3D printing, also referred to as additive manufacturing, is a technique used to create three-dimensional objects from a digital design. Objects are produced through an additive process, where material is deposited layer by layer until the final form is completed. Each layer represents a thin cross-section of the object.

An exception to this approach is volumetric 3D printing. This emerging method allows entire objects to be formed simultaneously rather than built layer by layer. However, volumetric printing is still largely in the research and development stage.

Unlike subtractive manufacturing—which involves cutting or carving material away using tools such as milling machines—3D printing builds objects using only the necessary material. This makes it possible to create complex geometries while reducing material waste.

How Does 3D Printing Work?

The process begins with a 3D model. This can either be designed from scratch or downloaded from an online 3D model library. Various software tools are available for this purpose, and beginners are often encouraged to start with Tinkercad. Tinkercad is a free, browser-based platform that offers guided tutorials and allows users to export designs in common printable formats such as STL or OBJ.

Once a printable file is ready, it must be prepared for the printer through a process known as slicing.

Slicing: From Digital File to Printed Object

Slicing software divides a 3D model into hundreds or thousands of thin layers and generates instructions the printer can follow. After slicing, the file can be transferred to the printer via USB, SD card, or Wi-Fi. The printer then builds the object layer by layer based on these instructions.

3D Printing in Industry

The adoption of 3D printing has reached a turning point, with companies that have not yet incorporated additive manufacturing becoming increasingly rare. Initially used mainly for prototyping and one-off parts, 3D printing is now rapidly evolving into a viable production method.

Industrial applications currently drive most of the demand for 3D printing. According to Acumen Research and Consulting, the global 3D printing market is projected to reach £40 billion by 2026. As the technology advances, it is expected to significantly impact nearly every major industry.

Examples of 3D Printing Applications

3D printing includes a wide range of technologies and materials and is used across numerous sectors. Rather than a single industry, it can be viewed as a collection of diverse applications, including:

• Consumer goods (eyewear, footwear, furniture, design items)
• Industrial products (manufacturing tools, prototypes, functional end-use components)
• Dental devices
• Prosthetics
• Architectural models and maquettes
• Fossil reconstruction
• Replication of historical artefacts
• Forensic evidence reconstruction
• Rapid Prototyping and Rapid Manufacturing

Since the late 1970s, companies have used 3D printers to develop prototypes during the design phase—a practice known as rapid prototyping.

Why Use 3D Printing for Rapid Prototyping?

Simply put, it is fast and cost-effective. Designers can move from an idea to a physical prototype in just days rather than weeks. Design iterations are easier and less expensive, and there is no need for costly moulds or tooling.

Beyond prototyping, 3D printing is also used in rapid manufacturing. This approach allows companies to produce small batches or customized products efficiently, making it ideal for short production runs.