Your Complete Guide to 3D Printing Technology in 2025

Professional 3D printing services, often referred to as additive manufacturing, continue to support businesses that need accurate prototypes, functional parts, and low-volume production. The core ideas in the original article remain important, and this refreshed version provides updated information, clearer explanations, and improved structure while keeping your foundation intact.

Key points:

• 3D printing builds objects layer by layer from a digital file, which reduces waste and supports complex designs.
• A wide range of technologies and materials now support both prototyping and end-use parts.
• Local Australian production provides fast turnaround, strong communication, and secure handling of intellectual property.
• Applications span healthcare, automotive, aerospace, education, architecture, and consumer products.
• Improvements in materials, accuracy, and production capability continue to expand what businesses can achieve.

How 3D Printing Works

At its core, 3D printing converts a digital 3D model into a physical object through an additive process. Instead of removing material, the printer builds the part layer by layer. This method reduces material waste and supports complex designs that traditional manufacturing cannot easily produce.

Types of 3D Printing Technologies

Formero operates 13 industrial 3D printers at our Nunawading facility in Melbourne, covering a wide range of technologies suitable for prototyping and production:

1. Masked Streolithography (MSLA)
2. Selective Laser Sintering (SLS)
3. Multi Jet Fusion (MJF)
4. Stereolithography (SLA)
5. Fused Deposition Modelling (FDM/FFF)
6. Carbon Reinforced Fibre (CFR)
7. Digital Light Processing (DLP/Figure 4)
8. Colour Jet Printing (CJP)
9. Metal 3D Printing using Selective Laser Melting (SLM)

These options allow designers and engineers to choose the right process based on strength, detail, temperature resistance, part performance, and budget.

Step-by-step overview of the 3D printing process

Formero manages the entire production workflow from the moment your file is submitted. Besides the designing, Formero handles everything, from slicing through to post-processing.

Here is how the process works:

1. Modelling: Designing the 3D model using computer-aided design (CAD) software
2. Slicing: The 3D model is divided into horizontal layers to create a printable file (usually in STL or Step format)
3. Preparation: The 3D printer is set up, and the appropriate printing material is loaded
4. Printing: The 3D printer builds the object layer by layer, following the instructions from the sliced file
5. Post-processing: After printing, some objects might require additional finishing or curing

This workflow ensures consistency and repeatability across multiple projects.

Materials used in 3D printing

The material choices for 3D printing have expanded significantly in recent years. Formero offers more than 28 specialised materials, including:

1. Thermoplastics: Nylon, PLA, ABS, PETG, and more
2. Photopolymers: Resins used in SLA and DLP
3. Composites: Reinforced materials for enhanced strength and properties

Different materials offer different mechanical properties, making it important to match the material to the application.

3D modelling and designing for 3D printing

Creating 3D models requires specialised software, such as SolidWorks, Autodesk Fusion 360, or AutoCAD. These tools enable designers to bring their concepts to life in a virtual environment.

CAD and STL file formats

CAD software generates designs in STL format, which divides the object into triangular facets, making it printable. This file format is widely accepted by 3D printers.

Tips for designing effective 3D printed parts

To ensure successful 3D printing, designers should consider several factors:

1. Wall Thickness Considerations: Designing with appropriate wall thickness ensures structural integrity
2. Overhangs and Bridging: Minimising overhangs and bridging gaps reduces the need for supports

By choosing an experienced local supplier, you gain a team that reviews every file with care, making sure it suits the selected technology and material before printing begins.

We manage the orientation, support strategy, and all technical setup behind the scenes, so you can stay focused on your design while we handle the production expertise.

Applications of 3D printing

3D printing continues to support a wide range of industries.

1) Healthcare, orthotics, and medicine

• Concept Presentation Models: Precise and detailed models that accurately represent your design concepts.
• Customised Medical Devices and Prosthetics: Patient-specific medical devices, orthotics and prosthetics can be produced efficiently.

2) Space, automotive, and drones

• Prototyping and Rapid Manufacturing: 3D printing accelerates the prototyping and testing phases of aerospace and automotive components.
• Lightweight and Complex Part Production: 3D printing enables the fabrication of lightweight, intricate parts for improved performance.
• High-strength, Lightweight Automotive Parts: Printing in technologies such as our Markforged FX20 gives designers the ability to integrate carbon fiber reinforcement for superior strength-to-weight ratios

3) Architecture, construction, and packaging

• Rapid Prototyping of Architectural Models: Architects use 3D printing to visualise and refine their concepts quickly.
• 3D Printed Houses and Infrastructure: The construction industry explores 3D printing for cost-effective and sustainable building projects.

4) Education and research

• Enhancing Learning Experiences: 3D printing introduces hands-on learning and better understanding of complex concepts.
• Scientific and Engineering Research Applications: Researchers use 3D printing to create prototypes and custom lab equipment.

5) Consumer goods and fashion

• Customised Products and Accessories: 3D printing allows personalised consumer goods and fashion items.
• 3D Printed Fashion and Jewellery: Designers leverage 3D printing to create avant-garde fashion pieces for movie props and alike.

Advantages of 3D printing

1. Design Freedom and Complexity: 3D printing enables the production of intricate shapes and geometries impossible with traditional methods
2. Faster Prototyping and Time-to-Market: Rapid iteration and testing reduce product development timelines
3. On-demand Manufacturing and Reduced Inventory Costs: Objects can be printed when needed, reducing storage costs
4. Sustainable and Eco-friendly Aspects: Material waste is minimised due to the additive nature of 3D printing

All printing is completed locally at Formero’s Melbourne facility, which supports fast delivery, reduced transport delays, and strong protection of confidential designs.

The future of 3D printing

3D printing continues to expand in capability, accuracy, and material performance. More businesses are exploring on-demand production as part of their workflow. As the technology improves, its role in manufacturing, engineering, and medical applications will continue to grow.

Bringing it all together

3D printing has evolved from a niche technology to a powerful tool used in diverse industries. Its ability to transform digital designs into tangible objects has made it invaluable for prototyping, customisation, and innovation.

As technology continues to advance, we can expect 3D printing to play an even more significant role in shaping the future of manufacturing and beyond.

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Frequently Asked Questions (FAQ): 3D Printing

What is the cost of 3D printing?

The cost varies depending on the material, technology, part size, and finishing work. Formero provides tailored quotes based on your file and application.

Can I 3D print any object?

While 3D printing offers great design flexibility, there are some limitations, in particular, the size of the print and the material properties. More often than not, Formero will have a workaround for most problems that arise. For example, large parts can be printed in sections and glued together with high precision. We also offer over 17 different materials, so we are sure to have something that suits your requirements.

How long does it take to 3D print an object?

The production time to 3D print an object varies depending on its size, complexity, the chosen 3D printing technology and the post-processing that is required. Formero can have parts printed and ready for shipping in as little as two days.

Is 3D printing environmentally friendly?

3D printing definitely has eco-friendly aspects compared to traditional manufacturing methods. It generates less waste because it adds material only where needed, reducing material waste and allows for material recyclability. Additionally, localised production through 3D printing can reduce transportation-related carbon emissions.
You can learn more by reading our Embracing Sustainability: The Role of 3D Printing & Additive Manufacturing blog.

Are 3D printed objects as strong as traditionally manufactured ones?

The strength of 3D printed objects depends on the chosen material and the printing process. Some 3D printing materials, such as HST, Onyx, Ultem & Carbon Fibre FR-A, can offer comparable, if not higher, strength to traditionally manufactured parts. Formero’s team of experts can help you decide which technology and material is right for you.

How can I learn 3D modelling for 3D printing?

Learning 3D modelling for 3D printing is accessible to beginners with various online resources. There are numerous tutorials and courses available for popular 3D modelling software SolidWorks, Autodesk Fusion 360, AutoCAD and more. Practice and experimentation are key to mastering 3D modelling for 3D printing. Consistent practice helps build confidence.

3D Printing, Knowledge Hub