3D Printing Cost Considerations and Money-Saving Tips

How much does 3D printing cost? Theanswer depends on the technology, whether you own the 3D printer, and otherfactors.

In 2024, the cost of 3D printing is lower thanever before. A competitive market, expiring patents, and new groups ofend-users are all contributing to lower 3D printing prices. However, the costof 3D printing can vary depending on the technology and application. Forexample, simple thermoplastic prototypes are not comparable in price to metalend-use parts made using powder bed fusion technology.

Technology type is just one factor that affects3D printing prices. Raw materials, labor, post-processing steps, and otherfactors will all have an impact upon the bottom line, which can make it trickyto assess the true cost of 3D printing versus other manufacturing technologies.

It is, however, possible to reduce 3D printingcosts in various ways. Strategies can include optimized print preparation(printing multiple parts at once, for example), design for additivemanufacturing (DfAM) to reduce material usage, cost-effective materials, andautomating post-processing steps. On the other hand, the most importantdecision for many businesses is calculating whether it is more cost-effectiveto invest in 3D printer hardware or use a service provider to fulfill printingoperations.

Factors that influence 3D printing cost

Calculating the cost of 3D printing is not alwaysstraightforward. When investing in a 3D printer, buyers will first consider themachine cost. The next priority is typically raw material costs, followed byother considerations such as software costs, labor costs, and facility costs.All of these factors must then be weighed against the cost saving and profitmaking opportunities afforded by 3D printing, in addition to hardware sell-onvalue.

Cost comparison of different 3D printing technologies

It is not an exaggeration to say that a 3Dprinter can cost between a hundred and a million dollars. This is because theterm encompasses several vastly different technologies with entirely differentapplications and end uses.

The table below provides a rough guide to 3Dprinter machine costs, looking at thermoplastic (FDM), resin (SLA/DLP), andmetal (DMLS, DED) printers to illustrate the wide cost variation betweentechnologies and the intended user base. Several other technologies exist witha slightly narrower price variation, including selective laser sintering andmaterial jetting.

Material costs for 3D printing

With the exception of machines that use(injection molding) pellets as feedstock, almost all 3D printers requireprinting-specific materials. FDM printers use extruded filament, which can costanywhere between $30 per kilogram for budget materials and over $1,000 forpremium engineering materials. SLA printers require specially formulatedphotopolymerizable resins, while powder bed fusion systems require powders, themost advanced of which are gas atomized. Materials for 3D printing cost morethan their equivalent in formats like pellets and bars.

All 3D printing technologies accommodate a rangeof materials that vary in price. The least expensive are often used for mockupsor parts that are not functionally critical, while the most expensive aretypically used for functional prototypes and critical applications.

Labor and operational costs

Machine and material costs are relativelytransparent and easy to calculate. However, other costs can be difficult toassess. These include:

•  Labor for part design,machine operation, and post-processing

•  Post-processing equipmentand supplies

•  Training for employees

•  Software for part design,slicing, and machine management

•  Facility expenses includingrent, electricity, and environmental control

•  Machine maintenance andrepair

•  Waste material disposal

How to reduce 3D printing costs

3D printer users can reduce their 3D printingcost in different ways. Here we look at two general strategies for minimizingcost without compromising manufacturing outcomes.

Print optimization

It is possible to minimize 3D printing costwithout downgrading machinery or materials. Expert printer users can tailortheir designs and printing parameters in a way that reduces total materialusage, printing time, and post-processing time, all of which leads to a lowertotal part cost. 

Some ways to reduce the cost of a 3D printed partthrough print optimization include:

•  Design for additivemanufacturing (DfAM): A successful part should be designed to exploit theadvantages and avoid the limitations of the 3D printing process. Adhering tothe principles of DfAM leads to more economical material and power usage.

•  Reducing infill density: Making a part partially hollow reduces the required material quantity.Furthermore, by using a high-strength infill pattern or designing atopologically optimized internal structure, the lower density does notnecessarily have to weaken the part.

•  Orienting the partstrategically: Reorienting the part before printing can sometimes lead to ashorter print time and/or a reduced need for costly support structures.

•  Packing the print bed: Some 3D printing technologies allow for part nesting on the print bed, allowingusers to print multiple parts at once rather than sequentially. This reducestotal machine operating time, reducing energy and labor costs.

•  Increase layer height: Prototypes can be printed with a lower Z-axis resolution, drasticallyshortening print times. The resolution can then be increased on future printswhen necessary.

Outsourcing

Companies looking to implement 3D printing canchoose between investing in their own 3D printing equipment or using a 3Dprinting service provider to make parts for them. The type and quantity ofrequired parts ultimately determines which route is more cost-effective.

Purchasing a 3D printer can be cost-effective ifa company plans to use it regularly, if it plans to use a limited range ofmaterials for a limited range of applications, or if there are substantial costbenefits to achieving short lead times (when manufacturing on-demand spareparts, for example). Furthermore, companies that only require thermoplasticextrusion may find that the relatively low cost of an FDM printer is worth thesmall financial risk.

However, using a service bureau and 3D printingonline costs less than investing in a 3D printer if parts are only neededsporadically. The cost of ordering parts from a service provider is also fullytransparent (quotations are generally provided up front) and companies do nothave to worry about financial pitfalls such as machine breakdown or expiredmaterials. Outsourcing is also recommended if the company plans to use a broadrange of materials or use technologies with a very high machine cost like DMLS.

3D printing costs for your business

With the right planning, 3D printing can be ahighly cost-effective technology for prototyping and part production. However,prospective users of the technology should consider the primary and secondarycosts associated with 3D printing before making an investment in a machine. Fornewcomers to 3D printing, using a service provider is often the safer and morecost-effective route to high-quality 3D printed parts.