Methods

All pro's and con's are in relation to the manufacturing of musical instruments

Note: All diy 3d printers (reprap, makerbot…) are of the FDM/FFF type.
If you don't have access to your own 3d printer, you could check out this site.

Hardware

We're covering the printing method here, as a lot of 3d printing machines share the same method. Also, while there are differences between machines which use the same method, it is not within the scope of this research to test this. If you read this and have experience in this field, please contribute to this wiki or contact me directly!

The methods are regarded as if we're making an instrument with just this method. The use of certain methods for specific parts of an instruments (like a guitar bridge) are not discussed.

3d Printing

All methods work by working in layers, adding material, etc.
Diffrent to other technieques, which are substractive

Supports needed because

Almost all methods could support multi material printing, but it is currently only available in certain top tier machines.

A method of turning digital shape into physical objects. Due to it's nature, it allows us to accurately control the shape of the product. So unlike conventional instruments, we'll have control over the inside structures of our instrument.

Size Restraints

Materials often not dureable

While FDM doesn't seem like the best method for instrument manufacturing, it is one of the cheapest and most universally available methods.

There are a few different methods of 3d printing, of which I will explain the pro's and con's for instrument making.

Schematics of how some 3d printing methods work. Source: http://www.3dprinting.org

Selective laser sintering (SLS)

• Description

This method uses a high powered laser to melt powder together. When set up carefully, this can create an almost perfectly uniform material of nearly injection mold quality. This make for very durable products. This is very interesting for musical instruments, as this allows us to create objects with the same materials as conventional instruments, but with the ease of printing instead of manual labor. The method is relatively simple, due to inherent supports it avoids additional step in between the 3d model and printing. The surface quality is fair, but not as detailed as other techniques.

• Materials

Plastics, Elastomers, Metal, Ceramics, Glass

• Product example

• Machines which use this technique¹

Stereolithography (SLA)

• Description

A layer of fluid resin is hardened by UV or laser. It makes for great surface quality and build accuracy. Useful, as this removes the need for post-finishing. But the products remain brittle, which disqualifies this method for musical instruments, because an instrument which could break during performance, is no use at all.

• Materials

Epoxy polymers, both rigid or flexible

• Product example

• Machines which use this technique

Polyjet or Jetted Photopolymer (J-P)

• Description

Extrudes a photo polymer which hardens with UV light. Can create rubber-like objects. This could be interesting for creating one-piece string instruments (is 1 - 20 MPa Tensile strength enough??²

• Materials

Photopolymers, both solid as rubber-like.

• Product example

• Machines which use this technique

Fused deposition modeling/fused filament fabrication (FDM/FFF)

• Description

The most seen 3d printing method, as most inexpensive machines use this method. (Usually) A plastic wire is molten and laid down in layers. Inherently unsolid material, always has air-spaces and fuse lines. In default setting this provides a material which is not interesting for musical instruments, but with a careful setup, the air spaces could be tuned, so it could resonate in a controlled fashion.
A big advantage is that is method is used in the cheapest and most common 3d printers. This is also the method that seems to make most promise for cheap home printers.

• Materials

ABS, PC, concrete, chocolate, icing and other food

• Product example

• Machines which use this technique

RepRap

Cladding or Laser Powder Forming or Laser Fusing

• Description

Instead of feeding the printing head a solid core of material, a powder is fed. This provides a more accurate method. It creates a full density product without porosity or weld-lines. A method for making very detailed and small parts. This method seem perfect for 3d printing replica's of mouthpieces. The biggest disadvantage is that this is one of the most expensive 3d printing methods.

• Materials

Metal, Ceramic, Polymer³

• Product example

• Machines which use this technique

Laminated object manufacturing or LOM

• Description

Sheets of raw material are laid on each other, after which it will be cut out by laser or knife. Objects can get wood-like properties, by simulating year ring.

• Materials

Paper, Plastic or Metals.

• Product example

• Machines which use this technique

Laser cutting

• Description

A method of using a laser to cut shapes in sheets of material. Only allows 2d shapes but could allow for IKEA style diy instruments on the fly.

• Materials

Wood, metal, polymers, paper

• Product example

• Machines which use this technique

CNC milling

• Description

A computer controlled tool mills the material based of a CAM file. Allows for extremely detailed products. Yet it deals with the same space constrains as manual milling. So not that interesting for new possibility's.
Could be seen as reverse 3d printing, instead of adding layers of material, you remove them.

• Materials

Wood, Polymers, foam, metal.

• Product example

• Machines which use this technique

Software

Design your own 3D model with a CAD program. Here are some free ones:
- Google SketchUp (Easy to use entry into 3D design - I'm not a big fan though)
- Autodesk 123D (Nice one if you prefer a more conventional GUI)
- OpenSCAD (Parametric design - for math pros ;)
BLender

Semiprofessional:
- Paul's tip: Alibre Design PE is pleasing the creator of Netfabb's current high quality profiles. Looks good from my perspective.

Professional:
Autodesk Inventor Professional, PTC Creo, Solidworks, CATIA, etc.
You'll find the links… and start crying when checking the pricing.

Additonal tip: If you're a student you're elgible for a couple of high-end software solutions for free. E.g.: Autodesk Education Community, PTC Creo Student program

Sources
http://www.efunda.com/processes/rapid_prototyping/intro.cfm membership? sucks
http://www.additive3d.com/techn.htm
http://www.additive3d.com/rp_int1.htm
http://www.printers3d.co.uk information about machines

Footnotes

1. http://www.protocam.com/html/sls.html

2. http://www.protocam.com/html/materials-polyjet.html

3. http://www.additive3d.com/lens.htm