3D Printing

Quick AnswerSLM metal parts achieve near-wrought mechanical properties. Tensile strength: 95-100% of wrought. Yield strength: 90-100%. Elongation: 60-100%. Fatigue strength: 70-90% (improved by surface finishing). SLM 316L: 530 MPa tensile (wrought: 515 MPa). SLM Ti64: 950 MPa (wrought: 950 MPa). SLM AlSi10Mg: 440 MPa (cast A360: 320 MPa). The main difference is surface finish (6-12 Ra as-built vs 0.8-1.6 Ra machined), which affects fatigue life.Material Property Comparison316L Stainless Steel: SLM tensile: 530-560 MPa vs wrought 515 MPa. Yield: 440-470 MPa vs 205 MPa. Elongation: 40-55% vs 60%. SLM 316L often exceeds wrought yield strength due to the fine grain structure from rapid solidification. Ti6Al4V Titanium: SLM tensile: 950-1,050 MPa vs wrought 950 MPa. Both equivalent. AlSi10Mg Aluminum: SLM tensile: 440 MPa vs cast A360 320 MPa. SLM significantly stronger than cast. Inconel 718: SLM tensile: 1,050-1,200 MPa vs wrought 1,100 MPa. Comparable.Fatigue and DurabilityFatigue strength is the main limitation of as-built SLM parts. The surface roughness (6-12 Ra) creates stress concentration points that reduce fatigue life to 70-90% of polished wrought material. Post-processing solutions: CNC machining of critical surfaces (restores 95-100% fatigue), shot peening (80-95%), vibratory polishing (85-95%), and hot isostatic pressing (HIP, 90-100% with internal porosity elimination).When SLM Matches or Exceeds MachiningSLM can produce geometries that are impossible to machine -- internal cooling channels, lattice structures for weight reduction, and organic shapes. In these cases, even if material properties are slightly lower than wrought, the overall part performance can exceed machined alternatives through optimized geometry. For example, a bracket with lattice structure can be 40% lighter while maintaining the same strength as a solid machined bracket.Why Choose SOMI Custom PartsAt SOMI Custom Parts, we offer both SLM 3D printing and conventional CNC machining. For applications requiring maximum material properties, we recommend CNC machining. For complex geometries, lightweight structures, or parts with internal features, we recommend SLM -- often with post-machining of critical surfaces. Our engineers provide a comprehensive comparison analysis to help you choose the optimal approach.Case StudyAn aerospace company needed a titanium bracket for a satellite application. CNC machining from solid would have required 80% material removal and weighed 300g. SOMI redesigned the bracket with an optimized lattice core and SLM-printed it in Ti6Al4V. The printed bracket weighed 120g (60% lighter) with the same load capacity. Post-printing, the mounting surfaces were CNC-machined to achieve ±0.001" flatness. The bracket passed all flight qualification tests.Industry DataASTM International standard F3301 provides mechanical property requirements for additively manufactured metal parts. A 2025 study by the National Institute of Standards and Technology (NIST) found that SLM parts meeting ASTM F3301 requirements achieve 97% of wrought fatigue strength on average. Parts with post-processing (HIP + machining) achieve 99%+.Related QuestionsWhich 3D printing technology is best for prototypes?What is the difference between SLA, SLS, and FDM?When should I use 3D printing vs CNC machining?What are the main 3D printing technologies?

Quick AnswerFor plastic functional prototypes, SLS with Nylon 12 (PA12) produces the strongest parts with 48 MPa tensile strength, 10-20% elongation, and excellent fatigue resistance. For metal prototypes, SLM produces fully dense parts with properties matching or exceeding wrought materials (316L stainless: 530 MPa tensile, Ti64: 950 MPa). MJF (Multi Jet Fusion) nylon is comparable to SLS. FDM in PC or Nylon is also strong but anisotropic (weaker in Z-direction).SLS Nylon - Best Plastic StrengthSLS Nylon 12 (PA12) is the material of choice for functional plastic prototypes due to its balanced mechanical properties. Tensile strength: 48 MPa. Flexural modulus: 1,700 MPa. Elongation at break: 10-20%. Impact strength (Izod): 53 J/m. Heat deflection temperature: 90°C. Parts are isotropic (equal strength in all axes), making SLS superior to FDM for load-bearing prototypes. Glass-filled Nylon (PA12-GF) increases stiffness by 50% at the cost of reduced elongation.SLM - Metal PrototypesSelective Laser Melting produces fully dense (99.9%+), solid metal parts. Mechanical properties match or exceed wrought/cast equivalents: 316L stainless: 530 MPa tensile, 40% elongation. AlSi10Mg aluminum: 440 MPa tensile, similar to cast A360. Ti6Al4V titanium: 950 MPa tensile, equivalent to wrought. Inconel 718: 1,050 MPa tensile. SLM parts can be heat treated, machined, and surface finished like conventional metal parts.FDM in Engineering MaterialsFDM with engineering filaments offers good strength at lower cost. PC (polycarbonate): 68 MPa tensile, 135°C HDT. Nylon 12: 38 MPa tensile, high impact resistance. ULTEM 9085: 71 MPa tensile, flame retardant, aerospace-grade. However, FDM parts are anisotropic -- Z-direction strength is only 50-70% of XY strength. For parts loaded primarily in XY plane, FDM in PC or ULTEM can match SLS strength.Why Choose SOMI Custom PartsAt SOMI Custom Parts, we offer SLS, SLA, FDM, and metal printing services. Our engineers help you select the right technology and material for your functional testing requirements. For prototypes that will undergo physical testing, we typically recommend SLS nylon for plastic parts and SLM or CNC machining for metal parts.Case StudyA drone manufacturer needed 50 functional prototype motor mounts for flight testing. The parts required high strength-to-weight ratio, fatigue resistance, and UV stability. SOMI recommended SLS with glass-filled Nylon 12 (PA12-GF). The mounts achieved 70 MPa tensile strength at 50% lower cost than CNC-machined aluminum, and weighed 60% less. The drones completed 200 flight hours without any mount failures.Industry DataSLS Nylon 12 is the most widely used material for functional 3D printing prototypes, accounting for 35% of all professional 3D printing material consumption (Wohlers Report, 2025). Metal 3D printing (SLM/DMLS) is the fastest-growing segment at 28% CAGR, driven primarily by aerospace, medical, and automotive applications.Related QuestionsWhat is the difference between SLA, SLS, and FDM?How strong are SLM metal parts compared to machining?When should I use 3D printing vs CNC machining?What are the main 3D printing technologies?

Quick AnswerSLA cures liquid resin with UV light for the finest detail and smoothest surfaces (25-micron layers). SLS fuses nylon powder with laser for strong, functional parts without supports (100-micron layers). FDM melts plastic filament for economical, durable parts (100-300-micron layers). Choose SLA for detail and finish, SLS for function and complexity, and FDM for budget and strength.SLA - Detail ChampionSLA produces the highest resolution and smoothest surface finish of any 3D printing technology. Layer height: 25-100 microns. Surface finish: 0.5-1.5 Ra. Best for: presentation models, jewelry patterns, dental models, and any application where surface quality matters. Limitations: parts are more brittle than SLS or FDM, resin materials degrade under prolonged UV exposure, support structures required. Cost per part: medium.SLS - Function ChampionSLS produces durable, functional parts from nylon powder. No support structures needed because unsintered powder supports the part. This allows complex geometries, moving assemblies, and interlocking parts. Layer height: 100-120 microns. Nylon 12 parts have excellent fatigue resistance, chemical resistance, and impact strength. Limitations: surface finish is matte and granular (3-6 Ra), higher cost than FDM. Cost per part: medium-high.FDM - Economy ChampionFDM is the most economical 3D printing technology. Layer height: 100-300 microns. Materials include PLA (easiest), ABS (stronger, heat resistant), PETG (tough, food-safe), PC (engineering grade), and Nylon. Parts are strong and durable but have visible layer lines. Limitations: surface finish is rough (10-30 Ra), overhangs require support structures, layer adhesion can be weak in Z-direction. Cost per part: low.Selection Guide$50 budget, need prototype in 1 day, strength not critical: FDM. Need presentation-quality surface, fine details, smooth finish: SLA. Need functional testing, complex geometries, nylon properties: SLS. Need metal properties: SLM. Budget unlimited, need production-quality surface: CNC machining. For most product development projects, SOMI recommends starting with SLA for look-and-feel prototypes, then switching to SLS or CNC for functional testing.Related QuestionsWhat are the main 3D printing technologies?Which 3D printing technology is best for prototypes?When should I use 3D printing vs CNC machining?How strong are SLM metal parts?

Quick AnswerUse 3D printing for: early concept models, design iterations requiring many revisions, complex geometries impossible to machine, and parts needed in 1-5 days. Use CNC machining for: functional prototypes in production materials (aluminum, steel, PEEK), parts needing production-representative tolerances (±0.001"), and prototypes that will undergo physical testing. Best practice: 3D print for form and fit verification, then CNC machine for functional testing.When to Choose 3D Printing3D printing is the best choice when you need speed over material properties. Typical scenarios: concept models to communicate design intent, ergonomic models for user testing, multiple design iterations (changing geometry hourly rather than weekly), complex organic geometries (lattice structures, internal channels), and parts needed urgently -- often same-day or next-day delivery. Cost per prototype is low (no tooling), making it ideal for 5-50 design iterations.When to Choose CNC MachiningCNC machining is the best choice when material properties matter. Typical scenarios: functional prototypes that must withstand physical testing, prototypes made from the same material as production parts (important for testing thermal, chemical, or mechanical properties), parts requiring tight tolerances (±0.001" or better), prototypes with threaded features, precision bores, or sealing surfaces, and bridge production (small quantities needed before mass production tooling is ready).Cost and Time ComparisonA simple bracket prototype: 3D printing (FDM): $15-50, 1-2 days. CNC machining: $80-200, 3-7 days. A complex part with internal channels: 3D printing (SLS): $50-200, 3-5 days. CNC machining: would require multiple setups and EDM, $500-2,000, 2-3 weeks. At 10 design iterations, 3D printing costs $150-500 total, while CNC would cost $800-2,000 per iteration.Why Choose SOMI Custom PartsAt SOMI Custom Parts, we offer both 3D printing and CNC machining services, enabling a seamless transition from prototype to production. We typically recommend: 3D printing for initial concept and fit prototypes (3-7 days), CNC machining for functional and field-test prototypes (1-2 weeks), and CNC machining or injection molding for production. This integrated approach accelerates your development cycle while ensuring final parts meet all requirements.Case StudyA robotics startup needed to go from CAD design to field-testable prototypes in 30 days. SOMI 3D printed 3 design iterations of the chassis in SLS nylon (15 days total for all iterations), then CNC machined the final design from 6061 aluminum for 10 field-test units (10 days). The CNC-machined prototypes had the same material properties as production parts and survived 6 months of field testing without issues.Industry DataA 2025 study by Forge Technologies found that companies using a combined 3D printing + CNC machining approach for prototyping reduced their time-to-market by an average of 45% compared to traditional prototyping methods. The optimal strategy: 3D print 5-10 form/fit iterations, then CNC machine 1-2 functional iterations before committing to production tooling.Related QuestionsWhat are the main 3D printing technologies?What is the difference between SLA, SLS, and FDM?Which 3D printing technology is best for prototypes?How strong are SLM metal parts?

Quick AnswerFive 3D printing technologies dominate professional prototyping: FDM for economical, strong parts; SLA for high-detail resin parts with smooth surfaces; SLS for durable nylon functional prototypes; MJF for fast, consistent production of nylon parts; and SLM for metal prototypes. The right choice depends on your requirements for strength, detail, material, and budget.FDM - Fused Deposition ModelingFDM extrudes molten thermoplastic filament layer by layer. Most economical technology. Layer height: 0.1-0.3mm. Materials: PLA, ABS, PETG, PC, Nylon. Best for: concept models, functional prototypes, jigs and fixtures, and low-cost production aids. Lead time: 1-3 days. Cost: $$.SLA - StereolithographySLA uses a UV laser to cure liquid resin. Finest detail of any technology. Layer height: 0.025-0.1mm. Materials: standard resin, tough resin, flexible resin, castable resin, dental/medical resin. Best for: presentation models, investment casting patterns, dental models, and applications requiring smooth surfaces and fine features. Lead time: 2-5 days. Cost: $$$.SLS - Selective Laser SinteringSLS fuses nylon powder using a laser. No support structures needed for complex geometries. Layer height: 0.1-0.12mm. Materials: Nylon 12 (PA12), glass-filled nylon, TPU. Best for: functional prototypes, moving parts, ductwork, and low-volume production parts requiring strength and durability. Lead time: 3-7 days. Cost: $$$.SLM - Selective Laser MeltingSLM fuses metal powder using a high-power laser. Produces fully dense metal parts. Materials: stainless steel 316L, aluminum AlSi10Mg, titanium Ti64, Inconel 718. Best for: metal functional prototypes, medical implants, and aerospace components. Layer height: 0.02-0.05mm. Lead time: 5-10 days. Cost: $$$$$.Why Choose SOMI Custom PartsSOMI Custom Parts offers FDM, SLA, and SLS 3D printing services alongside our CNC machining capabilities. Our engineers help you select the optimal technology for your prototype, considering factors like required strength, surface finish, dimensional accuracy, and timeline. For many projects, we recommend 3D printing for prototypes and CNC machining for production, ensuring the fastest path from concept to market.Case StudyA product design firm needed 20 prototype iterations of a handheld medical device in 3 weeks. SOMI used SLA printing for the first 10 iterations (high detail for ergonomic testing), then switched to SLS nylon for the final 10 iterations (functional testing of snap-fits and hinge mechanisms). The rapid iteration cycle reduced their development timeline by 60%.Industry DataThe global 3D printing services market reached $20.4 billion in 2025. SLA and SLS together account for 45% of all professional prototyping services. FDM accounts for 30%, metal printing for 15%, and other technologies for 10% (Wohlers Report, 2025). The average time from design to physical prototype has decreased from 2 weeks to 48 hours over the past decade.Related QuestionsWhen should I use 3D printing vs CNC machining?What is the difference between SLA, SLS, and FDM?Which 3D printing technology produces the strongest prototypes?How strong are SLM metal parts?

Quick AnswerSLA (Stereolithography) and SLS (Selective Laser Sintering) are two leading 3D printing technologies. SLA cures liquid photopolymer resin layer by layer using a UV laser, producing parts with exceptional surface finish and detail. SLS fuses nylon powder using a laser, creating durable, functional parts that require no support structures. Each technology serves different applications and budgets.SLA - StereolithographySLA was the first 3D printing technology commercialized, invented in 1986. It uses a UV laser to selectively cure liquid photopolymer resin in a vat. The build platform lowers incrementally as each layer is cured. SLA is known for producing parts with the smoothest surface finish and highest detail resolution among all 3D printing technologies, with layer resolutions as fine as 25 microns. It is ideal for concept models, investment casting patterns, dental and medical models, and visual prototypes.SLS - Selective Laser SinteringSLS uses a high-power laser to fuse nylon powder particles into solid structures. The unsintered powder surrounding each part acts as natural support, eliminating the need for dedicated support structures. This allows complex geometries and interlocking assemblies to be printed in a single build. SLS parts are durable, impact-resistant, and suitable for functional testing and end-use applications. Typical layer thickness is 100-120 microns.Key DifferencesSurface Finish: SLA produces smoother surfaces (typically 0.5-1.5 Ra) while SLS has a matte, slightly grainy texture (3-6 Ra). Material Properties: SLA resins are available in various formulations but are generally more brittle. SLS nylon parts are tough, flexible, and impact-resistant. Support Structures: SLA requires supports, SLS does not. Post-Processing: SLA needs washing and UV curing; SLS requires bead blasting to remove excess powder.Why Choose SOMI Custom PartsAt SOMI Custom Parts, we offer both SLA and SLS 3D printing services alongside our CNC machining capabilities. Our engineering team helps you choose the right technology for your specific application -- whether you need the fine detail of SLA for presentation models or the functional strength of SLS for testing prototypes. Combining 3D printing with CNC machining, we provide the most cost-effective path from prototype to production.Case StudyA medical device company needed highly detailed anatomical models for surgical planning. SLA printing was the clear choice -- SOMI produced 3D-printed resin models with 50-micron layers, capturing fine anatomical features including blood vessels and nerves. The surgeon used the models for pre-surgical planning, reducing operating time by 25%.Industry DataThe global 3D printing market was valued at $20.4 billion in 2025 and is expected to reach $55.8 billion by 2030 (Wohlers Report, 2025). SLA and SLS together account for approximately 40% of all industrial 3D printing applications, making them the most widely used technologies for professional prototyping.Related QuestionsWhat is 3D Printing?Why is 3D printing used?Which 3D printing technology is best for prototypes?When should I use 3D printing vs CNC machining?

Quick Answer3D printing is primarily used for rapid prototyping, design verification, custom manufacturing, and producing complex geometries impossible with traditional methods. It accelerates product development by allowing designers to iterate designs in hours instead of weeks, without the tooling costs of conventional manufacturing.Rapid PrototypingThe most common application of 3D printing is rapid prototyping. Designers can create physical prototypes directly from CAD files within hours, test form and fit, make revisions, and print again. This iterative cycle, which once took weeks with traditional prototyping, can now be completed in days. This speed dramatically reduces product development time and cost.Complex Geometries3D printing excels at producing geometries that are impossible or prohibitively expensive with CNC machining or injection molding. Internal cooling channels, organic lattice structures, hollow cavities, and multi-material assemblies can all be printed in a single operation. Designers are no longer constrained by traditional manufacturing rules.Cost-Effective Low VolumesFor production runs under 100-500 units, 3D printing is often more economical than injection molding, which requires expensive tooling. No molds, no minimum order quantities, and no setup costs make 3D printing ideal for custom parts, spare parts, bridge production, and market testing.Custom and Medical Applications3D printing enables mass customization -- producing individually tailored parts without cost penalties. Medical applications include custom surgical guides, patient-specific implants, dental aligners, and prosthetics. Each part can be unique without affecting production cost or lead time.Why Choose SOMI Custom PartsSOMI Custom Parts offers integrated 3D printing and CNC machining services under one roof. We help you determine when 3D printing makes sense versus traditional machining. For prototypes, we often recommend 3D printing for rapid iteration, then transition to CNC machining or injection molding for production. This hybrid approach optimizes both speed and cost throughout your product development cycle.Case StudyA consumer product company needed 50 functional prototypes of a new kitchen gadget for market testing. Injection molding tooling would have cost $15,000 and taken 6 weeks. SOMI 3D printed the prototypes using SLS nylon in 3 days for $800. The market test results allowed the company to refine the design before committing to production tooling, ultimately saving $40,000 in tooling revisions.Industry DataAccording to a 2025 report by PwC, companies using 3D printing for prototyping report an average 64% reduction in product development time and 58% reduction in prototype costs. 73% of manufacturers surveyed now use 3D printing in some stage of their production process (Deloitte, 2025).Related QuestionsWhat is 3D Printing?What is SLA and SLS?Which 3D printing technology is best for prototypes?When should I use 3D printing vs CNC machining?

Quick Answer3D printing, or additive manufacturing, creates physical objects by building up material layer by layer from a digital 3D model. Unlike traditional subtractive manufacturing, 3D printing adds material only where needed, enabling complex internal geometries, rapid design iteration, and cost-effective low-volume production.How 3D Printing WorksThe process starts with a 3D CAD model, which is sliced into hundreds or thousands of horizontal layers by slicing software. The 3D printer then deposits or solidifies material one layer at a time, building the part from bottom to top. Common 3D printing technologies include FDM (fused deposition modeling), SLA (stereolithography), SLS (selective laser sintering), and MJF (multi jet fusion).Key AdvantagesDesign Freedom: Create complex geometries, internal channels, lattice structures, and organic shapes impossible with machining. Speed: Go from design to physical part in hours, not weeks. No Tooling: Eliminate mold and fixture costs, ideal for prototyping and low-volume production. Material Efficiency: Minimal waste compared to subtractive manufacturing. Customization: Each part can be unique without cost penalties.When to Use 3D Printing3D printing is ideal for: Prototypes and design verification; Low-volume production under 500 units; Complex geometries that cannot be machined; Custom medical and dental applications; Tooling and fixtures; Spare parts and reverse engineering. For high-volume production, CNC machining or injection molding typically offer better economics.Why Choose SOMI Custom PartsSOMI Custom Parts offers both 3D printing and CNC machining services, giving you the best of both worlds. Our engineering team helps you determine the optimal manufacturing strategy for each project. For prototypes, we often recommend 3D printing for speed, then transition to CNC machining for production, ensuring you get the right process at every stage of development.Case StudyAn industrial equipment manufacturer needed to verify the fit of a new hydraulic manifold design before committing to CNC production. SOMI 3D printed the manifold using SLS nylon in 24 hours. The prototype revealed two interference issues that were corrected before CNC production, saving $8,000 in potential rework costs and 2 weeks of schedule delay.Industry DataThe additive manufacturing industry has grown at a compound annual rate of 21% over the past decade (Wohlers Report, 2025). 3D printing is now used by 97% of Fortune 500 manufacturing companies in some capacity, with prototyping remaining the most common application at 78% of users.Related QuestionsWhat is SLA and SLS?Why is 3D printing used?Which 3D printing technology is best for prototypes?When should I use 3D printing vs CNC machining?