools or car parts, this is what you’ll use.
Plasma and Laser Cutters: Plasma cutters use hot gas to slice through metal. Laser cutters use focused light to make clean, detailed cuts. Both are great for cutting sheet metal and creating designs without wasting much material.
Aside from these types, we can also categorize CNC machines by how they move in different directions, as they give different levels of detail. Here’s how the axis system works:
3-Axis Machines: These move up/down, left/right, and forward/back. Perfect for simple shapes and flat surfaces.
4-Axis Machines: These add a rotation to one of the directions. This helps you work on parts with more complex shapes, like curves or angled holes.
5-Axis Machines: These can move in five directions. They give you the most control and are used when you need super-detailed, high-precision parts.
¿Qué es la impresión 3D?
Impresión 3D started in the 1980s as a way to make objects by adding material layer by layer. You can create shapes that are hard to make with regular tools. Over the years, it has developed a lot and keeps getting better.
In the present time, it starts with a 3D model, usually made in CAD software or scanned from a real object. Then, a program checks for errors in the design. Next, a slicer breaks the model into thin layers and creates a G-code file. This file tells the printer how to build the object layer by layer.
Unlike CNC machines that cut material away, 3D printing only adds what’s needed. This means less waste.
Common Types of 3D Printing Technologies
The way material is added depends on the type of 3D printer you’re using. Here’s how it works for the main types:
FDM: You feed in plastic filament. The printer heats it up and lays it down in layers.
SLA: You use liquid resin. A UV light hardens it layer by layer.
SLS: You start with powder. A laser melts the powder to build the shape.
Key Factors When Choosing Between CNC Machining and 3D Printing
When you’re deciding between CNC machining and 3D printing, think about what you really need. Do you need something custom? Do you need it fast? How much can you spend? Does it need to be super accurate?
Both methods are good, but one might fit your project better than the other.
Geometry and Size of Parts
Let’s tackle what’s the best way to manufacture complex parts. If your part has a complicated shape or tiny details, use 3D printing. If your part is simple and needs to be very exact, use CNC machining.
When it comes to part size with CNC, the smallest detail you can cut depends on the tool size. With 3D printing, the smallest shape you can print depends on the nozzle size. Most 3D printers can only make features as small as 1 to 3.2 mm.
File Types
CNC machining uses CAD files, usually in 2D, that are ready to be cut or shaped by the machine. 3D printing uses digital files like STL or OBJ; these files are easy to modify if you need to make quick design changes.
Turnaround Time
CNC machining might take longer because it requires more setup time. 3D printing is faster, especially for one-off parts, prototypes, and small runs.
Design Flexibility
CNC machining works well for making a large batch of identical parts, but if you want customization, do 3D printing. In 3D printing, you can easily change the design for each part.
Repeatability
CNC machining is great for repeating the same part over and over with high precision. 3D printing can repeat designs, but the quality might vary depending on the printer and material you use.
Speed and Product Volume
CNC machining is faster if you need to produce a lot of parts at once. It’s ideal for medium or high-volume production.
3D printing is better for small runs or prototypes. It’s slower for mass production, but it works well when you only need a few parts.
Material
CNC machining works with many materials, like metals (aluminum, steel, titanium) and plastics (ABS, Nylon, PEEK). It can also handle wood and specialty materials.
3D printing mainly uses plastics like PLA and ABS, but can also handle some metals like aluminum and titanium. Some materials, like superalloys, are hard to print and may not be as strong as those made by CNC.
Coste
Regarding 3D printing vs CNC cost, CNC machining has higher upfront costs because of equipment and skilled labor, but it gets cheaper per part when you make a lot of parts.
3D printing is cheaper to start with since it needs less setup and fewer tools, but the cost per part stays the same, so it’s not as cost-effective for large production.
Calidad
CNC machining makes high-quality, precise parts with smooth surfaces. If you need strong, durable parts, CNC is a better choice.
3D printing can also make good parts, but they might need extra finishing. The strength of these parts may not match what you get from CNC machining.
Quick Comparison of CNC machining vs 3D Printing
Categoría | Mecanizado CNC | Impresión 3D |
Material | Metals, engineering plastics, wood, specialty materials | Plastics, some metals, composites, ceramics, biomaterials |
Acabado superficial | Smooth with little extra work (125 Ra finish for as-machined parts) | Good, needs post-processing for a better finish |
Part Design | Good for simple to medium parts; limited by machine tools | Great for hollow parts and complex shapes and features |
Part Size | Can make large parts (up to 2000 x 800 x 1000 mm) | Smaller parts (up to 914 x 610 x 914 mm) |
Number of Parts | 50 or more pieces; medium volume depends on part complexity and tolerances | 1-10 pieces; medium volume depends on part complexity and tolerances |
Precision & Tolerances | Very accurate (±0.025 – 0.125 mm) | Good enough for basic use (±0.3 mm) |
Operator Skill | Requiere operarios cualificados | Requires some training, more user-friendly |
Turnaround Time | Longer, due to the machining process (typically more than 10 days) | Faster, particularly for prototypes (usually 30 minutes to a few days) |
Propiedades mecánicas | Very strong and durable; good for heavy-duty use | Moderate strength; best for light-use and test parts |
Coste | Expensive setup, but cheap for large runs | Low setup cost; best for small batches or one-off items |
Workflow | Requires more setup and adjustments | Quick setup, iterative changes possible |
Prototyping | Suitable for functional prototypes | Excellent for rapid prototyping |
Environment | More waste; requires more energy | Less waste; lower energy consumption |
Pros and Cons of 3D Printing vs CNC Machining
CNC machining and 3D printing both have their advantages and disadvantages, so one might be better for your project than the other. Here’s a simple comparison:
Ventajas del mecanizado CNC
- Makes parts accurately.
- Works with many materials.
- Produces smooth parts.
- Lower cost for more parts.
- Creates tough parts.
- Repeats the same part every time.
- Handles big parts.
- Parts stay strong.
Disadvantages of CNC Machining
- Creates waste.
- Waste is hard to recycle.
- Costly for small jobs.
- Takes time to set up.
- Requires trained workers.
- Struggles with complex shapes.
- Tools wear out often.
- Uses more energy and creates waste.
Ventajas de la impresión 3D
- Handles complex, intricate designs.
- Creates less material waste.
- Supports quick prototyping.
- Cost-effective for small batches
- Easy to modify designs
- Lower setup costs and simpler operation.
- Allows mass customization.
- Makes internal structures and complex shapes.
Disadvantages of 3D Printing
- Lower precision and surface finish.
- Limited material options.
- Requires extra post-processing.
- Less cost-effective for large batches.
- Weaker material properties in some directions.
- Limited by build size.
- Slower for large-scale production.
Applications and Industries
Here’s how you might use each one in different industries:
Mecanizado CNC
Aeroespacial: turbine blades and structural pieces
Automóvil: engine parts, transmission components, and custom tools
Médico: surgical tools or implants
Industrial Equipment: custom parts like molds or dies
Woodworking: furniture, cabinets, or detailed carvings
Prototyping: strong and accurate models of components
Functional Parts: tough parts that work well under stress
Impresión 3D
Creación rápida de prototipos: print out ideas, check the design, and make changes fast
Medical Devices: custom items like prosthetics, dental tools, and body models
Aeroespacial: lightweight parts like brackets or air ducts
Automóvil: test parts or design car interiors before you start mass production
Architectural and Art: detailed building models or unique art pieces
New Industries: 3D printing in fashion (like accessories), construction (building parts), bioprinting (tissues), or even food
Making Molds: molds for casting
Can You Combine 3D Printing and CNC Machining?
You might ask, will 3D printing replace CNC machining? The answer is no. 3D printing won’t fully replace it.
Instead, use both together. 3D print the shape and details, then use CNC to smooth and size it correctly. This helps when you need detailed and exact parts, like for medical tools or planes.
It can save time and improve quality. So, use both when you can.
Which Process Can Replace 3D Printing and CNC Machining?
If you need many of the same part, try injection molding as an alternative to both 3D printing and CNC machining.
It gives smooth, strong parts, but it’s not great if you need just a few or want to change the design.
You make a mold, fill it with melted plastic, and let it cool into a solid part. The mold costs more at first, but each part is cheap in big batches.
Conclusión
Choosing the right manufacturing method, like CNC machining or 3D printing, depends on what you need for your project, your budget, and how many parts you need to make. CNC machining is good for making precise and durable parts. 3D printing is quick and flexible, great for testing ideas.
DEK helps you get custom parts made faster and easier. Take a look at our CNC machining services. With DEK, you get high-quality CNC-machined parts in just 3-7 days for both prototypes and full production.
If you’re getting into 3D printing, you’ve probably heard of ABS. It’s a popular material for making strong and durable prints. In this guide, we’ll break down what ABS for 3D printing is, its properties, benefits, challenges, and how to get the best results when printing with it.
What is ABS?
ABS, short for acrylonitrile butadiene styrene, is a popular material used in 3D printing. It’s a strong plastic that can handle changes in temperature. You’ll often see ABS used with FDM (Fused Deposition Modeling) 3D printers. Since it was patented in 1948, it has become widely used because it is strong, flexible, and easy to shape.
Properties of ABS
Here are the properties of ABS material for 3D printing:
Propiedades mecánicas
ABS does not break easily, even if you drop it or hit it. It stays strong in cold weather, so you can use it for things that need to handle rough conditions. Even though it is tough, it is also lightweight, so it won’t make your parts too heavy. Unlike some brittle plastics, ABS can bend a little before it breaks, which makes it more reliable for many uses.
The table below shows the value of some mechanical properties of ABS.
Propiedades mecánicas | Injection Molded ABS | FDM ABS |
Resistencia a la tracción | 44 MPa | 30 MPa (xy axis) |
Impact Strength | 44 J/m | 27 J/m (xy axis) |
Young’s Modulus | 1790 MPa | 1460 MPa |
Flexural Modulus | 2250 MPa | 45 MPa |
Propiedades físicas
ABS is a hard plastic with a smooth, matte surface. You can make it shiny by treating it with acetone. It comes in different colors and two common filament sizes (1.75 mm and 2.85 mm), so you have options when printing.
ABS melts at around 200°C, but you need to print it at a higher temperature (230-260°C) for the best results. A heated print bed (80-130°C) is necessary because ABS shrinks when it cools, which can cause it to warp or come off the bed.
If you use an enclosed 3D printer, it will help keep the temperatura steady and protect you from harmful fumes.
Propiedades químicas
ABS is made from three ingredients: acrylonitrile, butadiene, and styrene. Each one gives it different properties—acrylonitrile helps with chemical resistance, butadiene makes it tough, and styrene makes it rigid and smooth.
ABS can handle heat and chemicals, so it works well for industrial parts. It is made from petroleum, which is not the most eco-friendly option. However, it is recyclable, even though most recycling centers do not accept it. ABS also absorbs moisture from the air, so you should store it in a dry container before using it to print.
3D Printing ABS
ABS has been used in Impresión 3D for years because it produces durable parts that withstand heavy use. When printing with ABS, make sure you’re in a well-ventilated space because it can have a slight smell. Also, ABS shrinks as it cools, so keeping your print area warm and stable will help improve your results.
Pros of ABS 3D Printing
ABS was one of the first plastics used in industrial 3D printers and is still popular today because of the following benefits:
- It’s affordable.
- Strong and durable, making parts less likely to break or crack.
- Good impact and wear resistance.
- Resists heat, so it can handle warm environments like a car or delivery truck.
- Produces smoother prints with less oozing and stringing.
- You can use acetone to remove layer lines for a clearer finish.
- Works well for functional prototypes and end-use parts.
- More accessible for 3D printing compared to injection molding.
- A widely used and standardized material across many industries.
Cons of ABS 3D Printing
There are some challenges of 3D printing with ABS even though it has many benefits, and they are listed below.
- ABS shrinks as it cools, which can make your prints bend or crack.
- It gives off fumes while printing, so you need good airflow.
- Your prints might not stick well to the bed, causing warping or failures.
- You need a heated bed and an enclosed space to stop warping.
- PLA prints easier, sticks better, and doesn’t need as much heat.
Tips for 3D Printing ABS
Want to make 3D printing with ABS easier and more successful? Try these simple tips:
- Keep your printer in a stable-temperature room. Sudden temperature changes can ruin your print. Also, turn off or lower the cooling fan—letting the print cool naturally helps avoid problems.
- Use glue on the print bed. If your printer has a heated bed, set it around 90–100°C. The heat and glue help prevent warping and keep the print from peeling off.
- Print slowly. A slower speed gives each layer time to cool before the next one is added. Start at 30 mm/s and don’t go over 50–60 mm/s to prevent corners from lifting.
- Store ABS in an airtight container. ABS absorbs moisture from the air, which can cause printing issues.
- Keep walls at least 1.5 mm thick. Thinner walls save material and print faster, but anything under 1.5 mm may be too weak, even if you need flexibility.
Applications of 3D Printed ABS Products
This material is great for making protective cases, project enclosures, toys, action figures, and even car parts. If you want to try a project, you can create things like Lego-style bricks, a door latch, or a fidget spinner.
If you’re looking for good ABS filament brands, some popular options include Hatchbox ABS, FormFutura (ABS pro, EasyFil ABS, TitanX), eSun (ABS, ABS+), and HobbyKing ABS.
ABS vs Other Filaments
Other similar filaments of ABS include PLA, PLA+, and PETG, but they have key differences.
PLA (Polylactic Acid): Made from corn starch, it’s biodegradable and great for quick projects like models. Need to decide between PLA or ABS for 3D printing? Well, it’s not as strong as ABS and melts at lower temperatures.
PLA+: An improved version of PLA with added materials. It prints at lower temperatures (200–230°C) and usually gives better print quality than ABS.
PETG (Polyethylene Terephthalate Glycol): Strong and durable, it’s UV-resistant, so it’s good for outdoor use. However, ABS handles heat better than PETG.
Check out the table below for a side-by-side comparison of these materials.
Propiedades | ABS | PLA | PETG |
Impact strength | 200-215 J/m | 26 J/m | 101 J/m |
Resistencia a los rayos UV | Average | Average | Better than average |
Densidad | 1.03-1.14 g/mL | 1.24 g/mL | 1.27 g/mL |
Conductividad térmica | 0.17-0.23 W/mK | 0.111 W/mK | 0.21 W/mK |
Elongation at break | 10-50% | 7% | 130% |
Yield strength | 2.96-48 MPa | 70 MPa | 50 MPa |
Flexural strength | 2400 MPa | 106 MPa | 70 MPa |
Hardness shore D | 100 | 88 | 106 |
Resistencia a la tracción | 2.96-43 MPa | 59 MPa | 53 MPa |
Specific heat capacity | 1.60-2.13 kJ/(kg.k) | 1.590 kJ/(kg.k) | 1.30 kJ/(kg.k) |
Young modulus | 1.79-3.2 GPa | 3.5 GPa | 2.1 GPa |
High Quality ABS-Like Resin 3D Printing
Most ABS 3D printing uses FDM (Fused Deposition Modeling), but new resin-based materials now offer similar benefits. While it’s not exactly the same as ABS plastic, it is designed to perform in a similar way. Plus, resin-based printing has some advantages over traditional ABS pellets for 3D printing.
Why Use ABS-like Resin for 3D Printing?
Stronger in All Directions: FDM prints are weaker along the Z-axis (layer seams), while resin prints have even strength in all directions.
Smoother Finish: Resin prints have a surface closer to injection-molded parts, so they are better for the final product.
Faster Printing: With modern resin printers, you can complete full print jobs in less than a day.
ABS for 3D Printing Services - DEK
DEK offers many manufacturing services like 3D printing, laser cutting, and CNC machining. Many customers use ABS 3D printing filament. If you want to learn more or get a free quote, contact us today.
Conclusión
ABS is a great choice for 3D printing if you need strong, durable parts. It can handle heat, impact, and wear, making it useful for many projects. However, it does require a heated bed and good ventilation due to warping and fumes.
By following the right printing tips, you can get the best results. Whether you’re making prototypes, tools, or custom parts, ABS is a reliable option for your 3D printing needs.
If you need a part that lets light pass through, you have a few options. Whether you’re making lenses, covers, or display panels, choosing the right method is important.
In this article, we’ll tackle more about 6 ways to make translucent and transparent parts.
What is a Transparent Material?
A transparent material lets light pass through completely, without scattering or blocking it. They do not absorb much visible light, which makes them clear.
Transparent materials also follow the rules of refraction (bending of light). They usually appear as a single color, but some can show a mix of colors, creating a beautiful spectrum.
Many liquids are highly transparent because they have no internal defects like cracks or gaps. Some materials allow almost all light to pass through with very little reflection. These are called optically transparent materials. Examples include flat glass and a camera lens.
What is a Translucent Material?
Translucent materials let light pass through, but not as clearly as transparent materials. They scatter the light, which makes objects on the other side appear blurry. They do not always follow the rules of refraction. This happens because of the way light interacts with the material’s surface, causing some of it to scatter.
Translucent materials are not as clear as transparent ones because they absorb more light. Examples include frosted glass, tinted glass, and wax paper.
Translucent vs Transparent Parts
Both transparent and translucent materials let light pass through, but they are not the same. Here’s how they differ:
Característica | Transparent Materials | Translucent Materials |
Amount of Light Passing Through | Allows most light to pass through | Allows some light, but scatters it |
Law of Refraction | Follows the law of refraction | Doesn’t always follow the law |
Clarity | Very clear | Blurry or hazy |
Image Formation | Allows clear images to be seen | Does not form a clear image |
Structural Defects | Has fewer defects | Has more defects |
Why Choose Translucent and Transparent Parts?
There are many reasons why product designers choose to make parts clear. Look around—you’ll probably see something transparent or translucent, like a window, a plastic cup, or a food container.
There are three main reasons for using clear materials:
To See Through It
Some things need to be clear so you can see what’s behind them. This includes windows, eyeglasses, plastic storage boxes, and ID card holders. These are usually fully transparent, meaning you can see everything behind them clearly.
To Let Light Through
Some objects need to be clear, not for human sight, but so light can pass through. Examples include greenhouse panels, solar panels, and terrariums. Things like flashlight covers or car headlamp covers also fall into this category. They don’t need to be fully see-through but must let light out.
For Looks
Sometimes, clear parts are used just because they look good. They don’t have a functional reason, but they make products more interesting. Examples include transparent gaming consoles, watches, musical instruments, designer bags, and some tool handles.
6 Ways to Make Translucent and Transparent Parts
Here are six ways to manufacture high-quality transparent and translucent parts:
1. SLA 3D Printing
Stereolithography (SLA) 3D printing uses a laser to harden liquid resin into a solid shape. This method produces smooth, detailed parts, but they may look frosted at first. To make them clear, you need to sand, polish, and apply a clear coat.
2. CNC Machining
Mecanizado CNC cuts parts from a solid block of material. It works well for making super-clear parts, especially with acrylic or polycarbonate. Polishing is needed to remove tool marks and make the part completely see-through.
3. Urethane Casting
Urethane casting pours liquid plastic into silicone molds to create clear parts. This method is good for making small batches of parts that look like injection-molded plastic.
4. Injection Molding
Moldeo por inyección melts plastic and injects it into a mold. This is the best way to make large numbers of clear parts that are strong and smooth.
5. Vacuum Casting
Vacuum casting is similar to urethane casting but removes air bubbles using a vacuum. This makes the parts smoother and clearer.
6. Material Jetting (3D Printing)
Material jetting sprays liquid resin in tiny drops, which are hardened by UV light. This method is great for making detailed, clear parts, but polishing is needed for full transparency.
Materials Used for Translucent and Transparent Parts
There are different materials for making translucent and transparent parts depending on the manufacturing process. Check the table below for examples of materials for each process.
Proceso | Material | Pros | Contras |
SLA (3D Printing) | Clear resin | Affordable, detailed parts | Fragile, needs extra support while printing |
Mecanizado CNC | PMMA (acrílico) | Very clear, easy to polish | Breaks more easily than PC |
PC ( Polycarbonate) | Strong, heat-resistant | Not as clear as PMMA, more expensive | |
ABS | Tough, low-cost, resists cracks | Harder to color than PC | |
Urethane Casting | PX520 (PC-like) | Stronger than some plastics | Not as tough as real PC |
PX521 (PMMA-like) | Very clear | Not as clear as real PMMA | |
Moldeo por inyección | PMMA (acrílico) | Very clear, easy to polish, colorable | Brittle, needs drying before molding |
PC (policarbonato) | Strong, heat-resistant | Less clear, more expensive, needs drying | |
ABS | Tough, low cost, resists cracks | Harder to color than PC | |
Fundición en vacío | PU Resin (PMMA-like) | Clear, customizable, lower cost for small batches | Not as strong as real PMMA |
PU Resin (PC-like) | Stronger than PMMA-like resin | Not as tough as real PC | |
Material Jetting (3D Printing) | Clear photopolymer | Very high detail, smooth surface | Brittle, not as strong as CNC or molding |
Factors To Consider When Choosing Material for Translucent and Transparent Parts
When choosing materials for translucent and transparent parts, keep these four factors in mind:
Claridad óptica: Ensure the material allows light to pass through clearly. For example, acrílico (PMMA) is known for its excellent clarity, so it is ideal for applications requiring transparency.
Mechanical Strength: Consider how strong and durable the material needs to be. Materials like polycarbonate offer high impact resistance, suitable for applications where durability is essential.
Thermal Resistance: Think about temperatures the material will encounter. Some materials can withstand higher temperatures without losing their properties.
UV Resistance: If the part will be exposed to sunlight, choose a material that resists UV light to prevent yellowing or degradation over time.
Translucent and Transparent Parts Design and Assembly
When making translucent and transparent parts, you need the right material, shape, and assembly, and these are explained below:
Transparency Needs
Think about how clear your material needs to be based on how it looks and works. If you’re making optical instruments, the material should be very clear with no distortions. For things like phone screens, you need both clarity and durability.
To get good transparency, pick materials with little to no natural color and use additives that help light pass through. Testing different materials and running simulations can help make sure your design looks good in different lighting.
Shape and Size Matter
The size and shape of your part can affect how easy it is to make and how clear it stays. Complicated shapes or big sizes can cause problems like uneven cooling and bending, which can make the material look cloudy.
To avoid this, try to keep walls thin and avoid sharp edges, so light can pass through more smoothly. Using testing tools and prototypes can help you find the best design while keeping your part strong.
Joining and Assembly
If your part connects to other materials, you need to make sure it stays clear. Use sealing methods like adhesive bonding or ultrasonic welding to keep out dust and prevent light from scattering.
When designing your part, plan for seals and gaskets so everything fits well and stays clear. Careful planning helps avoid problems that could make the material less transparent.
Post Processes for Translucent and Transparent Parts
After making transparent and translucent parts, you often need extra steps to improve their look and clarity. Below, we discuss how to polish and add color to clear parts.
Sanding
Sanding is a process where you use rough materials like sandpaper to smooth a surface. This helps create the right texture before other finishing steps like polishing, painting, or sandblasting.
If your part has a complex shape, sanding can still be useful, though getting a fully transparent finish is challenging. However, with enough effort, you can make it look as clear as glass.
Polishing and Fumigation
Polishing makes the surface smoother but doesn’t change the shape or size of the part. It works well for SLA and CNC acrylic parts, making them shinier and more transparent. However, CNC parts made from PC or PS may still look cloudy after polishing. In such cases, using acetone fumigation can help make them much clearer.
Spray Painting or Coating
If you need transparent or colored parts—like red transparent headlights or textured designs—you can use spray painting. This method is often used before mass production with injection molding.
By adjusting the paint’s location, color, and thickness, you can create different effects. Spray coating is also a quick way to make an object shinier and more transparent, hiding layers and protecting against UV exposure.
Resin Coating
For the clearest, smoothest finish, especially on flat surfaces, you can apply a thin layer of resin. This method helps remove scratches and uneven spots. Simply apply the resin with a syringe, letting it spread evenly over the part. The thinner and more even the layer, the better the results.
Coloring
Instead of just polishing, you can also add color to your transparent parts for a more attractive look. During molding, you can mix in textures, additives, or colorants. Common coloring methods for CNC-machined parts include tinting, sandblasting, and texture painting. Primary colors like red, green, and blue are often used, but you can also mix secondary colors.
Where Do You Use Translucent and Transparent Parts?
These are some examples of objects where you need transparent and translucent parts:
Transparent Parts:
- Glass (Windows, Spectacles)
- Prism
- Camera Lens
- Fish Tank
- Computer Screen (if made of glass)
- Sand Timer (Glass part)
Translucent parts:
- Colored Plastic Bottle
- Colored Balloon
- Tinted or Frosted Glass
- Tracing Paper
- Sunglasses
Conclusión
The best way to make clear parts depends on your project. For prototypes, use SLA 3D printing or material jetting—they make smooth, detailed parts but may need polishing. For strong, clear parts, choose CNC machining or injection molding. CNC machining gives high clarity, while injection molding is best for large batches.
If you need only a few parts, urethane or vacuum casting work well. They create smooth, clear parts but aren’t as strong as injection-molded ones.
Need clear parts? DEK offers various manufacturing options, from CNC machining to 3D printing, to match your project needs. Contact us to find the best solution for you.
Quality control is a key part of manufacturing. It ensures that the products you create meet high standards and work as expected. Without it, defects can slip through, leading to waste, unhappy customers, and extra costs.
Let’s explore the importance of quality control in manufacturing and the different methods used to maintain high standards in manufacturing.
What is Quality Control?
Quality control (QC) is a way for a business to make sure its products meet certain standards and improve over time. It involves training employees, setting quality goals, and testing products to catch any major issues.
A key part of QC is setting clear rules and processes. These rules help keep production consistent and ensure problems are handled the right way. By assigning specific tasks to trained employees, companies reduce mistakes and make sure work is done correctly.
Role of Quality Control in Manufacturing
Inspection and quality control in manufacturing is important because it helps you save money, work more efficiently, and keep customers happy.
When QC is done well, from planning and design to testing and maintenance, you waste fewer materials, spend less time fixing mistakes, and keep production costs low. It also helps avoid supply chain problems by reducing the need for extra materials.
Good QC makes sure your products are consistent and reliable. This means fewer returns and a better reputation for your brand. It also helps you spot problems in your production process.
If defects keep happening, there may be a bigger issue that needs fixing. Improving your process with methods like Lean manufacturing can help reduce mistakes and make your work more efficient.
Quality Control vs Quality Assurance
People often mix up quality control and quality assurance, but they are not the same. Both are part of quality management, but they focus on different things.
Quality assurance (QA) is about setting standards and making sure processes are designed to meet them. It focuses on planning and improving how things are done. It asks, “What steps do we need to take to meet our quality goals?”
Quality control (QC) happens during production. It checks if the final product meets the set standards and looks for any defects. It asks, “Did we follow the right steps? If not, what needs to change?”
Benefits of Quality Control in Manufacturing
Having clear rules and guidelines for quality control has many benefits, including:
- Keeping customers coming back
- Getting referrals from happy customers
- Making customers more satisfied
- Creating a safer work environment
- Avoiding problems from low-quality products
- Working faster, more efficiently, and making more profit
Types of Quality Control in Manufacturing
There are many types of quality control that you can use in manufacturing components, such as the following:
Just in Time (JIT)
With JIT, materials and parts arrive exactly when you need them for production—no sooner, no later. To make this work, you must set strict quality rules for your suppliers. That way, everything you receive is already up to standard, and production isn’t delayed.
Total Quality Management (TQM)
TQM is all about long-term success by keeping customers happy. You and your team must take responsibility for quality at every step. The goal is to find what works, repeat it, and constantly improve. This method relies on data and looks for ways to make processes more efficient.
100% Inspection Method
As the name suggests, you check every single product quality. This ensures accuracy and prevents defects from reaching customers. It’s best for industries where even tiny mistakes can be dangerous, like food poisoning. However, this method is expensive and not practical for every product.
Six Sigma
Six Sigma helps you improve products and processes by identifying and removing defects. The goal is to make production as consistent as possible. You do this by defining the problem, measuring performance, finding the cause of defects, fixing them, and keeping the process under control.
X-Bar Chart
An X-bar chart helps you track quality over time by measuring changes in things like weight, temperatura, or thickness. It shows whether your production process is stable or needs improvement. It’s often used alongside an R-chart, which helps determine if a process is predictable.
Taguchi Method
This method focuses on improving product design to reduce defects before they happen. Instead of just fixing mistakes during manufacturing, you design products in a way that makes them more reliable from the start.
Workstation Quality
In industries like Mecanizado CNC, skilled workers check parts before passing them to the next workstation. This helps catch mistakes early, so they don’t affect later steps.
Statistical Quality Control (SQC)
SQC uses data and sampling to check quality. You test a few products from a batch to see if they meet standards. If needed, you increase the sample size for better accuracy. A control chart helps track variations and spot problems early so you can fix them.
Quality Control Tools
There are many tools to help you manage product quality. Here are three common ones:
Quality Control Chart
A quality control chart is a graph that shows how consistent your product quality is. It tracks the number of defective products over time, helping you spot patterns. If defects stay the same, your process is stable, if they go up and down a lot, there may be a problem in production. This tool helps you find and fix issues to make your work more efficient and reduce costs.
Pareto Chart
A Pareto chart is a bar graph that helps you identify the main causes of quality problems. The bars show the number of defects, arranged from biggest to smallest. This makes it easy to see which issues affect quality the most, so you can focus on fixing them first.
Check Sheet
A check sheet is a simple table for tracking defects. You can use it to record how many defective products are made each day, week, month, or quarter. It also helps you identify patterns in defects and find their causes over time.
Quality Control Roles
In manufacturing, everyone plays a part in maintaining quality, but some jobs focus specifically on quality control. Here are three key roles:
Quality Manager
As a supervisor, you make sure the product development process follows company and regulatory standards for quality and efficiency. You also work with clients to ensure the final product meets their needs.
Quality Inspector
You work under the quality manager and check that products meet company, regulatory, and customer requirements. You use tools to test products and ensure they are safe, high-quality, and free of defects.
Quality Engineer
Also known as a QA or QC engineer, you focus on overall product quality. You test processes, set quality standards, document findings, create quality tests, and fix any problems. You also work with design teams, suppliers, and customers to ensure the final product is safe, reliable, and meets expectations.
Quality Control in Different Industries
Quality Control varies by industry to make sure products and services meet set standards.
- In manufacturing, QC checks raw materials, parts, and final products to keep quality high and reduce defects.
- In the food industry, QC ensures food is safe by testing for harmful substances and following health rules.
- In pharmaceuticals, QC confirms that medicines are pure, effective, and safe to use.
- In the software industry, QC involves testing programs to find and fix errors before they are released, ensuring a smooth user experience.
How to Implement Quality Control in Manufacturing
If you want to make sure your products meet high-quality standards, follow these steps:
Set Clear Quality Standards: Decide what makes a product “good” and create measurable rules to follow.
Choose the Right Quality Methods: Use methods like Total Quality Management (TQM) or Six Sigma to keep quality high.
Train Your Team: Teach employees how to check for quality and follow the right procedures.
Monitor Quality Continuously: Set up a system to check products during manufacturing so you can fix problems early.
Improve Over Time: Regularly review quality data, find patterns, and make changes to keep getting better.
How to Improve Quality Control in Manufacturing
To make quality control (QC) better in manufacturing, try these steps:
Data Collection
Good QC depends on collecting data from different areas, like suppliers, planners, inventory, production machines, and shipping.
Manual data collection takes a lot of time and can lead to mistakes. It also limits how much QC can do before it becomes too expensive.
Automated data collection gives you real-time information, helping you catch and fix problems faster.
As factories upgrade to smarter technology, better data collection and sharing will solve issues caused by outdated systems and manual tracking.
Auditing Processes
Before you improve anything, you need to understand how your machines and processes work. Many manufacturers use machines from different brands and different time periods. By reviewing each step and how it applies to your machines, you can find the best way to maintain quality.
This review should also include comparing your shop’s performance to industry standards. Look at things like cycle times and how much scrap material is wasted. This helps quality managers understand what’s happening on the factory floor.
A Pareto chart is a useful tool to see the most common reasons parts get rejected.
Conclusión
Quality control is essential for keeping your manufacturing process efficient and your customers happy. By following a strong SOP for quality control in manufacturing, you can reduce defects, cut costs, and improve overall production quality.
If you need high-quality manufacturing components with strict quality control, DEK ensures precision and reliability in every part. Reach out to learn more.
Aluminum extrusions are used in many industries because they are strong, lightweight, and easy to work with. Two common types are 2020 aluminum extrusion and 8020 aluminum extrusion.
If you are wondering which one to choose, this guide will help you know the differences, advantages, and uses between 2020 vs 8020 aluminum extrusions.
What is 2020 Aluminum Extrusion?
2020 aluminum extrusion is a lightweight, strong aluminum profile made using advanced extrusion technology. While “2020 aluminum extrusion” is not a standard aluminum grade, it is sometimes compared to 2024 aluminum, which contains a high amount of copper for added strength and durability.
Since 2024 aluminum is widely used in aerospace for its hardness and high strength, 2020 aluminum extrusion may have similar qualities.
Below, we discuss the key features of 2020 aluminum extrusion.
- Designed to be 20mm x 20mm.
- Includes a 6mm wide T-slot for easy attachment of accessories and modular assembly.
- Usually made from 6063-T5 aluminum alloy.
- Weighs about 0.65 kg per meter, so it is easy to carry and install.
Advantages of 2020 Aluminum Extrusion
The benefits of using 2020 aluminum extrusions are as follows:
- It holds up well under repeated stress, so it’s a good choice for parts that move or carry loads.
- 2020 aluminum extrusions are extremely strong and hard.
- Even though it’s strong, you can still cut and shape it easily using CNC machines.
- With treatments like anodizing, it can resist rust and corrosion even better.
Disadvantages of 2020 Aluminum Extrusion
2020 aluminum has some drawbacks that you also need to know, and here they are:
- Because of the materials used and the advanced processing needed, it costs more than some other aluminum types.
- You need to carefully control heating and cooling to get the best strength and performance.
- It can crack or weaken when welded, so you need special techniques and equipment.
Applications of 2020 Aluminum Extrusion
2020 aluminum is used in different applications, such as the following:
Military Equipment: Found in tank armor, missile parts, and other strong, impact-resistant components.
Aeroespacial: Used to make important airplane parts like the body, wings, and landing gear.
High-performance Cars: Used in race cars and sports cars for engine blocks, suspension systems, and other key parts.
What is 8020 Aluminum Extrusion?
8020 aluminum extrusion is a type of aluminum alloy used in various industries, though it doesn’t have a standardized classification like 6061 or 7075. It is created through an extrusion process, forming profiles with specific sizes and cross-sections. These profiles are commonly used in CNC machining and structural applications.
Different manufacturers may use slightly different compositions, but it usually contains elements like cobre, manganese, magnesio, and zinc. These materials help improve strength, resistance to corrosion, and ease of machining.
Here are the key features of 8020 aluminum extrusion:
- Available in multiple sizes, such as 25x25mm or 40x40mm, to fit different design needs.
- Includes a built-in T-slot, usually 8mm or larger, for easy assembly.
- Typically made from 6105-T5 or 6061-T6 aluminum alloy.
Advantages of 8020 Aluminum Extrusion
8020 aluminum extrusion has many benefits, such as the following:
- You can easily cut, drill, shape 8020 aluminum extrusion, that’s why it’s great for CNC machining and for creating precise, complex parts.
- It weighs less than metals like steel or copper, so it’s perfect for projects where keeping things light is important.
- It is stronger than pure aluminum because of the added alloying elements. It’s ideal for structural parts that need to support weight.
- Like most aluminum alloys, it holds up well in different environments without rusting, or breaking down easily.
Disadvantages of 8020 Aluminum Extrusion
While 8020 aluminum extrusion offers advantages, it has some disadvantages too, which are discussed below.
- It doesn’t handle high temperatures well because aluminum conducts heat easily, so it can lose shape or stability.
- The price of 8020 aluminum extrusion can change based on market demand and production costs, so it may not always be the most budget-friendly option.
- Even though it’s strong, it’s not as hard as some other aluminum alloys. It is less ideal for parts that face a lot of wear or heavy impacts.
Applications of 8020 Aluminum Extrusion
As mentioned earlier, 8020 aluminum extrusion is used in various industries. Some of the common applications are the following:
Car Manufacturing: Used to make structural parts, engine brackets, and suspension systems.
Electrónica: Works as heat sinks, protective housings, and internal support parts.
Machines & Equipment: Great for making machine parts that need to be strong and resistant to rust.
Detailed Comparison Between 2020 vs 8020 Aluminum Extrusions
The table below is a detailed comparison of 2020 vs 8020 aluminum extrusion, so you can understand their differences better.
2020 Aluminum Extrusions | 8020 Aluminum Extrusions | |
Cross-sectional Dimensions | 20 x 20 mm | 80 x 20 mm (the common size but exact dimensions may vary by product) |
Material | 6063-T5 Aluminum Alloy | 6105-T5 or 6061-T6 aluminum alloy |
Peso | 0.5 kg/m² (common) | Usually heavier, but depending on the specific product |
Appearance | Similar to 1515 profile but with different dimensions | Long strips with larger widths for specific applications |
Resistencia a la tracción | ~ 214 Mpa | ~ 241 Mpa |
Límite elástico | ~ 152 Mpa | ~ 214 Mpa |
T-slot Design | Four T-slots (one on each side); designed for lightweight parts and assemblies | T-slots can be arranged in series (e.g. four, six, or more); supports more complex and modular assemblies |
Maquinabilidad | Good (requires higher cutting forces and more wear-resistant tools) | Good (with moderate cutting forces and low tool wear) |
Acabado superficial | Available in anodized or polished finishes; anodizing improves corrosion resistance and appearance | Available in anodized or powder-coated finishes; powder coating adds color options and extra surface protection |
Costes | Typically higher | Bajo |
Application Areas | Automation equipment, small frames, machinery and equipment, etc. | Production lines, assembly lines, large industrial equipment, heavy frame structures, etc. |
Customizability | Typically customizable to fit specific requirements | Customizable, with variations in size and design complexity. |
When to Choose 2020 vs 8020 Aluminum Extrusions
When choosing between 8020 aluminum extrusions and 2020 aluminum extrusions, you need to think about what you will use them for. Each type has different strengths and works best for different applications.
If you need a material that is strong, resistant to corrosion, and easy to machine, 8020 aluminum extrusions might be the right choice. They are good for general projects, Mecanizado CNC, and structures that don’t need to handle heavy loads.
On the other hand, if you need something that can handle extreme pressure, has high strength, and lasts a long time, 2020 aluminum extrusions are a better option. They can definitely withstand tough conditions.
Think about what you need for your project, and choose the aluminum extrusion that best fits your requirements.
Conclusión
To summarize, 2020 aluminum is lightweight and strong, while 8020 is versatile and customizable. Choose the one that best fits your project, budget, and needs.
If you need precision-cut, durable aluminum extrusions for your project, contact DEK. We offer high-quality 2020 and 8020 aluminum extrusions tailored to your needs.
Preguntas frecuentes
What is the strongest aluminum profile?
The strongest aluminum profiles are made from 7-series alloys, like 7075 aluminum. It is strong, hard, and wear-resistant. However, the best aluminum depends on your needs, as different projects require different strengths.
How to choose the right aluminum for CNC machining?
To choose the right aluminum, think about where and how the part will be used. Consider strength, corrosion resistance, machinability, and cost. If you’re unsure, ask a CNC machining expert for advice based on your needs.
2020 vs 8020 aluminum extrusions, which is better?
2020 aluminum extrusion is best for small projects like 3D printers. 8020 aluminum extrusion is better for heavy-duty structures and industrial use.
In manufacturing, insulation is important for keeping machines, buildings, and products working efficiently. Plastics are one of the best materials for insulation.
Learn about the different types of plastics used in insulation and know their advantages and applications.
Why is Insulation Important?
Before talking about plastic as insulator, let’s first understand why insulation is important. The three main benefits are as follows:
Heat Barrier: Insulation slows down heat transfer. It helps you stay warm in winter and cool in summer.
Noise Reduction: Some insulation materials absorb sound. They make rooms quieter and improve acoustics.
Energy Savings: Good insulation reduces the need for heating and cooling so it lowers your energy use and utility bills.
Advantages of Using Plastics in Insulation
Plastics are widely used in manufacturing insulation because of the following:
- They are lightweight so they are easy to handle, transport, and install.
- They are resistant to moisture, chemicals, and wear over time.
- They offer excellent insulation with low thermal conductivity.
- They are less expensive than traditional materials like mineral wool or fiberglass.
- They are versatile as they can be used in many applications in different industries.
Common Types of Plastics Used in Insulation
Here are some common plastic insulation materials you can use:
Polyurethane
Polyurethane (PU) is a type of foam that comes in two forms: rigid boards and spray foams. It has excellent thermal resistance and helps reduce heat transfer.
Polietileno
Polietileno (PE) is a flexible plastic that does not absorb water. It is lightweight and easy to work with.
Polyvinyl Chloride
Polyvinyl Chloride (PVC) is a strong plastic that resists chemicals and weather damage. It is often made into foam boards for insulation.
Polyisocyanurate
Polyisocyanurate (PIR) is a rigid foam with high thermal resistance. It is lightweight but very effective at reducing heat loss.
Expanded Polystyrene
Expanded Polystyrene (EPS) is a lightweight and affordable plastic. It is usually made into boards or panels. It provides good insulation against heat and sound.
Extruded Polystyrene
Extruded Polystyrene (XPS) is a strong and moisture-resistant type of polystyrene foam. It has high compressive strength, that’s why it’s more durable than EPS.
Factors When Choosing Plastic for Insulation
When choosing a plastic as insulator, there are things that you need to consider and here are some of them:
Environment
The weather in your area affects the type of insulation you need. If you live in a cold place, you need insulation that keeps heat inside. If you live in a hot place, insulation helps keep your home cool.
Look at the R-value (thermal resistance) on the packaging or the product label, as it tells you how well the insulation works. A higher R-value means better insulation.
Water and Moisture Resistance
Some areas, like basements or bathrooms, can be wet or humid. If you put the wrong insulation there, it can soak up water and stop working.
Wet insulation can grow mold, which is bad for your health. Some types of plastics do a better job of keeping water out.
Fire Resistance
Some places need insulation that does not catch fire easily. If you are putting insulation near stoves, heaters, or electrical wires, choose fire-resistant plastics.
Intended Use
Different areas need different types of insulation. The insulation for an attic is not the same as the insulation for walls or floors. Appliances like refrigerators and water heaters also use special insulation. Make sure you choose the right type for each place.
Coste
Some insulation costs more than others. Expensive insulation may last longer and save you money on energy bills. If you are on a budget, look for insulation that is both affordable and good quality. Spending a little more now can help you save money later.
Applications of Plastic Insulation Materials
Below we discuss where each plastic insulation material can be used.
Polyurethane (PU)
You can use PU foam for insulating homes and buildings. Rigid boards work well for walls and roofs, while spray foam fills gaps and seals spaces. This makes buildings more energy-efficient.
Polietileno (PE)
PE foam is mainly used for insulating pipes to prevent them from freezing in cold weather. It is also found in HVAC systems to insulate air ducts.
Cloruro de polivinilo (PVC)
PVC is used in HVAC systems, construction, and vehicles. It is a good choice for outdoor insulation because of its durability.
Polyisocyanurate (PIR)
PIR is commonly used in commercial buildings and industrial spaces. It is a popular choice for insulating walls and roofs because it is easy to install.
Expanded Polystyrene (EPS)
EPS is useful for insulating walls, roofs, and floors. Many people choose it because it is easy to handle and install.
Extruded Polystyrene (XPS)
XPS is often used in underground areas like basements and foundations. It is also a common choice for roofing and wall insulation.
DEK - The Best Manufacturing Company for Plastic Parts
If you need help choosing the right materials for your project, DEK has the experience to guide you. We can also help manufacture high-quality plastic insulation for your needs. Contact us to get started!
Conclusión
Now you know the different types of plastic insulation materials and their uses. With the right plastic insulation, you can improve comfort and efficiency in your home, workplace, or industry.
If you work with metal casting, you know how important it is to get smooth, precise parts while keeping production efficient. Shell molding is one method that helps achieve high accuracy and consistency in manufacturing.
In this guide, you’ll learn what's shell molding, how it works, its applications, and much more.
What's Shell Molding?
Shell molding is a casting process that uses a thin shell of hardened sand to form the mold.
Unlike traditional sand casting, where the mold is made entirely of packed sand, shell molding uses a resin-coated sand mixture that creates a smoother and more precise mold. This results in castings with better surface finishes and tighter tolerances.
The Role of Shell Molding in the Manufacturing
Shell molding helps you make metal parts that are more precise and smoother than regular sand casting can achieve. This process offers fast production with less manual work.
If you need high-precision parts, like camshafts, shell molding is a better choice because sand casting isn’t accurate enough.
Pros and Cons of Shell Molding
If you automate shell molding, you can save money on labor. Other benefits include:
- Smooth surfaces and accurate shapes so less finishing work.
- The resin binder burns away during casting, so removing the final part is easy.
- Works well for making complex shapes.
- You can reuse the sand and resin mixture.
- The tools used are inexpensive, and production can start quickly.
- You can use this process for both ferrous and nonferrous metals.
To make the casting process work well, you often need special gating systems, but they cost a lot and create extra waste. Other downsides include:
- Phenolic resin used is expensive, though only a small amount is needed.
- The equipment costs a lot upfront.
- The final part may have tiny air pockets or shrinkage.
- Even with a smooth finish, some parts may still need extra work.
- If you don’t automate the process, it can take a lot of manual labor.
How Does Shell Molding Work?
First, you create the mold by covering a heated pattern with a sand-and-resin mixture. This hardens into a shell. The mold usually has two halves.
Once you remove the process, you clamp the two halves together and pour molten metal inside. After the metal cools and hardens, you break the mold to take out the finished part.
Step-by-Step Process of Shell Molding
Shell molding follows six main steps:
1. Create the Pattern
First, you need to make a metal pattern that matches the shape of the final part. This pattern is usually made from steel or iron.
If you’re working with reactive metals, you may need to use graphite instead. Each pattern usually represents one-half of the part, so you’ll need two patterns to form a complete mold.
2. Make the Mold
You can reuse the same pattern to create multiple molds. Start by coating the pattern with a lubricant, like calcium stearate. Then, heat it to 175-370°C (350-700°F).
Next, place the pattern over a box filled with a mixture of sand and resin. Flip the box so the sand and resin stick to the heated pattern, forming a shell. The heat cures the resin, hardening the shell.
3. Assemble the Mold
Once the shell has cooled, remove it from the pattern. Then, join the two halves of the shell mold inside a container called a flask.
To keep the mold stable, fill the space between the shell and the flask walls with a metal shot. Clamp the mold halves tightly together to prevent leaks.
4. Pour the Molten Metal
Now, pour the molten metal into the mold. This can be done manually or with an automated pouring machine.
5. Let the Metal Cool
The molten metal needs time to cool and solidify. Let it cool naturally at room temperature– using liquid coolants or forced cooling can change the metal’s structure and properties.
The exact cooling time depends on the type and size of the metal part.
6. Remove the Casting
Once the metal has fully cooled, remove the casting from the mold. You can do this by separating the two mold halves or breaking the mold apart.
If the pattern was properly lubricated before pouring, the mold material will come off easily.
What are the Metals Used in Shell Molding?
You can use many types of metals in shell molding and below are some of the most common ones.
Aleación de aluminio
Aleaciones de aluminio like ASTM A356, ASTM A413, and ASTM 360 are used when lightweight materials are needed instead of heavy steel. Aluminum also conducts heat and electricity well.
However, it’s not as strong as steel, and its production creates more greenhouse gases so it’s less eco-friendly.
Acero inoxidable
Stainless steel contains at least 10.5% chromium so it is highly resistant to rust and corrosion. It comes in different types, including ferritic, martensitic, austenitic, precipitation-hardened, and duplex stainless steel.
While stainless steel is less durable, it’s more brittle and has less tensile strength than carbon steel.
Cobre
Cobre is a soft, lightweight metal that is great for conductivity, machinability, and corrosion resistance. Most copper alloys work well in shell molding, except brass.
The downside is that copper alloys can be expensive and are not as strong as steel.
Acero dulce
Mild steel is a low-carbon steel that is strong, affordable, and easy to work with. It is commonly used in shell molding because it is ductile, weldable, and resistant to impact.
However, it rusts easily if not protected with coatings or treatments.
Acero aleado
Acero aleado contains different metals to improve strength, durability, and temperature resistance. Common grades used in shell molding include 20Mn, 45Mn, 40Cr, 42CrMo, and 20CrNiMo.
Each alloy has different properties, so you can choose one based on cost, strength, or corrosion resistance.
Hierro fundido
Cast iron used to be the most common metal for casting because of its strong properties. Even today, it is widely used in many industries.
Popular types of cast iron for shell molding include gray cast iron, nodular iron, white cast iron, malleable iron, and alloy cast iron.
Shell Molding vs Other Casting Processes
Shell molding is just one type of casting. Here’s how shell molding compares to other types:
Shell Molding vs Die Casting
Die casting and shell molding both produce metal parts, but their molds are very different. Die casting uses a permanent metal mold, also called a die, and injects molten metal under high pressure.
Shell molding, however, uses a disposable sand-and-resin mold and relies on the mold’s strength for precision instead of pressure. Die casting is a much faster process, but it only works for metals with low melting points and parts with simple shapes.
Shell Molding vs Injection Molding
Injection molding is another precise molding method, but it is used for plastics instead of metals. In injection molding, molten plastic is forced into a solid metal mold under high pressure.
Shell molding, on the other hand, pours molten metal into a temporary sand mold. The biggest difference between the two processes is the material– shell molding is for metals, while injection molding is for plastics.
Shell Molding vs Investment Casting
Investment casting works differently from shell molding. It starts with a wax pattern, which is coated in ceramic to create the mold. The wax is then melted away, leaving a cavity for the molten metal.
Shell molding, on the other hand, does not use wax. Instead, it forms a mold directly from a metal pattern and sand. Investment casting produces the smoothest surface finish, sometimes as fine as 1.3 microns, but it is a more complex and expensive process compared to shell molding.
Applications of Shell Mold Casting
Here are some common applications of shell molding in different industries:
Automóvil: Used to make engine blocks, cylinder heads, camshafts, crankshafts, and transmission housings.
Aeroespacial: Common for turbine blades and gear housings.
Industrial Machinery: Used for gears, valves, pump housings, and lever arms.
Electrical Equipment: Helps produce housings and components for electrical systems.
Oil and Gas: Used for valve bodies and custom precision components.
How Much Does Shell Molding Cost?
Shell molding usually costs between $0.25 and $0.30 per kilogram. It is more expensive than regular sand casting because the resin-infused sand costs more than ordinary casting sand.
Also, additional equipment is needed to heat and cure the resin-sand mixture, which increases the overall cost of production. For small production runs, shell molding is usually cheaper than die casting because it uses a simpler mold made of sand and resin.
However, shell molding is more expensive than die casting when producing a large number of parts because shell molding always requires new sand and resin for each batch.
What is the Quality of Shell Molding Products?
Shell molding creates high-quality finishes and precise dimensions compared to other casting methods. The smooth surface finish of shell-molded products reduces defects like cracks and corrosion.
The durability, wear resistance, and heat resistance of shell-molded products mostly depend on the type of metal used in the process.
Conclusión
Shell molding is a reliable casting method that offers high precision, smooth surfaces, and efficient production for a wide range of metal parts.
En DEK, we specialize in advanced manufacturing solutions, including high-quality shell molding services tailored to your needs. If you’re looking for precise, cost-effective casting solutions, contact us today and get a free quote.