Grand_Wag_85 wrote:3D printing has never crossed my mind but I'll check it out.
Would 3D printing work for load bearing structural components?
The best answer for that question is it depends.
How much load are on talking about? People build ar15s out of 3d prints using ABS plastic, as long as you use a high infill percentage it should be ok. However if the part is going to be subjected to higher loads you could use carbon fiber filament, or a company called filamet makes 3d printing filament out of 90 percent metal, then once the print is done you put it in the oven to cinter and it becomes 99% pure metal. All 3 of these filaments could be run in a relatively low cost printer as long as the part you need isn't too big. A folgertech ft5 is around 500 and can print anything up to 12x12x15.
If it's a complex shape you may need supports. You can do supports one of tree ways.
1. Use the build material for supports. You normally have to scrape this off and then send the part for a decent finish, and if your is in a specialty filament can be costly
2. Get a mod for for printer that allows it to use two print heads simultaneously. You then load one print head with your desired build filament, and the other with a water solluable support material. Then when the print is done, you soak it in water for an hour and the supports dissolve. This stops you from having to send the part, but has a lower resolution.
3. This is the most expensive option, but yields the best results. Buy a mosaic. The mosaic splices multiple filaments together to give you the better resolution of a single print head, and the ability to use a water solluable support so you don't have to waste high strength filament.