The Hardware Stack
I started this journey in 2022. Like any systems engineer, I didn't just want to print toys; I wanted to manufacture functional parts. My lab currently runs on Anycubic hardware.
There are two distinct disciplines here: FDM (Fused Deposition Modeling) for structural parts, and SLA (Stereolithography) for high-detail resin work.
FDM: The Workhorse
Filament printing is reliable, provided you respect the physics of thermal expansion. I primarily print with two materials:
- PLA: The daily driver. Easy to print, rigid, but brittle. Great for prototyping enclosures.
- TPU: The challenge. Flexible filament is like trying to push a rope. I had to tune my retraction settings to 0.5mm and slow the print speed to 20mm/s to stop the extruder from jamming.
SLA: The Detail King
Resin printing is a different beast. The detail is microscopic, but the workflow is toxic. You aren't just a printer; you are a hazmat tech.
- Safety First: Nitrile gloves and a respirator are mandatory. Liquid resin is a sensitizer.
- Post-Processing: The print isn't done when it leaves the plate. It needs an IPA wash and a UV cure cycle. It is messy, but the results look like injection molded plastic.
Common Failures
In 3D printing, failure is the default state. Success is the anomaly.
- Bed Adhesion: If the first layer doesn't stick, the print is doomed. I use a textured PEI sheet and keep it clinically clean with Isopropyl Alcohol.
- Z-Wobble: If your lead screws aren't greased, you get banding artifacts. Maintenance is key.
- Wet Filament: TPU absorbs moisture from the air in hours. I print directly from a dry box to prevent steam bubbles popping in the nozzle.
Why It Matters
Being able to visualize a bracket, model it in CAD, and hold it in your hand 2 hours later is a superpower. It closes the loop between digital design and physical reality.