I have used three or four different 3D Printers over the years and they have always focused around the FDM (Fused Deposition Modeling) process.  Fused Deposition Modeling extrudes a modeling material (commonly an ABS material) through a nozzle as it is heated to a soft extrusion state.   Various nozzle sizes offer different deposition rates and detail.   The head then moves the nozzle as it extrudes the ABS, laying down roads and tracks to build one layer of the finished model.   Different layer thicknesses can be selected in the software.  Then the z axis moves down and another layer is fused to the previous layer.   There are software options including, color, density, layer thickness, and support structure.   All 3-D printers require a .stl file for printing.  The .stl extension was first developed in the late 1980's, and named by 3D Systems after there 3D Printing process called Stereo Lithography.

(see action video)

  3D Printer in Action

       The major disadvantage of the less expensive AFINIA printer is that it does not have a second head to print support structure.   More advanced 3D Printers use a second head to deposit support material as it is needed.   When the model is completed the support structure may be in intricate passageways and overhang parts of the model.  The support material in intricate passageways can be dissolved in an ultrasonic tank.   Current Kenwood Sprocket parts are not being printed in the Afinia, they are being printed in a far more expensive industrial quality Stratasys FDM Printer.  I use the Afinia for prototyping and simple parts as it is less accurate and prints much less expensive parts.   It also has the option of colors.   



Production run of 36 sprockets.   (7 hour run)

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