APPLICATIONS

3D printing isn’t a direct replacement for traditional manufacturing, but it offers unique advantages that make it a powerful alternative or complement, depending on the application.

At Fracktal Works, we see 3D printing as a game-changer for:

Rapid prototyping – Designs can be turned into physical parts within hours, enabling faster product development.
Cost-effective low-volume production – No tooling or molds required, making it ideal for custom or small-batch parts.
Design freedom – Complex geometries and lightweight structures are easily achievable, which are often impossible with traditional methods.
On-demand manufacturing– Parts can be produced as needed, reducing inventory and waste.

Traditional manufacturing still has the edge in:

Mass production– It’s more cost-effective for large volumes.
Material variety and tolerances – Some metals, finishes, and precision levels are better suited for CNC or injection molding.

In summary, 3D printing isn’t superior in every situation, but it excels in speed, flexibility, and customisation—making it an essential tool in modern manufacturing.

At Fracktal Works, we specialise in two primary 3D printing technologies: Fused Deposition Modeling (FDM) and Selective Laser Sintering (SLS). Here's an overview of these technologies and how they cater to various applications:

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Fused Deposition Modeling (FDM)

FDM is an additive manufacturing process where thermoplastic material is extruded layer by layer to build a part. It's widely used for rapid prototyping and functional parts.

Key Features:

Cost-Effective: Ideal for low-volume production and prototyping.
Material Versatility:Supports a range of thermoplastics like PLA, ABS, and Nylon.
User-Friendly: Suitable for both beginners and professionals.

Fracktal's FDM Printers:

Snowflake:A compact, plug-and-play printer designed for versatility.
Julia Series: Offers precision and reliability for various applications.
Volterra: An industrial-grade printer with a 450°C nozzle and 150°C build chamber, suitable for high-performance materials. 

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Selective Laser Sintering (SLS)

SLS uses a laser to sinter powdered material, binding it together to create a solid structure. It's known for producing durable and complex parts without the need for support structures.

Key Features:

High Precision:Achieves fine details and smooth finishes.
Material Efficiency: Unused powder can often be recycled, reducing waste.
Complex Geometries:Ideal for intricate designs and functional prototypes.

Fracktal's SLS Printers:

Apollo 250: Designed for producing high-quality, functional parts.
MDS-1: A material dryer system ensuring optimal powder conditions for consistent results.
Printstick Accessories to enhance the SLS printing process.

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By offering both FDM and SLS technologies, Fracktal Works provides solutions tailored to a wide range of manufacturing needs, from rapid prototyping to producing end-use parts.

When it comes to 3D printing software, Fracktory  be the software of choice. This advanced software is designed for high-performance end-use parts and prototypes in controlled manufacturing environments. Some of its notable features include the Accuracy Center, Manufacturing Templates, support for 3rd Party Plugins, and Per-Part Estimation. Keep in mind that more features will be added in future updates.

3D printing, or additive manufacturing, involves the creation of a three-dimensional object based on a digital 3D model or CAD design. This manufacturing process encompasses a range of techniques where materials are either deposited, fused, or solidified in a controlled manner by a computer. Typically, these materials are added in a layer-by-layer fashion and can include plastics, liquids, or powders.

Fracktal Works' 3D printers are engineered to excel in both prototyping and production runs, offering flexibility and efficiency for various manufacturing needs.

Prototyping Capabilities:

• Rapid Prototyping: Fracktal's printers enable quick turnaround times, allowing for faster design iterations and product development.

• Cost-Effective: Ideal for creating prototypes without the need for expensive tooling or molds.

Production Capabilities:

• Low to Medium Volume Production: Fracktal's printers are suitable for producing small batches of end-use parts, making them ideal for custom or limited-run products.

• Consistency and Precision: The printers maintain high-quality output across multiple units, ensuring uniformity in production.

Fracktal's FDM printers, including the Snowflake, Julia Series, and Volterra, support a diverse selection of thermoplastics:

• PLA (Polylactic Acid): Known for high tensile strength and excellent surface quality, making it ideal for visual prototypes.Fracktal

• ABS (Acrylonitrile Butadiene Styrene): Offers temperature resistance up to 85°C and is suitable for functional parts.Fracktal

• PET-G (Polyethylene Terephthalate Glycol): Combines chemical resistance with toughness, functional up to 70°C.Fracktal

• PVA (Polyvinyl Alcohol): A water-soluble support material, perfect for printing complex geometries.

• Nylon: A durable, all-rounder material known for high strength and durability.

• Carbon Fiber Nylon: Provides an excellent strength-to-weight ratio, is impact-resistant, and flame-retardant.

• PC (Polycarbonate): Offers impact and heat resistance, functional up to 110°C.Fracktal

• TPU (Thermoplastic Polyurethane): A flexible material with 600% elongation, resistant to wear and tear.Fracktal

The Julia Series features a heated platform reaching up to 130°C, ensuring reliable printing with engineering-grade materials like ABS, PC, and Nylon. Fracktal

The Volterra printer is equipped with a 450°C nozzle and a 150°C build chamber, enabling the use of high-performance materials.

Fracktal's Apollo 250 SLS printer is designed for production-grade printing, capable of handling complex and functional parts with high precision.

FDM (Fused Deposition Modeling)

• Process: Melts and extrudes thermoplastic filament layer by layer.

• Materials: PLA, ABS, PETG, Nylon, TPU, etc.

• Applications: Prototypes, functional parts, education.

• Pros: Affordable, user-friendly, wide material choice.

• Used by: Hobbyists, engineers, manufacturers.

• Fracktal Works offers FDM printers like Julia and Volterra.

 SLS (Selective Laser Sintering)

• Process: Uses a laser to fuse powdered material (usually nylon).

• Materials: Nylon, TPU, composite powders.

• Applications: Functional parts, aerospace, automotive.

• Pros: No need for support structures, durable parts.

•  Fracktal Works offers SLS technology with Apollo 250.

1. Industrial-Grade Performance

• High-Temperature Capabilities: The Volterra printer features a 450°C nozzle and a 150°C build chamber, enabling the use of high-performance materials like PC and carbon fiber composites.

• Precision and Reliability: Fracktal's printers deliver consistent, high-quality prints suitable for both prototyping and end-use parts.

 2. Material Versatility

• Wide Material Compatibility: Supports a broad range of materials, including PLA, ABS, PET-G, Nylon, Carbon Fiber Nylon, PC, and TPU, catering to diverse application needs.

• Advanced Material Handling: The MDS-1 material dryer ensures optimal filament conditions, reducing moisture-related print issues.Fracktal

 3. User-Centric Design

• Ease of Use: Printers like the Snowflake are designed for plug-and-play operation, making them accessible to users of all experience levels.

• Innovative Accessories: Tools like the PrintStick enhance bed adhesion consistency, improving print reliability.Fracktal

 4. Trusted by Industry Leaders

• Clientele: Fracktal's solutions are utilized by prominent organizations such as TVS, TATA, and IISc, reflecting their reliability and performance in professional settings.Fracktal

5. Comprehensive Service Offerings

• End-to-End Solutions: Beyond hardware, Fracktal provides design engineering and 3D printing services, supporting clients from concept to final product.