Modeling is an important step in the additive manufacturing process. This technique allows the creation of detailed products with complex shapes. In the 3D printing space, there are many CAD software programs that make it possible to additively manufacture a part. Faced with the growing market, the players in the sector need to reduce their production time while saving on materials without compromising the quality of the parts. The question that could then arise is: How can the production of 3D printed products be accelerated? The answer is simple: just increase the number of components made in a single print. This is where nesting software or 3D nesting comes into play.
This 3D printing solution is designed to save material and part production time as much as possible. It’s not CAD software because you can’t use it to design a model. In fact, its mission is to optimize the placement of parts in the available manufacturing volume to increase the quantity of 3D printed products in a single print. Automated or manual, 3D nesting sorts, aligns, and organizes 3D files to maximize space in a 3D printer without impacting non-manufacturing areas.
Parts are placed and aligned to optimize space in the 3D printer (Image credit: Materialise)
Inefficient use of nesting can result in wasted materials and misprints. 3D printing nesting software thus works like the video game Tetris, where the aim is to place each block in a very specific box in order to optimize the space on the game board. It is now increasingly available in CAD as an additional design option. Among the solutions available on the market we can mention Fabpilot by Sculpteo, 4D_Additive by CoreTechnologie or Fusion 360 software and Inventor Nesting by Autodesk. Most nesting solutions are extensions of CAD software.
This method works with almost all 3D printing technologies. However, it is important to note that it is more beneficial to use 3D nesting for processes that use powder and do not require support structures. Therefore, 3D printers that benefit from PBF solutions such as DMLS, SLS or Multi Jet Fusion are more useful. Sintratec, a manufacturer of SLS 3D printers, confirmed the benefits of such software with a selective laser sintering 3D printer. According to him, out of the 100 print jobs the company completed, nesting saved 800 hours of part production, 47 kilos of powder, and 50 labor hours. The aim of this technique is to increase the productivity of companies operating in the 3D printing market while saving material. Binder jetting is also a technology used for nesting. However, powder bed fusion is preferred.
With powder-based technologies, nesting is more efficient
All materials used in these 3D printing techniques can be used with nesting software. Therefore, it is possible to benefit from the 3D nesting method with metal, nylon, PEEK, polypropylene or even resin. 3D nesting can also be used for technologies such as DLP and MSLA. However, since no material can be saved by the nesting, only a considerable time saving can be achieved in the production of the parts. Logically, therefore, 3D nesting is compatible with all types of 3D printers. However, the vast majority of the software is run on professional and industrial machines due to its larger build volume. In addition, 3D nesting can be used for automotive, medical and even aerospace industries. In fact, nesting is able to respond to all areas that can be touched by 3D printing technologies. The nested components don’t necessarily all have to be the same, it all depends on the customer’s preference. They can be of different sizes and shapes.
Mistakes to avoid with 3D printing nesting software
When using 3D nesting software, attention should be paid to a few important details in order to avoid printing errors. First, when doing automated or manual nesting, it is important to leave a minimum of 1.5mm spacing between all components of your 3D file for SLS techniques and 5mm for MJF techniques. The heat generated by 3D printers thus prevents the parts from fusing together during the printing process. Then there are so-called interlocking rings. This problem occurs when the software does not take into account the structure of two ring-shaped parts and the elements intersect or connect. This renders both parts unusable. The third mistake is to print a small object into the open space of a larger part, making it impossible to pull it out. The user must therefore provide a small opening to facilitate the extraction of the two components. However, even if these mistakes are avoided, the nesting process should not undergo drastic changes to avoid the risk of curling. This 3D printing phenomenon occurs when the print layers do not adhere properly to each other, resulting in bent edges or misaligned layers.
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*Photo credit for the cover photo: Sintratec
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