COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF ADDITIVE PRODUCTION
In today's conditions, 3D printing is used to create unique models, prototypes, and equipment necessary for conducting experiments and studying various phenomena and processes, for the rapid prototyping of various parts and devices in scientific and engineering research. 3D printing technologie...
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| Дата: | 2024 |
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General Energy Institute of the National Academy of Sciences of Ukraine
2024
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System Research in Energy| _version_ | 1871104348211118080 |
|---|---|
| author | Romanenko, Vladyslav Nazarenko, Oleg |
| author_facet | Romanenko, Vladyslav Nazarenko, Oleg |
| author_institution_txt_mv | [
{
"author": "Vladyslav Romanenko",
"institution": null
},
{
"author": "Oleg Nazarenko",
"institution": null
}
] |
| author_sort | Romanenko, Vladyslav |
| baseUrl_str | https://systemre.org/index.php/journal/oai |
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| datestamp_date | 2026-07-18T12:57:48Z |
| description | In today's conditions, 3D printing is used to create unique models, prototypes, and equipment necessary for conducting experiments and studying various phenomena and processes, for the rapid prototyping of various parts and devices in scientific and engineering research. 3D printing technologies are actively used to create individual medical implants, prostheses, and organ models for training and planning operations, which significantly improves the quality of medical care. In the aerospace and automotive industries, additive manufacturing is used to create lightweight and durable parts helping to reduce weight and improve vehicle efficiency. The use of additive manufacturing methods, technologies, and tools allows you to check and test designs and concepts before mass production. In this work, a detailed analysis of various existing 3D printers is carried out depending on the tasks, and modern technologies of additive manufacturing are investigated depending on the set goals and scientific and applied tasks. Such technologies include Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, and Digital Light Processing. In the work, a comparative analysis of these technologies was carried out according to various criteria, such as principle of operation, materials, resolution, surface finish, accuracy, speed, strength, application, cost, complexity of parts, and post-processing. For each technology, the advantages and disadvantages of its use are determined depending on the goals and objectives. It should be noted that some materials may not be suitable for printing complex parts or require additional support during the printing process. This can lead to complexity in the processing of products and increase the time and costs of printing. Improper selection of materials for 3D printing can be harmful to the environment or human health when used incorrectly. For example, some plastic materials may emit toxic elements or have low biodegradability. Also, using excess expensive material unnecessarily can increase the cost of the project. |
| doi_str_mv | 10.15407/srenergy2024.02.084 |
| first_indexed | 2026-03-24T02:03:15Z |
| format | Article |
| fulltext |
Системні дослідження в енергетиці. 2024. 2(77) 84
ISSN 2786-7102 (Online), ISSN 2786-7633 (Print)
https://doi.org/10.15407/srenergy2024.02.084
UDC 681.6
Vladyslav Romanenko*, https://orcid.org/0000-0002-3227-4183
Oleh Nazarenko, PhD (Engin.), https://orcid.org/0000-0003-1873-1971
General Energy Institute of NAS of Ukraine, 172, Antonovycha St., Kyiv, 03150, Ukraine
*Corresponding author: vlad.romanenko.24@gmail.com
_______________________________________________________________________________________
COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF
ADDITIVE PRODUCTION
Abstract. In today's conditions, 3D printing is used to create unique models, prototypes, and equipment
necessary for conducting experiments and studying various phenomena and processes, for the rapid
prototyping of various parts and devices in scientific and engineering research. 3D printing technologies
are actively used to create individual medical implants, prostheses, and organ models for training and
planning operations, which significantly improves the quality of medical care. In the aerospace and
automotive industries, additive manufacturing is used to create lightweight and durable parts helping to
reduce weight and improve vehicle efficiency. The use of additive manufacturing methods, technologies,
and tools allows you to check and test designs and concepts before mass production. In this work, a detailed
analysis of various existing 3D printers is carried out depending on the tasks, and modern technologies of
additive manufacturing are investigated depending on the set goals and scientific and applied tasks. Such
technologies include Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct
Metal Laser Sintering, and Digital Light Processing. In the work, a comparative analysis of these
technologies was carried out according to various criteria, such as principle of operation, materials,
resolution, surface finish, accuracy, speed, strength, application, cost, complexity of parts, and post-
processing. For each technology, the advantages and disadvantages of its use are determined depending
on the goals and objectives. It should be noted that some materials may not be suitable for printing complex
parts or require additional support during the printing process. This can lead to complexity in the
processing of products and increase the time and costs of printing. Improper selection of materials for 3D
printing can be harmful to the environment or human health when used incorrectly. For example, some
plastic materials may emit toxic elements or have low biodegradability. Also, using excess expensive
material unnecessarily can increase the cost of the project.
Keywords: additive manufacturing, 3D printing, additive manufacturing technologies, Fused Deposition
Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, Digital Light
Processing.
1. Introduction
3D printing is used in a variety of fields, from engineering to manufacturing, dentistry, healthcare,
jewelry, and other industries. 3D printing technology has a variety of applications, from making visual and
functional prototypes to manufacturing end-use parts. Each of the 3D printing technologies available on the
market has its own advantages and limitations, so each of them is better suited for certain purposes than others.
When choosing a 3D printer, it's important to consider the technology that best suits your needs and
requirements [1–3].
Choosing 3D printing technology and material with the right functional properties is crucial to ensure
that parts work correctly.
1) The dimensions of the construction field and the accuracy of the reproduction of the part (tolerances).
The most common printers offer a print volume with a cube side of about 200 mm, while large format options
reach a size of 300x300x600 mm. Professional desktop printers can be supplied in standard or large format
models. Moreover, most of the standard sizes are a cube with a side size of 200 mm. Larger models may offer
a print area 5 to 10 times larger.
The next thing to consider when it comes to functional properties is tolerances. Different technologies
have different tolerances. They use high-precision lasers to shape each layer of material with reliable and
reproducible results.
Системні дослідження в енергетиці. 2024. 2(77) 85
2) Choice of 3D printing technology. Properties of materials. First of all, you need to consider the types
of plastic for a 3D printer. Plastic for 3D printing, or filament, is made in the form of a thin thread, with a
diameter of 1.75 mm and 3 mm. Most often, threads with a thickness of 1.75 mm are used in the basic
configuration, but some manufacturers of 3D printers provide the opportunity to install a three-millimeter
plastic feeding system. Plastic for 3D printing has many varieties, among which the most common are ABS
and PLA plastic. In addition, desktop 3D printers can be used to create metal parts by casting 3D printed
templates out of plastic [2, 4, 5].
The wrong choice of materials in 3D printing can lead to various problems:
– If the chosen material is not strong enough for your needs, printing parts may lead to brittleness or
deformation;
– If the material cannot withstand high or low temperatures, it can lead to a loss of shape or properties
of the part during operation;
– Some materials may have different properties than those specified in the specifications, resulting in
unexpected printing results.
– some materials may not adhere well to the substrate or have problems with adhesion, leading to defects
on the print surface;
– Other problems may include dimensional changes during cooling, large deviations in geometry, or
improper surface texture.
Given the challenges above, it is important to carefully examine the properties of each material and its
suitability for a specific application before embarking on 3D printing.
2. Methods and materials
2.1. Classification of Modern 3D Printers
3D printing technology began to gain popularity in the 1980s, starting as a rapid prototyping method
[1, 6, 7]. The main goal of this technology was to help manufacturers create models of their products quickly
and economically. In 1983, Chuck Hull invented the first technique, called stereolithography, which used
ultraviolet light to cure resin into precise shapes. In the years that followed, various approaches emerged, such
as modeling deposited deposition, which melts plastic to form layers. Initially, such printers were large and
expensive, which limited their use in industrial settings. However, over time, they have been improved, with
more compact and affordable models appearing, making the technology accessible to hobbyists, schools, and
small businesses, radically changing the way we create and think about manufacturing objects [5, 8].
3D printers are advanced devices that convert digital drawings into physical objects through additive
manufacturing. This process involves applying materials layer by layer based on precise geometric data from
CAD. There are different types of 3D printers. All 3D printers are distinguished by their ability to produce
complex designs with high precision and minimal material waste. They have found applications in a variety
of industries, enabling rapid prototyping, custom manufacturing, and the production of complex components.
Modern 3D printers allow you to quickly create various products with variable geometry without the
need to create new molds or tools. They allow the creation of products with a high degree of complexity,
including internal cavities and complex structures. These types of printers reduce the cost of producing tools
and molds because the process is based on adding material rather than cutting from a block.
It is also worth mentioning the shortcomings that can appear during the printing process on modern 3D
printers. Although the range of materials available has expanded, the choice is still limited compared to
traditional production methods. Printing speeds with modern 3D printers are often slower than traditional
manufacturing methods, especially when creating large parts. Also, products created using 3D printing may
have less smooth surfaces, which requires additional processing to achieve the required quality. Some 3D
printers may have limited accuracy and repeatability when creating parts, especially when working with large
objects. An important factor is that investments in 3D printers and materials can be high, especially for more
advanced models and specialized materials.
Depending on their size, 3D printers can be classified into different categories. Here is a general
classification of 3D printers by size, as shown in Figure 1 below.
Системні дослідження в енергетиці. 2024. 2(77) 86
Figure 1. General classification of 3D printers depending on the goals and applied design tasks
2.2. Modern Technologies of Additive Manufacturing
The choice of 3D printing technology depends on the goals you set for the project [8–10]. In order to
rationally choose one or more 3D printing technologies, you need to take into account such factors as: printing
Desktop 3D printers:
•intended for use on a desk or table;
•compact, light and suitable for home use, small business and hobbyists;
•usually have dimensions from 100x100x100 mm to 300x300x300 mm (or
similar dimensions).
Medium-sized 3D printers:
•larger than desktop printers but still suitable for most workplaces;
•offer greater build volume compared to desktop printers, making them
suitable for prototyping, small-scale production, and educational purposes;
•dimensions can vary from 300x300x300 mm to 600x600x600 mm or more.
Industrial 3D printers:
•designed for high-volume production, rapid prototyping and production
applications;
•have a significantly larger volume of assembly compared to desktop printers
and medium-sized printers, which allows for the manufacture of larger parts
and components;
•dimensions can vary widely, starting from approximately 600x600x600 mm
and reaching the size of several meters.
Large-scale and serial 3D printers:
•have an extremely high production volume, capable of producing full-scale
prototypes, architectural models, furniture and even entire building
components.
•the volume of the assembly can vary from a few meters to tens of meters,
depending on the specific application and industry;
•3D printer size classification may vary by manufacturer and model. Some
manufacturers may use different terminology or size ranges to classify their
printers;
•in addition, advances in technology may lead to the development of printers
with different sizes and capabilities that exceed traditional classifications.
Системні дослідження в енергетиці. 2024. 2(77) 87
accuracy; the strength of the parts that will be obtained after printing; print speed; Materials; size and scope,
financial budget.
To date, there are only 5 additive manufacturing technologies. All of them are shown in Figure 2
below [8].
Figure 2. Classification of modern additive manufacturing technologies
A detailed description of each of the technologies in order to understand and choose the most optimal
of them is given below. It should be noted that the choice of the optimal technology is key for mass production
in general.
2.2.1. Fused Deposition Modeling
Fused Deposition Modeling (FDM) technology, also known as Fused Filament Fabrication (FFF), is a
3D printing method that is known for its speed, accuracy, and affordable cost. In FDM, molten plastic is
precisely applied by a parts creation machine, allowing parts to be produced in as little as one day [9–11].
The FDM 3D printing service makes it possible to create large parts on platforms up to 60 cm, x92 cm,
x92 cm. FDM also offers a wide variety of industrial-quality colors and thermoplastics, including ABS plastic,
ASA, polycarbonate, and ULTEM, making this method the most diverse of all 3D printing processes. The
FDM method is one of the most common 3D printing methods, which involves melting, extrusion, and
applying thermoplastic filament to a printing platform to create objects step by step. Widely used for rapid
prototyping, FDM can also be applied to create customized production aids and small parts. This method
allows you to print large objects [11, 12]. FDM offers a large selection of industrial-quality thermoplastics and
a variety of colors, making it the most diverse of all 3D printing technologies. The most commonly chosen
FDM materials are engineering-grade such as PLA+, ABS, ASA, PETG, PC, and TPU, as well as premium
materials with high strength and thermal stability for use in advanced automotive, aerospace, and medical
industries such as PEEK and ULTEM®. For complex geometric shapes, when using FDM, support structures
are required, which increases the consumption of materials, time and requires further processing. FDM
technology is used for the manufacture of various products, some of them are shown in the figure 3.
(a) b) c)
Figure 3. Practical application of FDM in the modern world: a) production of individual products; b) production in the
industry; c) production of functional parts
2.2.2. Stereolithography
Stereolithography belongs to a group of additive manufacturing technologies known as bath
photopolymerization. All of these methods are based on the same principle where a light source – a laser or
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Fused Deposition Modeling (FDM)
Stereolithography (SLA)
Selective Laser Sintering (SLS)
Direct Metal Laser Sintering (DMLS)
Digital Light Processing (DLP)
Системні дослідження в енергетиці. 2024. 2(77) 88
projector – is used to solidify the liquid resin into a solid plastic. The main difference between the two is the
location of the main elements, such as the light source, the construction platform, and the resin tank.
SLA is one of the three main technologies in 3D printing, along with FDM and SLS. It belongs to the
category of printing on resin. Another approach that is often compared to SLA is digital light processing (DLP),
which is an evolution of the SLA process by using a projector screen instead of a laser.
Although SLA technology is not as common as FDM, it is actually the oldest of the additive
manufacturing technologies. The SLA process itself was first developed in the early 1970s by Japanese
researcher Dr. Hideo Kodama, who created a modern method of stereolithography using ultraviolet light to
solidify photosensitive polymers. The term "SLA" was coined by Chuck Hull, the founder of 3D Systems, in
1986 when he patented the technology. According to his definition, SLA is the process of creating three-
dimensional objects by sequentially superimposing layers of photosensitive material. However, SLA 3D
printing technology was not the first to become widespread. When patents expired in the late 2000s, small-
format desktop 3D printers expanded access to additive manufacturing, and FDM became popular on desktop
platforms. Although FDM was available and attracted a lot of attention in the early days of 3D printing, high-
precision results and biocompatible materials, which are essential for professional applications, were important
factors in the development of SLAs. Small SLA 3D printers have brought high resolution and greater access
to a variety of materials that were previously only available on industrial systems. This has significantly
expanded the possibilities of using 3D printing in various industries, including engineering, design, dentistry,
jewelry, and other industries.
The SLA allows you to produce customized products such as personalized gifts, promotional items, and
specialized components tailored to individual requirements. It offers flexibility in design and customization
options. Examples of the application of the technology are shown in Figure 4.
(a) b) c)
Figure 4. Practical application of SLA in the modern world: a) aerospace and automotive industries; b) jewelry and
fashion; c) dental and medical models
2.2.3. Selective Laser Sintering
This method is also known as Selective Laser Sintering (SLS). It is one of the variants of 3D printing
technology widely used in industry. SLS is available only on expensive professional 3D printers and is
distinguished by the high quality of manufactured products. With its help, it is possible to achieve results close
to the reproduction of products by injection molding.
Selective laser sintering, like many other additive manufacturing methods in industry, uses powders and
powder mixtures as the material. This method allows you to create all-metal objects in just a few hours. The
ability to manufacture products with complex shapes explains its popularity among industrial organizations in
the world.
As with any other 3D printing technology, the main requirement is to have a ready-made 3D model that
meets certain criteria. This model is the basis for creating a product. The process of technology is quite simple:
a special compartment of the 3D printer is filled with material, then the printing process begins. Interestingly,
before playing begins, the material is heated to its melting point.
When using a laser rig and a scanning mirror, the laser beam is directed at the desired areas of the
powder, sintering them together, creating layer by layer. After the first layer is sintered, the surface leveling
mechanism adds a thin layer of powder on top, and the process is repeated until the object is fully constructed.
This means that the object is created from the bottom up, and due to the continuous filling of the chamber with
powder, there is no need for supporting structures.
Системні дослідження в енергетиці. 2024. 2(77) 89
Overall, selective laser sintering (SLS) is valued for its ability to produce functional parts with high
strength, precision, and complexity, making it a versatile technology suitable for a wide range of applications
in various industries. Figure 5 shows the main applications of SLS 3D printing technology.
(a) b) c)
Figure 5. Practical application of SLS in the modern world: a) medicine; b) automotive prototyping; c) aerospace
components
2.2.4. Direct Metal Laser Sintering
Direct Metal Laser Sintering (DMLS) technology is widely used in industry and is represented by a
variety of professional equipment for 3D printing. It consists in creating products according to specified 3D
models from a special metal powder using a laser. The technique of direct laser sintering of metals is in many
ways similar to the technologies of selective laser sintering (SLS) and selective laser melting of metals (SLM).
However, these techniques have their own unique characteristics and advantages. Direct laser sintering
of metals is used for additive manufacturing of metal products of almost any complexity. The high accuracy
of the equipment for such 3D printing minimizes errors during reproduction. The features of this technique
provide the products with high strength.
The basic principle of direct laser sintering of metals is similar to other 3D printing techniques. The
basis for creating a physical object is its three-dimensional model in the appropriate format for a 3D printer.
With the help of special software, the model is prepared for printing, all the necessary options for playback are
installed. Then the prepared file is transferred to a 3D printer, where the process of direct laser sintering of
metals begins.
At this stage, the key components are a metal powder chamber, a material, a special leveling roller and
one or more lasers. First, a certain amount of material is loaded into the chamber, sufficient to create one layer.
This powder is leveled with a special device, the excess is removed. Then the process of building the model
begins: the powder is sintered with a laser in the form of the first layer. Then a new layer of material is added,
leveling and the laser sinters the second layer of the 3D model. This procedure is repeated until a complete
reproduction of the product has been created. DMLS is a versatile additive manufacturing technology used in
a variety of industries (Figure 6) that require metal parts with complex geometries, high strength, and precision.
(a) b) c)
Figure 6. Practical application of DMLS in the modern world: a) metal parts and their structures; b) production of tools
and molds; c) industry
2.2.5. Digital Light Processing
Resin has been used in the field of 3D printing for a long time. The first patent for this technology was
granted in 1986 by Charles Hall, who developed stereolithography (SLA) technology. Over time, new
Системні дослідження в енергетиці. 2024. 2(77) 90
technologies have emerged that have improved the 3D printing process. With the expiry of patents, new
developers have appeared in the market. Currently, resin-based 3D printers are represented by various
categories from hobbyists to industrial professional units. With the variety of devices, many resin technologies
have emerged, such as LCD, mSLA, DLP, SLA, and others.
ISO standards apply to all areas of activity in various fields. This is especially important in industries
where efficiency is ensured by the use of homogeneous expectations and terminology. In the context of 3D
printing, there is some confusion about using the term "stereolithography" to describe the entire resin printing
process. But stereolithography is only a primitive technology. In the ISO/ASTM 52900:2015 standard, users
can find a clear definition of this technology. All resin 3D printing technologies refer to bath polymerization,
because the photopolymer resin is in a special tank. For example, in inkjet printing, the process is carried out
through a nozzle. On the Figure 7 shows the various applications of this 3D printing technology.
(a) b) c)
Figure 7. Practical application of DLP in the modern world: a) studying materials and conducting experiments;
b) medicine; c) miniature objects
2.3. Analysis of Technologies, Materials and Methods of Additive Manufacturing
2.3.1. Technologies of Additive Manufacturing
FDM is one of the most widely used additive manufacturing technologies. It works by squeezing molten
material (usually plastic filament) through a heated nozzle onto a printing platform, where the material
solidifies and forms a layer. After that, the next layer is printed and the process is repeated until the final part
is created. The main components of the FDM system include a molten material extruder, a movable printing
platform, and printing process control software. FDM allows you to create medium to high precision parts and
can be used for a wide range of applications from prototyping to the production of functional parts. The
advantages of FDM include relatively low hardware and material costs, a wide variety of materials available
(e.g., ABS, PLA, PETG), the ability to create large parts, and relatively fast print speeds for some applications.
However, FDM also has disadvantages, such as limitations in accuracy and detail compared to some other
technologies, visible layers on the surface of parts (requiring post-printing processing to obtain a smooth
surface), and some material limitations compared to more modern methods such as DMLS (direct laser
sintering of metals).
SLA, due to its ability to produce high-resolution parts and detailed parts, has several applications in
various industries, for example, the technology is widely used for rapid prototyping in product development
and design. This allows designers and engineers to quickly create accurate prototypes to test shape, fit, and
function before mass production. Taking into account the principles of SLA, this technology is actively used
in the production of dental models, surgical guides, prostheses and anatomical models for medical education
and planning of surgical operations. The high precision of the technology makes it suitable for creating
complex dental and medical devices. SLA is also used in the aerospace and automotive industries to prototype
components, create tools and fixtures, and produce functional prototypes of parts with complex geometries. It
helps to test and inspect designs before manufacturing.
SLS uses a high-power laser to selectively fuse powdered materials, typically plastics or metals, to create
solid objects. This technology has several applications in various industries due to its ability to produce
complex parts with high strength and precision. Applications include widely used to create functional
Системні дослідження в енергетиці. 2024. 2(77) 91
prototypes of parts and components in product development and design. This allows designers to test and
validate designs before mass production, especially for parts with complex geometries. The technology is also
suitable for the production of end-use parts and components, especially in industries such as aerospace,
automotive, and consumer goods. Parts manufactured with SLS can have high mechanical strength and
withstand demanding application conditions. Another of the practical applications of SLS is to use it to make
tools, fixtures, fixtures and molds for various manufacturing processes. The ability to create complex and
durable tools makes SLS valuable in industries that require rapid tooling solutions.
DMLS uses a high-power laser to fuse metal powders layer by layer to create solid metal parts. This
process is also known as direct laser metal melting (DMLM) or powder bed laser melting. DMLS can handle
a variety of metal materials, including stainless steel, aluminum, titanium, cobalt-chromium, and nickel alloys.
This makes the technology suitable for the manufacture of parts with specific mechanical, thermal or chemical
properties. DMLS is capable of producing parts with complex geometries, internal cavities, and complex
structures that would be difficult or impossible to achieve with traditional manufacturing methods. Data
technology provides high dimensional accuracy and surface finishes, making it suitable for applications where
tight tolerances and smooth surfaces are required. With this technology, parts are built layer by layer, allowing
for design freedom and integration of features such as internal channels, lattice structures, and conformal
cooling channels. DMLS is widely used in the aerospace industry to produce lightweight yet durable
components such as turbine blades, brackets, structural parts, and engine components. The ability to create
complex geometries and lightweight structures is critical in aerospace applications. DMLS technology is also
used in medicine and dentistry for the manufacture of implants, prostheses, orthopedic devices and dental
restorations. The biocompatibility of certain metals used in DMLS makes the technology suitable for medical
implants.
DLP uses a digital light projector to cure the photopolymer resin layer by layer, creating solid objects.
Printers that use this technology can produce high-resolution prints with fine detail and a smooth surface,
making them suitable for applications that require complex designs. DLP printing is typically faster compared
to other resin-based 3D printing technologies, such as SLA (stereolithography), making it effective for rapid
prototyping and small-scale production. DLP printers provide high precision and dimensional accuracy,
ensuring that the printed parts meet the intended design specifications. DLP technology supports a variety of
photopolymer resins, including standard resins, engineer-grade resins, flexible resins, and dental-grade resins,
ensuring the versatility of material properties. DLP technology is actively used in dental laboratories for the
manufacture of dental models, crowns, bridges, orthodontic devices and surgical guides. This allows dental
professionals to receive precise and customized dental solutions. DLP is also suitable for creating miniature
models, figurines, architectural models and scale copies with intricate details. It is popular among hobbyists,
fashion designers, and artists to create detailed miniatures.
Brief characteristics for each type of modern additive manufacturing can be presented in Table 1.
Table 1. Additive Manufacturing Technologies Analysis
Technology FDM SLA SLS DMLS DLP
Principle of
operation
Extrusion of
thermoplastic
filaments
Laser Curing of
Liquid Resin
Laser Sintering of
Powder Materials
Laser Melting of
Metal Powders
Light Curing of
Photopolymer
Resins
Materials
Wide range of
thermoplastics
Photopolymer resins
Various plastics,
metals, ceramics
Metals (e.g. stainless
steel, titanium)
Photopolymer
resins
Resolution Average High High High High
Surface Finishing Satisfactory Excellent Excellent Excellent Excellent
Accuracy Average High High High High
Speed Medium to High Medium to High Average Medium to High Medium to High
Strength Average Average High High Medium to High
Application
Prototyping, training,
custom parts
Prototyping,
Dentistry, Jewelry
Aerospace,
Automotive,
Medical
Aerospace,
Automotive, Medical
Jewelry, dental,
prototyping
Cost Low to medium Low to medium High High Low to medium
Complexity of
details
Limited complexity High Complexity High Complexity High Complexity High Complexity
Post-processing Minimum Average Average Medium to High Average
Системні дослідження в енергетиці. 2024. 2(77) 92
Based on the above characteristics of each of the known technologies, the corresponding advantages
and disadvantages can be recorded. They are listed in Table 2.
Table 2. Advantages and disadvantages of additive manufacturing technologies
Technology Advantages Disadvantages
FDM
Low cost of equipment and materials Limited resolution and surface finish
A wide range of thermoplastic materials are available Limited precision for complex geometries
Suitable for rapid prototyping and simple parts Layer Lines and Visible Stepping
Easy post-processing and support removal Not ideal for highly detailed or complex designs
SLA
High Resolution and Excellent Surface Finish Relatively higher cost of equipment and materials
High Precision for Complex Designs Limited build capacity for some machines
Wide range of resin materials available Resin processing and post-processing can be messy
Suitable for dental, medical and jewelry work The resin can be sensitive to environmental factors
SLS
High strength and durability of parts Higher cost compared to FDM and SLA
Ability to use a variety of materials, including
plastics, metals, ceramics
Limited resolution compared to SLAs
Complex geometry and internal structure possible Powder handling and recycling can be challenging
Suitable for functional prototypes and end-use parts
Post-processing may be required to remove excess
powder
DMLS
High precision and accuracy of metal parts High cost of equipment and materials
Wide range of metal materials available Limited build capacity for some machines
Complex geometries and lightweight designs are
possible
Some metals may require post-processing, such as heat
treatment
Suitable for aerospace, automotive, and medical
applications
Limited to metals and high-temperature materials
DLP
High-resolution printing with fine details
Limited material capabilities compared to other
technologies
Excellent surface finish and smoothness Resin processing and subsequent curing process required
Printing speed compared to some other resin-based
methods
Limited build capacity for some machines
Suitable for jewelry, dental, and highly detailed
prototypes
The resin can be sensitive to environmental factors
2.3.2. Analysis of Technologies, Materials and Methods of Additive Manufacturing
Based on an overview of the materials used in additive manufacturing using FDM, it is possible to
identify the advantages and disadvantages of each of these materials. The main summary data of the
comparison are shown in Table 3.
Table 3. Comparative Analysis of 3D Printing Materials Using Fused Deposition Modeling (FDM)
Material Advantages Disadvantages Application
ABS Plastic
Durable and impact-
resistant
May decrease in size when cooled
Prototyping, high-
strength parts
PLA Plastic Biologically Stiffer and brittle than ABS
Prototyping, training,
decorative products
Polyamide
High impact resistance and
flexibility
Requires special printing conditions to
prevent deformation
Mechanical Parts,
Flexible Structures
Polycarbonate
Very durable and heat-
resistant
Requires high printing temperatures
High Temperature
Parts
Polyethylene Good chemical resistance
Not very suitable for precision parts due to
possible lubrication of the layers
Pipelines, chemically
resistant parts
Thermoplastic
Rubber Material
Flexibility and elasticity
Requires a specialized extruder and
printing setup
Prototyping of flexible
parts, shoes, seals
PVA
Dissolves in water and is
used to support printing
Not suitable for creating parts, requires
additional post-printing processing
Printing stand, water-
soluble
Based on an overview of the materials used in additive manufacturing using SLS, the advantages and
disadvantages of each of these materials can be similarly highlighted. The main summary data of the
comparison are shown in Table 4.
Системні дослідження в енергетиці. 2024. 2(77) 93
Table 4. Comparative Analysis of the Main Materials Used in SLS Technology
Material Advantages Disadvantages Application
Acrylate Resin High precision and detail
Materials may be prone to
shrinkage
Prototyping, decorations, highly detailed
details
Epoxy Resin
Very high detail and
smooth surface
Materials can be more fragile and
less flexible
Medical Models, Jewelry, Electronic
Components
Polyurethane Resin Flexibility and elasticity
Materials may be more prone to
wear and tear and deformation
Flexible Parts, Resilient Prototypes, Test
Products
Dental Resin
Biocompatibility and
safety when used in
orthodontics and
dentistry
High Cost and Requirements for
Resin Processing and Curing
Equipment
Dental implants, dentures, orthodontic
appliances, models for surgical planning
High-strength resin
High strength and
resistance to mechanical
stress
Higher Price and Requirements for
Resin Recycling Equipment
Mechanical Parts, Functional Prototypes,
High Load Capacity Parts
Based on an overview of the materials used in additive manufacturing using SLA, the advantages and
disadvantages of each of these materials can be similarly highlighted. The main summary data of the
comparison are shown in Table 5.
Table 5. Comparative analysis of the main materials used in SLA technology
Material Advantages Disadvantages Application
Polyamide High strength and flexibility Material shrinkage is possible
Functional Prototypes,
Mechanical Parts
Polyurethane Flexibility and elasticity
Materials may be less durable and wear-
resistant
Flexible Parts, Resilient
Prototypes, Test Products
Polyethylene Good chemical resistance
Less suitable for precision parts due to
possible layer lubrication
Pipelines, chemically resistant
parts
Polypropylene
Low density and good
chemical resistance
Less durable and resistant to
mechanical stress
Packaging Materials,
Lightweight Parts
Polyamide with filler
Improvement of mechanical
properties due to the addition
of filler
Can be more rigid and less flexible
Specialized Functional Parts,
Prototypes
Metal powders (e.g.
stainless steel,
aluminum, titanium,
etc.)
High strength and heat
resistance
Requires specialized printing equipment
and processes
Manufacture of metal parts,
prototyping of metal products
Ceramic powders (e.g.
alumina, silicon
carbide, etc.)
Heat resistance and chemical
inertness
Requires specialized printing equipment
and processes
Production of ceramic parts,
prototyping of ceramic
products
Based on an overview of the materials used in additive manufacturing using DMLS, the advantages and
disadvantages of each of these materials can be similarly highlighted. The main summary of the comparison
is shown in Table 6.
Table 6. Comparative Analysis of the Main Materials Used in DMLS Technology
Material Advantages Disadvantages Application
Stainless Steel
High strength and corrosion
resistance
Limited geometry complexity
Production of functional metal parts,
tools
Aluminium
Light weight and good thermal
and electrical conductivity
Less durable compared to some
other metals
Prototyping, production of light metal
parts, components
Titanium
Very high strength at low
weight
High cost of material and
equipment
Production of medical implants,
aerospace components
Cobalt-
chromium
High strength and heat
resistance
Limited choice of colors and
finishes
Manufacture of medical prostheses,
dental structures, instruments
Inconel
High temperature and corrosion
resistance
Requires specialized printing
equipment and processes
Production of parts for high-
temperature and corrosive
environments
Aluminum alloys
Variety of alloys with different
properties
May have limitations in
strength and durability
Production of various metal parts and
components
Nickel alloys
High corrosion resistance and
heat resistance
High cost and limited choice of
finishes
Production of parts for the aerospace,
energy and chemical industries
Based on an overview of the materials used in additive manufacturing using DLP, the advantages and
disadvantages of each of these materials can be similarly highlighted. The main summary data of the
Системні дослідження в енергетиці. 2024. 2(77) 94
comparison are shown in Table 7. As mentioned above, the wrong selection of materials can critically affect
not only the quality of printing, but also the condition of the 3D printer.
Table 7. Comparative Analysis of the Main Materials Used in DLP Technology
Material Advantages Disadvantages Application
Photopolymers
Highly detailed and
smooth surface
Limited mechanical
properties
Jewelry, Medical Models,
Highly Detailed Parts
Elastomeric resins Flexibility and elasticity
May be less durable and
wear-resistant
Flexible parts, seals, shock-
absorbing components
Ceramic Resins
Heat Resistance and
Chemical Resistance
Limited mechanical
properties, requiring
specialized machining
Production of ceramic parts,
heat-resistant products,
insulation components
Metal-containing
resins
Simulating the properties
of metals
High cost, require
specialized processing
Production of parts with
metallic properties, decorations,
decorative elements
Dental Resins
Biocompatibility and
safety in dental
prosthetics
High cost, require
specialized processing
Manufacture of dentures,
orthodontic appliances, dental
models
3. Practical Results
Based on the analysis, it is possible to select a technology taking into account the project, which will be
developed using modern printing technologies. The resulting analysis provides an assessment of print quality
based on each of the five existing technologies, which forms a complete picture of the features of each of the
technologies, the description of which is presented in this article.
4. Discussion
The obtained analysis of the comparison of modern 3D printing technologies will make it possible to
continue the search for optimal materials for 3D printing of the project, form an understanding of the pricing
policy, this is the cost of consumables, as well as build mathematical models for the selection of optimal
printing materials in accordance with the requirements for the project, which are the relevant requirements for
the project.
Although the number of materials available for 3D printing is constantly increasing, it is still limited
compared to the materials available in traditional manufacturing. This can limit the ability to create products
with certain properties, such as strength, flexibility or heat resistance. It should be noted that products that are
made using 3D printing may have less smooth surfaces compared to products created by traditional methods.
This may require additional processing or processing to achieve the desired quality. While 3D printing
technologies are often used to create small batches or individual products, scaling the process for large series
can present challenges in terms of time and resources.
5. Conclusions
In the course of the study of modern technologies of additive manufacturing, the spheres of their
application were analyzed, the main advantages and disadvantages of each additive manufacturing technology
were determined. It should be noted that before choosing a specific technology of additive manufacturing, it
is necessary to determine the goals of this kind of production, its volumes, the total financial costs that are
necessary for the formation of the full volume of products, the scope of application of production products.
Also, an important factor in additive manufacturing is a clear selection of printing technology for a specific
type of parts, since the mechanical characteristics of the 3D printing product depend on it. Each technology
uses different printing materials, which determine the quality of the product and its durability. If the material
does not meet the requirements of the final product (e.g., does not have the required temperature resistance,
chemical resistance, or other characteristics), this may result in defects or unsuitability of the product for use.
The use of unsuitable material may result in poor print quality and degradation of the product's strength
characteristics. An incorrectly selected material may not provide the necessary strength or rigidity, which can
lead to deformations or breakage of the product.
Additive manufacturing technologies provide the flexibility to customize processes and make changes
to product designs without the need to create new molds or tooling. This allows production processes to be
Системні дослідження в енергетиці. 2024. 2(77) 95
adapted to different customer needs or changing market conditions. The use of such technologies makes it
possible to effectively create products with complex geometric shapes, which often turns out to be difficult or
impossible when using traditional production methods. This opens up new opportunities for designers and
engineers to develop innovative products. Unlike traditional methods, where creating molds and tools requires
significant time and money, in additive manufacturing these costs are significantly reduced because production
is based on the principle of adding material rather than cutting material from a block.
References
1. Beltagui, A., Kunz, N., & Gold, S. (2020). The role of 3D printing and open design on adoption of socially
sustainable supply chain innovation. International Journal of Production Economics, 221, 107.
https://doi.org/10.1016/j.ijpe.2019.07.035
2. Lu, J., & Zhuo, L. (2023). Additive manufacturing of titanium alloys via selective laser melting: fabrication,
microstructure, post-processing, performance and prospect. International Journal of Refractory Metals and Hard
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3. Colorado, H. A., Velasquez, E. I. G., & Monteiro, S. N. (2020). Sustainability of additive manufacturing: the
circular economy of materials and environmental perspectives. Journal of Materials Research and Technology, 9(4),
8221–8234. https://doi.org/10.1016/j.jmrt.2020.04.062
4. Wegner, M. (2022). New trends in aviation and medical technology enabled by additive manufacturing. Frontiers
in Manufacturing Technology, 2, 1–14. https://doi.org/10.3389/fmtec.2022.919738
5. Dejene, N. D., & Lemu, H. G. (2023). Current status and challenges of powder bed fusion-based metal additive
manufacturing: literature review. Metals (Basel), 13(2). https://doi.org/10.3390/met13020424
6. Galati, M., Calignano, F., & Minosi, F. (2022). Numerical and experimental investigations of a novel 3D
bucklicrystal auxetic structure produced by metal additive manufacturing. Thin-Walled Structures, 180, 109850.
https://doi.org/10.1016/j.tws.2022.109850
7. Chua, K., Khan, I., Malhotra, R., & Zhu, D. (2021). Additive manufacturing and 3D printing of metallic biomaterials.
Engineered Regeneration, 2, 288–99. https://doi.org/10.1016/j.engreg.2021.11.002
8. Maroti, P. (2019). Printing orientation defines anisotropic mechanical properties in additive manufacturing of upper
limb prosthetics. Materials Research Express, 6(3). https://doi.org/10.1088/2053-1591/aaf5a9
9. Morais, M. M., de Camargo, I. L., Colombo, P., & Fortulan, C. A. (2023). Additive manufacturing of calcium
carbonate parts through vat-photopolymerization and sintering in carbon dioxide atmosphere. Open Ceramics,
100348. https://doi.org/10.1016/j.oceram.2023.100348
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11. Bakhshi, R., Mohammadi-Zerankeshi, M., Mehrabi-Dehdezi, M., Alizadeh, R., Labbaf, S., & Abachi, P. (2023).
Additive manufacturing of PLA-Mg composite scaffolds for hard tissue engineering applications. Journal of the
Mechanical Behavior of Biomedical Materials, 138, 105655. https://doi.org/10.1016/j.jmbbm.2023.105655
12. Adeniran, O., Cong, W., & Aremu, A. (2022). Material design factors in the additive manufacturing of carbon fiber
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100100. https://doi.org/10.1016/j.aime.2022.100100
ПОРІВНЯЛЬНИЙ АНАЛІЗ СУЧАСНИХ ТЕХНОЛОГІЙ
АДИТИВНОГО ВИРОБНИЦТВА
Владислав Романенко*, https://orcid.org/0000-0002-3227-4183
Олег Назаренко, канд. техн. наук, https://0000-0003-1873-1971
Інститут загальної енергетики НАН України, вул. Антоновича, 172, м. Київ, 03150, Україна
*Автор-кореспондент: vlad.romanenko.24@gmail.com
Анотація. В умовах сьогодення 3D-друк використовується для створення унікальних моделей,
прототипів та обладнання, необхідних для проведення експериментів та вивчення різноманітних
явищ та процесів, для швидкого створення прототипів різних деталей та пристроїв у наукових та
інженерних дослідженнях. Технології 3D-друку активно застосовуються для створення
індивідуальних медичних імплантатів, протезів, моделей органів для навчання та планування
операцій, що значно покращує якість медичного обслуговування. В авіаційній та автомобільній
промисловості адитивне виробництво використовується для створення легких та міцних деталей,
що сприяє зниженню ваги та покращенню ефективності транспортних засобів. Використання
методів, технологій та засобів адитивного виробництва дозволяє перевіряти та тестувати
https://doi.org/10.1016/j.jmrt.2020.04.062
https://doi.org/10.1016/j.oceram.2023.100348
https://doi.org/10.1016/j.addma.2017.10.019
Системні дослідження в енергетиці. 2024. 2(77) 96
дизайн та концепції перед масовим виробництвом. У даній роботі проведений детальний аналіз
різних існуючих 3D-принтерів залежно від завдань, досліджено сучасні технології адитивного
виробництва залежно від поставлених цілей і науково-прикладних завдань. До таких технологій
відносять: Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser
Sintering, Digital Light Processing. У роботі проведено порівняльний аналіз даних технологій за
різними критеріями, такими як: принцип роботи, матеріали, роздільна здатність, фінішна
обробка поверхні, точність, швидкість, міцність, застосування, вартість, складність деталей,
постобробка. Для кожної технології визначено переваги і недоліки її використання залежно від
поставлених цілей і завдань. Слід зазначити, що деякі матеріали можуть погано підходити для
друку складних деталей або вимагати додаткової підтримки під час процесу друку. Це може
призвести до складності в обробці виробів і збільшити час і витрати на друк. Неправильний підбір
матеріалів для 3D-друку може бути шкідливим для навколишнього середовища або здоров’я людини
при неправильному використанні. Наприклад, деякі пластикові матеріали можуть виділяти
токсичні елементи або мати низьку біорозкладність. Також використання надлишкового дорогого
матеріалу без необхідності може збільшити вартість проєкту.
Ключові слова: адитивне виробництво, 3D-друк, технології адитивного виробництва,
моделювання наплавлення, стереолітографія, вибіркове лазерне спікання, пряме лазерне спікання
металу, цифрова обробка світла.
Надійшла до редколегії: 26.03.2024
|
| id | systemreorg-article-835 |
| institution | System Research in Energy |
| keywords_txt_mv | keywords |
| language | English |
| last_indexed | 2026-07-19T01:22:40Z |
| publishDate | 2024 |
| publisher | General Energy Institute of the National Academy of Sciences of Ukraine |
| record_format | ojs |
| resource_txt_mv | systemreorg/2d/feebba49c4e6a05216f4c8ee7d54452d.pdf |
| spelling | systemreorg-article-8352026-07-18T12:57:48Z COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF ADDITIVE PRODUCTION ПОРІВНЯЛЬНИЙ АНАЛІЗ СУЧАСНИХ ТЕХНОЛОГІЙ АДИТИВНОГО ВИРОБНИЦТВА Romanenko, Vladyslav Nazarenko, Oleg additive manufacturing, 3D printing, additive manufacturing technologies, Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, Digital Light Processing адитивне виробництво, 3D-друк, технології адитивного виробництва, моделювання наплавлення, стереолітографія, вибіркове лазерне спікання, пряме лазерне спікання металу, цифрова обробка світла. In today's conditions, 3D printing is used to create unique models, prototypes, and equipment necessary for conducting experiments and studying various phenomena and processes, for the rapid prototyping of various parts and devices in scientific and engineering research. 3D printing technologies are actively used to create individual medical implants, prostheses, and organ models for training and planning operations, which significantly improves the quality of medical care. In the aerospace and automotive industries, additive manufacturing is used to create lightweight and durable parts helping to reduce weight and improve vehicle efficiency. The use of additive manufacturing methods, technologies, and tools allows you to check and test designs and concepts before mass production. In this work, a detailed analysis of various existing 3D printers is carried out depending on the tasks, and modern technologies of additive manufacturing are investigated depending on the set goals and scientific and applied tasks. Such technologies include Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, and Digital Light Processing. In the work, a comparative analysis of these technologies was carried out according to various criteria, such as principle of operation, materials, resolution, surface finish, accuracy, speed, strength, application, cost, complexity of parts, and post-processing. For each technology, the advantages and disadvantages of its use are determined depending on the goals and objectives. It should be noted that some materials may not be suitable for printing complex parts or require additional support during the printing process. This can lead to complexity in the processing of products and increase the time and costs of printing. Improper selection of materials for 3D printing can be harmful to the environment or human health when used incorrectly. For example, some plastic materials may emit toxic elements or have low biodegradability. Also, using excess expensive material unnecessarily can increase the cost of the project. В умовах сьогодення 3D-друк використовується для створення унікальних моделей, прототипів та обладнання, необхідних для проведення експериментів та вивчення різноманітних явищ та процесів, для швидкого створення прототипів різних деталей та пристроїв у наукових та інженерних дослідженнях. Технології 3D-друку активно застосовуються для створення індивідуальних медичних імплантатів, протезів, моделей органів для навчання та планування операцій, що значно покращує якість медичного обслуговування. В авіаційній та автомобільній промисловості адитивне виробництво використовується для створення легких та міцних деталей, що сприяє зниженню ваги та покращенню ефективності транспортних засобів. Використання методів, технологій та засобів адитивного виробництва дозволяє перевіряти та тестувати дизайн та концепції перед масовим виробництвом. У даній роботі проведений детальний аналіз різних існуючих 3D-принтерів залежно від завдань, досліджено сучасні технології адитивного виробництва залежно від поставлених цілей і науково-прикладних завдань. До таких технологій відносять: Fused Deposition Modeling, Stereolithography, Selective Laser Sintering, Direct Metal Laser Sintering, Digital Light Processing. У роботі проведено порівняльний аналіз даних технологій за різними критеріями, такими як: принцип роботи, матеріали, роздільна здатність, фінішна обробка поверхні, точність, швидкість, міцність, застосування, вартість, складність деталей, постобробка. Для кожної технології визначено переваги і недоліки її використання залежно від поставлених цілей і завдань. Слід зазначити, що деякі матеріали можуть погано підходити для друку складних деталей або вимагати додаткової підтримки під час процесу друку. Це може призвести до складності в обробці виробів і збільшити час і витрати на друк. Неправильний підбір матеріалів для 3D-друку може бути шкідливим для навколишнього середовища або здоров’я людини при неправильному використанні. Наприклад, деякі пластикові матеріали можуть виділяти токсичні елементи або мати низьку біорозкладність. Також використання надлишкового дорогого матеріалу без необхідності може збільшити вартість проєкту. General Energy Institute of the National Academy of Sciences of Ukraine 2024-05-06 Article Article application/pdf https://systemre.org/index.php/journal/article/view/835 10.15407/srenergy2024.02.084 System Research in Energy; No. 2 (77) (2024): System Research in Energy; 84-96 Системні дослідження в енергетиці; № 2 (77) (2024): Системні дослідження в енергетиці; 84-96 2786-7102 2786-7633 en https://systemre.org/index.php/journal/article/view/835/744 Copyright (c) 2024 Vladyslav Romanenko, Oleg Nazarenko https://creativecommons.org/publicdomain/zero/1.0 |
| spellingShingle | additive manufacturing 3D printing additive manufacturing technologies Fused Deposition Modeling Stereolithography Selective Laser Sintering Direct Metal Laser Sintering Digital Light Processing Romanenko, Vladyslav Nazarenko, Oleg COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF ADDITIVE PRODUCTION |
| title | COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF ADDITIVE PRODUCTION |
| title_alt | ПОРІВНЯЛЬНИЙ АНАЛІЗ СУЧАСНИХ ТЕХНОЛОГІЙ АДИТИВНОГО ВИРОБНИЦТВА |
| title_full | COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF ADDITIVE PRODUCTION |
| title_fullStr | COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF ADDITIVE PRODUCTION |
| title_full_unstemmed | COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF ADDITIVE PRODUCTION |
| title_short | COMPARATIVE ANALYSIS OF MODERN TECHNOLOGIES OF ADDITIVE PRODUCTION |
| title_sort | comparative analysis of modern technologies of additive production |
| topic | additive manufacturing 3D printing additive manufacturing technologies Fused Deposition Modeling Stereolithography Selective Laser Sintering Direct Metal Laser Sintering Digital Light Processing |
| topic_facet | additive manufacturing 3D printing additive manufacturing technologies Fused Deposition Modeling Stereolithography Selective Laser Sintering Direct Metal Laser Sintering Digital Light Processing адитивне виробництво 3D-друк технології адитивного виробництва моделювання наплавлення стереолітографія вибіркове лазерне спікання пряме лазерне спікання металу цифрова обробка світла. |
| url | https://systemre.org/index.php/journal/article/view/835 |
| work_keys_str_mv | AT romanenkovladyslav comparativeanalysisofmoderntechnologiesofadditiveproduction AT nazarenkooleg comparativeanalysisofmoderntechnologiesofadditiveproduction AT romanenkovladyslav porívnâlʹnijanalízsučasnihtehnologíjaditivnogovirobnictva AT nazarenkooleg porívnâlʹnijanalízsučasnihtehnologíjaditivnogovirobnictva |