# 3D printing
**3D printing**, or **additive manufacturing**, is the construction of a solid object from a digital model by adding material, usually one thin layer at a time, rather than by cutting it away from a block or forcing it into a mould. A file describing the surface of the part is sliced into layers, and a machine deposits, fuses, cures or binds each layer onto the one below until the part is complete. The method reverses the logic of machining, where every feature costs a cut, and of [[Casting|casting]], where every shape costs a mould: an internal passage or a lattice costs no more to print than a solid block, while a large, plain, precise surface costs more, because it must be built up and then finished.
In the microsim below the reader tilts an L-shaped bracket on the build plate through an angle φ from 0° to 90°. Every face is tested against the 45° rule of the design-for-additive literature, `needs_support = n_z < −sin(45°)`, where *n_z* is the vertical component of the face's outward normal: faces that need support turn red, self-supporting faces green, the readout gives the supported area, the build height and the layer count at an illustrative layer thickness, and a *teardrop hole* toggle reshapes the bracket's round horizontal hole so that its unsupported crown disappears. On the [[Materials_science|Materials science]] flagship this article is the *Additive manufacturing* section of Part IV, Fundamentals › Processing; its second-wave sibling, [[Design_for_additive_manufacturing|design for additive manufacturing]], carries the process design-rule checker built from the same book.
## Terminology
*Additive manufacturing* is the term of the standards: ISO/ASTM 52900 defines it as joining materials to make parts from 3D model data, usually layer upon layer, in contrast to subtractive and formative [[Manufacturing|manufacturing]], and sorts the processes into seven families.[^iso52900] *3D printing* began as the name of one family, the binder-jetting process patented at the Massachusetts Institute of Technology in the early 1990s, in which a print head deposits liquid binder onto a bed of powder,[^sachs1993] and became the public's word for all of them once desktop machines arrived. *Rapid prototyping* is the older industrial name from the years when the parts were only models, and *stereolithography*, *fused deposition modeling* and *selective laser sintering* are proprietary names that turned generic. The book behind this article, *Additive Manufacturing Essentials*, writes AM throughout, and its shorthands are used below: PBF for powder bed fusion, DED for directed energy deposition, FDM for material extrusion and SLS for polymer laser [[Sintering|sintering]].[^barnes-ch4]
## History
The processes arrived in a cluster in the 1980s, each from a different laboratory and each with a different way of turning a layer into a solid, and the industry that grew from them has spent four decades scaling them up from models to certified parts.
### 1980s
The first working process was stereolithography. Charles Hull's patent, filed in 1984 and granted in 1986, describes a vat of liquid photopolymer cured layer by layer by an ultraviolet beam steered from a computer model,[^hull1986] and the STL file format devised for it is still the field's common language; it was born with 1980s stereolithography "and the file protocol hasn't changed since."[^barnes-stl] Before the decade was out Carl Deckard had patented selective laser sintering, in which a [[Laser|laser]] fuses a bed of [[Polymer|polymer]] powder,[^deckard1989] and Scott Crump had filed the patent for fused deposition modeling, the extrusion of a [[Thermoplastic|thermoplastic]] filament through a heated [[Nozzle|nozzle]] that became the desktop printer.[^crump1992]
### 2000s
Metal parts began to be made for use rather than for show, as laser melting of [[Titanium|titanium]], [[Nickel|nickel]] and [[Steel|steel]] powders in a bed, today's [[Selective_laser_melting|powder bed fusion]], and the deposition of metal from powder or wire fed into a beam or arc, today's [[Laser_metal_deposition|directed energy deposition]], matured into processes that aerospace and medical customers could qualify. The foundational patents began to expire twenty years after filing, the fused-deposition patent of 1989 in 2009 (derived from the patent's dates),[^crump1992] and the open-source RepRap project, begun in 2005 with the aim of a printer that could print most of its own parts, showed how cheaply an extrusion printer could be built.[^reprap2011]
### 2010s
The 2010s were the decade of the desktop printer and of industrial metal AM at once. Consumer [[Fused_filament_fabrication|extrusion printers]] built on the RepRap designs spread by the hundreds of thousands, and at the other end of the scale appeared the large-format machines the book uses to bound the field: a polymer extruder with a 240 by 90 by 72 inch build envelope, a metal powder bed of 31.5 by 15.75 by 19.68 inches, and wire-fed deposition machines up to 19 feet long.[^barnes-envelopes]
### 2020s
The present decade is one of consolidation. *Additive Manufacturing Essentials*, published in 2025, describes a maturity model for powder bed fusion running from Phase 0 to Phase 4, experiment to qualified production,[^barnes-maturity] and treats certification and qualification in chapters of their own.[^barnes-cert] Its large-part case is a seven-foot excavator boom of nearly 400 pounds of low-cost steel, built vertically by wire-fed deposition in five days with self-supporting teardrop holes and a throw-away substrate.[^barnes-boom] The build volume, the book notes, is the first process constraint and grows every year.[^barnes-envelopes]
## Benefits of 3D printing
The benefits are geometric, logistical and economic. Curved internal channels, [[Metal_foam|lattices]] and parts consolidated from many pieces into one cost nothing extra to print, and the generative-design tools the book describes optimize a part against constraints that include the manufacturing overhang angle.[^barnes-generative] A part exists as a file until it is needed, so spares can be printed where and when they are wanted instead of stocked. There is no tooling, so the first part costs the same as the thousandth, which makes small batches and one-off customization cheap, and the near-net shape wastes less of an expensive [[Superalloy|alloy]] than machining it from a billet. The book's list of what build orientation alone affects, build time and material, height and layer count, surface roughness, thermal cycling and residual stress, [[Microstructure|microstructure]] and post-processing, is also a list of what the designer must now manage that a mould once fixed.[^barnes-orientation]
## General principles
Every additive process follows the same chain: a solid model is tessellated into a surface file, the file is sliced into layers, a build plan sets orientation, supports and toolpath, the machine builds, and the part is finished. The book lays the chain out as an eight-step design workflow.[^barnes-workflow]
### Modeling
The part begins as a solid model and becomes an STL file, "a faceted representation of the part that is created by tessellation, a process that approximates the boundary of an object with many triangles."[^barnes-stl] "The more triangles created, the more accurate the tessellation, but the larger the .STL file size," and since "the AM machine will print whatever the .STL surface is defined as," a coarse file prints faceted.[^barnes-stl] The trade is quantifiable. For *n* equal facets around a circle of radius *R* the chord error is `δ = R·(1 − cos(π/n))`, a standard [[Geometry|geometric]] relation rather than the book's: at R = 10 mm, six facets miss the circle by 1.34 mm, twenty-four by 0.086 mm and ninety-six by 0.005 mm, while a binary STL of a capped cylinder grows from about 1 to 19 kilobytes over the same range (derived).[^manual12] Newer formats add units, colour, multiple materials and lattice descriptions that STL lacks.[^barnes-stl]
### Printing
The build plan specifies "the orientation and layout of the part(s) on the build platform, including layer thickness, support structures (if needed), and the toolpath."[^barnes-orientation] Orientation is the decision the microsim is built around, because in the powder-bed and extrusion processes a face that hangs too far past the layer below it has nothing to build on. The book's Table 4.4 states the rule for both: "keep features < 45 degrees from vertical z-plane," and for extrusion "the general golden rule to build at 45 degrees or steeper still applies."[^barnes-table44][^barnes-fdm] Read geometrically, with *z* the build direction and *n* the outward unit normal of a face, a face is downward-facing when *n_z* is negative and its angle from vertical is `asin(|n_z|)`, so support is needed exactly when `n_z < −sin(45°) = −0.7071`: a horizontal ceiling (n_z = −1) needs support, a vertical wall (n_z = 0) never does, and a 45° chamfer sits on the boundary.[^manual12]
The bracket makes the rule bite. Lying flat, the underside of its horizontal arm is a ceiling and turns red; tilting the bracket by φ rotates that normal to `n_z = −cos φ`, so the arm becomes self-supporting once φ passes 45°, but the same tilt turns the formerly vertical leg into an overhang with `n_z = −sin φ`, which needs support once φ passes 45°. At 45° both faces sit on the threshold, so no tilt minimizes both the support area and the build height. Height is the price of the tilt: for an illustrative bracket with a 50 mm arm and a 50 mm leg the bounding-box height runs from 50 mm flat to 71 mm at 45° and back to 50 mm on edge, which at an illustrative 50 µm layer is 1,000, 1,414 and 1,000 layers (derived), and every layer costs time, material and a thermal cycle.[^barnes-orientation] The round horizontal hole has a crown that is a ceiling at any tilt; the teardrop toggle replaces it with two 45° faces, the book's remedy for holes and cavities along *z*.[^barnes-teardrop] The threshold is process-specific: polymer laser sintering needs no supports because the unfused powder holds the part, and directed energy deposition can tilt the table instead of the part, so the sim names its process on screen.[^barnes-table44][^barnes-ded-tilt]
### Finishing
Supports are broken or dissolved away, and internal supports are designed out because those left inside "may be difficult (or impossible) to remove."[^barnes-passages] The layered surface carries staircasing, "a regular interruption in the part surface that looks like a staircase," worst on surfaces at a low angle to the build plane;[^barnes-staircase] for a layer thickness *t* and a surface at angle α from the plane the cusp height is `t·cos α`, a standard relation the book does not give, so a 0.2 mm layer leaves a 0.14 mm cusp at 45° and 0.19 mm at 15° (derived).[^manual12] Metal parts are [[Heat_treating|heat-treated]] to relieve residual stress, cut from the build plate and machined wherever a fit matters.[^barnes-table46]
### Materials
The materials are polymers first, then metals, [[Ceramic|ceramics]] and [[Composite_material|composites]], surveyed by process in the book's materials chapter.[^barnes-ch3] Extrusion prints thermoplastics whose smallest feature is the nozzle diameter and whose large flat surfaces "tend to curl," with properties anisotropic along *z*;[^barnes-fdm][^barnes-table44] laser sintering prints polymer powders, [[Nylon|nylon]] above all; vat processes cure photopolymers. Metal powder-bed fusion handles [[Titanium_alloys|titanium]], nickel and [[Aluminium_alloy|aluminium]] alloys and [[Stainless_steel|steels]], and the book warns that large titanium structures can crack from residual stress and that distortion needs process simulation rather than a rule of thumb.[^barnes-distortion] Wire-fed deposition builds in weldable alloys, and features "less than .39 inches (10mm) thick" are difficult without post-process milling.[^barnes-wire]
### Multi-material 3D printing
Some processes deposit more than one material in a build: extrusion machines with two nozzles print a soluble support beside the part or two colours, and material jetting lays droplets of different photopolymers side by side to grade stiffness or colour. Only the newer file formats the book lists, not STL, can describe such a part.[^barnes-stl]
### 4D printing
A part printed from a material that responds to heat, moisture or light can change shape after it is built, and 4D printing names that programmed change. It is a research subject rather than a production method, resting on the control of composition that multi-material printing provides.
## Processes
The seven process families of the standard are vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, sheet lamination and directed energy deposition.[^iso52900] The book's design tables treat the four that carry most industrial work, and their rules of thumb are the most useful comparison of them, because allowables belong to processes, not to parts:[^barnes-table46][^manual12]
| rule (inches) | PBF | DED | FDM | SLS |
|---|---|---|---|---|
| minimum wall | > 0.016 | not given; wire-fed < 0.39 difficult | > 0.047 | > 0.028 |
| minimum hole | > 0.020 | > 0.2 blown powder; > 1 wire-fed | > 0.040 | > 0.068 |
| minimum gap | > 0.020 | not given | > 0.020 | > 0.031 |
| general tolerance | ±0.005 | ±0.008 blown powder | ±0.004 XY, ±0.010 Z | ±0.012 |
| nesting spacing | > 0.125 | > 0.5 | > 0.100 | > 0.175 |
The same 0.030-inch wall passes a metal powder bed and a polymer sinter and fails a desktop extruder (derived). Powder bed fusion melts or sinters a bed of powder with a laser or [[Electron|electron]] beam and must avoid trapped powder; directed energy deposition melts powder or wire as it is fed, a close cousin of [[Welding|welding]] that can weld-repair an existing part; polymer laser sintering needs no supports and nests parts in three dimensions.[^barnes-table44][^barnes-table46] The allowables are current practice that "process development could always expand."[^barnes-allowables]
## Applications
The uses follow the economics: wherever geometry is complicated, volumes are small or the part must be customized, additive manufacturing competes, and wherever a simple shape is wanted by the million it does not. The three cases below are the ones the sources behind this page can vouch for.
### Transportation
[[Aerospace_engineering|Aerospace]] and heavy equipment led the metal adoption because their parts are expensive, complicated and few. The book's large-part case comes from construction equipment: the excavator boom above, built as a hollow, symmetric shape against warping and machined only at its mating interfaces.[^barnes-boom] The envelope table shows why such parts are deposition jobs: the metal powder bed it cites holds under six cubic feet, while the wire-fed machines reach nineteen feet.[^barnes-envelopes]
### Health
[[Medicine|Medical]] devices were among the first production uses, because every patient is a custom part: dental appliances, surgical guides and implants matched to a scan. In the United States the Food and Drug Administration issued guidance in 2017 on the technical considerations for additively manufactured medical devices, covering design, material controls, post-processing and testing.[^fda2017]
### Hobbyists
The RepRap project, begun at the University of Bath in 2005, set out to build a rapid prototyper that could reproduce most of its own parts, released its designs under an open licence, and seeded the desktop-printer industry and the maker communities around it.[^reprap2011] Its descendants in home workshops print the same thermoplastics and obey the same 45° rule as the industrial machines.
## Legal aspects
The law meets additive manufacturing where a file becomes an object: in the patents that covered the processes and have now expired, in the regulation of what may be printed and by whom, and in the certification of parts for service in aircraft and in bodies.
### Intellectual property
The founding process patents have expired. Hull's stereolithography patent of 1986, Deckard's sintering patent of 1989 and Crump's extrusion patent of 1992 all ran out by the end of the 2000s (derived from their filing and grant dates), and the desktop industry followed within a few years.[^hull1986][^deckard1989][^crump1992] What remains contested is the model file, which can be copied like any other file, and whether printing a protected object from one infringes on the part of the printer or of the publisher.
### Aerospace regulation
An aircraft part must be certified, and a process must be qualified before its parts can be. *Additive Manufacturing Essentials* treats the two in separate chapters,[^barnes-cert] and its account of the digital thread from design to inspection lists up to six software types and thirteen risk steps between a concept and a finished part.[^barnes-risks] Nondestructive inspection, including radiographic and computed-tomography examination of internal features, is part of that thread.[^barnes-ndt]
### Quality assurance
[[Quality_assurance|Quality]] in a process that builds a part from thousands of layers means controlling the process rather than inspecting the part alone. The book's maturity model for powder bed fusion, Phases 0 to 4, is a scale of that control,[^barnes-maturity] and its warning that distortion needs process simulation, not a rule of thumb, is why the microsim's readouts stop at geometry.[^barnes-distortion]
## Health and safety
Desktop extrusion printers emit ultrafine particles and volatile organic compounds as they melt filament, at rates that depend on the polymer, and belong in ventilated rooms.[^stephens2013] Metal powders are the industrial hazard: fine titanium and [[Aluminium|aluminium]] powders are reactive, and the enclosures, inert atmospheres and handling procedures of a metal machine keep them out of lungs and away from ignition. Photopolymer resins are skin sensitizers, and the beams of the fusion processes are enclosed like any other industrial beam.
## Impact
The technology has been forecast to change who makes things and where, and the forecasts have partly come true: the file has become a unit of manufacturing, and the printer a tool that individuals as well as factories own.
### Social change
Manufacturing that needs no tooling can be distributed: a file made in one place is printed in another, and a hospital, a school or a ship can carry a printer instead of a store. The maker communities that grew from the RepRap project put the tools of small-scale manufacturing into hands that had never held them.[^reprap2011]
### Environmental change
Additive manufacturing wastes less of a machined billet, because the part is built near its final shape, and it can lighten a part by putting material only where the loads are. Against that, the processes are energy-intensive per kilogram and the feedstocks are specialized, so the balance is assessed part by part, not for the technology as a whole.
## See also
- [[Design_for_additive_manufacturing]]
- [[Selective_laser_melting]]
- [[Fused_filament_fabrication]]
- [[Laser_metal_deposition]]
- [[Sintering]]
- [[Welding]]
- [[Speeds_and_feeds]]
- [[List_of_3D_printing_software]]
## References
[^iso52900]: ISO/ASTM 52900, *Additive manufacturing — General principles — Fundamentals and vocabulary*. Geneva: International Organization for Standardization; West Conshohocken: ASTM International. (Edition year and clause to pin.)
[^hull1986]: Hull, C. W. (1986). "Apparatus for production of three-dimensional objects by stereolithography." U.S. Patent 4,575,330, filed August 8, 1984, granted March 11, 1986.
[^deckard1989]: Deckard, C. R. (1989). "Method and apparatus for producing parts by selective sintering." U.S. Patent 4,863,538, filed October 17, 1986, granted September 5, 1989.
[^crump1992]: Crump, S. S. (1992). "Apparatus and method for creating three-dimensional objects." U.S. Patent 5,121,329, filed October 30, 1989, granted June 9, 1992.
[^sachs1993]: Sachs, E. M.; Haggerty, J. S.; Cima, M. J.; Williams, P. A. (1993). "Three-dimensional printing techniques." U.S. Patent 5,204,055, granted April 20, 1993. (Filing date to pin.)
[^reprap2011]: Jones, R.; Haufe, P.; Sells, E.; Iravani, P.; Olliver, V.; Palmer, C.; Bowyer, A. (2011). "RepRap – the replicating rapid prototyper." *Robotica* 29 (1): 177–191. (DOI to pin; not a Portal Book.)
[^stephens2013]: Stephens, B.; Azimi, P.; El Orch, Z.; Ramos, T. (2013). "Ultrafine particle emissions from desktop 3D printers." *Atmospheric Environment* 79: 334–339. (DOI to pin; not a Portal Book.)
[^fda2017]: U.S. Food and Drug Administration (2017). *Technical Considerations for Additive Manufactured Medical Devices: Guidance for Industry and Food and Drug Administration Staff*. Silver Spring, Maryland: FDA, Center for Devices and Radiological Health. (Page to pin.)
[^barnes-ch4]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, Design for Additive Manufacturing, pp. 75–100.
[^barnes-ch3]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 3, AM Materials, pp. 49–74 (page to pin).
[^barnes-workflow]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, Table 4.1, the eight-step AM design workflow, p. 76.
[^barnes-stl]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, STL tessellation, export errors and alternative formats, pp. 78–79.
[^barnes-orientation]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, the build plan and the effects of orientation, p. 81.
[^barnes-staircase]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, staircasing, pp. 81–82.
[^barnes-table44]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, Table 4.4, orientation and nesting rules by process, pp. 82–83.
[^barnes-distortion]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, residual stress, cracking and distortion, pp. 83–84.
[^barnes-ndt]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, reference to nondestructive testing and radiographic/CT inspection, p. 84.
[^barnes-teardrop]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, teardrop holes and cavities along z, pp. 85 and 93.
[^barnes-table46]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, Table 4.6, design rules of thumb and allowables by process, pp. 85–86; nesting spacing from Table 4.4, p. 82.
[^barnes-generative]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, generative design and the manufacturing overhang angle, p. 89.
[^barnes-passages]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, internal passageways and self-supporting profiles, p. 90.
[^barnes-allowables]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, allowables as current practice, p. 92.
[^barnes-envelopes]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, build volumes of representative machines, p. 92.
[^barnes-ded-tilt]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, DED tilt tables and wire-fed feature limits, p. 93.
[^barnes-wire]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, wire-fed DED features under 0.39 inch, p. 93.
[^barnes-boom]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, the excavator-boom case, pp. 93–94.
[^barnes-fdm]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, extrusion (FDM) design notes: the 45° rule, supports and the nozzle-diameter feature limit, p. 95.
[^barnes-risks]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, Table 4.9, software hand-offs and risk steps, pp. 96–97.
[^barnes-maturity]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 4, the AM maturity model, Phases 0–4, p. 98.
[^barnes-cert]: Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials* (Portal Book 110). Chapter 5, Certification, pp. 101–114, and Chapter 6, Additive Manufacturing Qualification, pp. 115–130 (page to pin).
[^manual12]: Wikitube Microsim Guide, Sub-manual 12, Design and Manufacturing, §6.1 Build orientation and the 45° rule, §6.2 Staircasing, §6.3 Process design-rule checker and §6.4 STL tessellation (the geometric reading of the rule, the standard cusp and chord-error relations and their derived tables, and the Table 4.4/4.6 column reconstruction). Internal document.
## Further reading
- Barnes, J.; Simpson, T. (2025). *Additive Manufacturing Essentials*. Portal Book 110. https://open.umn.edu/opentextbooks/textbooks/additive-manufacturing-essentials
- Jensen, David (2024). *Introduction to Mechanical Design and Manufacturing*. Portal Book 109, Chapter 10, Product Design Prototyping, pp. 233–244 (prototyping with AM; not cited in the body). https://open.umn.edu/opentextbooks/textbooks/introduction-to-mechanical-design-and-manufacturing
- ISO/ASTM 52900, *Additive manufacturing — General principles — Fundamentals and vocabulary*.
## External links
- *Additive Manufacturing Essentials* on the Open Textbook Library: https://open.umn.edu/opentextbooks/textbooks/additive-manufacturing-essentials
- For process galleries, printer databases and community sites, see the external links of the Wikipedia pair.
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## Wikipedia : Wikitube
**Strict pair:** [Wikipedia](https://en.wikipedia.org/wiki/3D_printing) : [Wikitube](https://en.wikitube.io/wiki/3D_printing) · pinned revision [1374282453](https://en.wikipedia.org/w/index.php?oldid=1374282453) · 2026-09-11
## Previous hub tags
Hubs: `Life_Physics`. Portals: [[PORTAL_Materials_science]].
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*Matter & Energy Cluster child articles, wave 1 · 2026-09-11 · drafted · Materials_science row M23 · sim pending (matter/3D_printing).*