3D Printing for Laboratory Research

by Vincenzo Mastrolia, Research Associate, Burrone lab, KCL

Why 3D Printing in Laboratory Settings?

In a laboratory setting, we sometimes need a very specific tool for our experiments that is either too expensive or not even produced by companies. What to do in this situation? One answer is to create our own designs tailored around our experiments and see them brought to life using 3D printing technology. 3D printing allows researchers to quickly prototype and iterate on their designs, ensuring that the final product meets their exact specifications. This capability can significantly reduce the time and cost associated with developing custom tools and components. This level of customization and precision is invaluable in laboratory settings where unique experimental setups are often required.

In this blog post, we’ll discuss some useful software and equipment necessary to produce the unique designs necessary for your experimental needs.

Modelling Software

To create custom tools and equipment, you'll first need to design them using 3D modelling software. Here are some popular options:

FreeCAD

FreeCAD is a free, open-source parametric 3D CAD modeler. It has a great tradition, being around for several years now. It's great for beginners and advanced users alike due to its robust features and active community. FreeCAD allows you to create complex geometries and offers a range of modules tailored for different needs, such as architecture or mechanical engineering. Its parametric nature means you can easily modify your designs by going back into your model history and changing parameters. FreeCAD also supports various file formats, making it compatible with other CAD tools.

Fusion 360

Fusion 360, by Autodesk, is a powerful, cloud-based tool that integrates CAD, CAM, and CAE. It’s particularly popular in professional settings due to its comprehensive suite of features that support the entire product development process. Fusion 360 offers a free license for students, educators, and startups, making it accessible to a wider audience. Its cloud-based nature allows for easy collaboration and access to your projects from anywhere. Fusion 360 also provides advanced simulation and analysis tools, enabling you to test your designs under various conditions before printing.

Blender

Blender is a free and open-source 3D creation suite. It is my favourite modelling software and I’ve been using it for years. While it is primarily known for its use in creating animations, visual effects, and video games, Blender is also highly capable in 3D modelling for 3D printing. It offers extensive tools for sculpting, texturing, and rendering, allowing for very detailed and intricate designs. Its large community and plethora of tutorials make it easier to learn and troubleshoot. Blender’s flexibility and range of features, from basic modelling to advanced simulations, make it a versatile tool for laboratory settings. Whether you need to design a simple container or a complex apparatus, Blender has the capabilities to meet your needs. Additionally, Blender supports various file formats and offers powerful add-ons, further enhancing its functionality.

Slicing Software

Once you've created your 3D model, you'll need slicing software to prepare it for printing. This software converts your 3D model into instructions that the 3D printer can understand. Here are some popular options:

PrusaSlicer

PrusaSlicer is a free, open-source slicing software developed by Prusa Research. It supports a wide range of 3D printers and provides a user-friendly interface with advanced features. PrusaSlicer is highly customizable, allowing you to fine-tune settings for optimal print quality. It includes features like variable layer height, support material customization, and multiple infill patterns. PrusaSlicer is continuously updated with new features and improvements, thanks to its active development community.

MatterControl

MatterControl is an all-in-one software package that allows you to design, slice, organize, and manage your 3D prints. It’s open-source and compatible with a wide range of 3D printers. MatterControl is particularly useful for managing multiple prints and organizing complex projects. It features an integrated design tool that lets you make quick adjustments to your models without switching software. MatterControl also supports plugins and extensions, allowing for additional functionality tailored to your needs.

Ultimaker Cura

Ultimaker’s Cura is one of the most popular slicing software tools available, known for its ease of use and powerful features, and I have worked with it for years. Cura is free and open source, supporting a wide variety of 3D printers. It offers pre-configured profiles for many printer models, making it easy to get started quickly. Cura’s intuitive interface and advanced customization options allow users to optimize their prints for various materials and desired outcomes. With features like print time estimation, support generation, and a variety of infill patterns, Cura is a versatile tool suitable for both beginners and experienced users. Additionally, Cura integrates with Ultimaker’s ecosystem, providing seamless compatibility with Ultimaker printers and materials.

3D Printers

Printer Types

Choosing the right 3D printer is crucial for your laboratory needs. Here are some common types of 3D printers:

FDM (Fused Deposition Modeling): FDM printers use a thermoplastic filament, which is heated and extruded layer by layer to create a model. They are widely used due to their affordability and versatility. FDM printers are suitable for a wide range of materials and applications, making them a popular choice for prototyping and functional parts.
Resin Printers (SLA/DLP): These printers use a photosensitive resin, which is cured layer by layer using a laser (SLA) or a digital light projector (DLP). They offer higher resolution prints, making them ideal for detailed work. Resin printers are particularly useful for applications requiring fine details and smooth surfaces, such as medical models and intricate prototypes.
SLS (Selective Laser Sintering): SLS printers use a laser to sinter powdered material, typically nylon, layer by layer. They are more expensive but offer high durability and complexity, suitable for functional prototypes and end-use parts. SLS printing is known for its strength and ability to produce complex geometries without the need for support structures, making it ideal for industrial applications.

Popular 3D Printers

If you don’t have the budget to buy a 3D printer, don’t despair. There’s a variety of online services that offer the possibility of printing and delivering to you your designs. However, if you have the budget, I warmly recommend to buy a 3D printer. Here are some popular and affordable 3D printers, along with their types:

Creality Ender 3 (FDM): Known for its affordability and reliability, the Ender 3 is a popular choice for both beginners and experienced users. It offers a large build volume and excellent print quality. The Ender 3 has a strong community support, which means plenty of resources and upgrades are available. Its open-source nature allows for extensive modifications and enhancements.
Prusa i3 MK3S+ (FDM): This printer is renowned for its reliability, print quality, and robust features. The Prusa i3 MK3S+ is slightly more expensive but offers advanced capabilities, such as automatic bed leveling, a filament sensor, and crash detection. Prusa Research also provides extensive documentation and support, making it easy to troubleshoot and maintain your printer.
Anycubic Photon Mono (Resin): A budget-friendly resin printer, the Photon Mono is known for its high-resolution prints and ease of use. It’s a great option for detailed and intricate designs with fine detail. Its compact design and relatively low cost make it an excellent choice for high-detail prints.
WASP 3D Printers (FDM): WASP (World's Advanced Saving Project) offers a range of 3D printers known for their robustness and innovative features. The WASP Delta series includes printers that excel in speed and build volume, making them suitable for both small and large-scale projects. These printers are designed with a focus on sustainability and versatility, accommodating a variety of materials and applications. What’s also interesting is the ability of WASP’s printers to print using clay.

Materials

The choice of material can significantly impact the functionality and durability of your printed objects. Here are some common materials used in 3D printing:

PLA (Polylactic Acid)

PLA is a biodegradable thermoplastic derived from renewable resources like corn starch or sugarcane. It is easy to print with, has a low warping tendency, and is suitable for a wide range of applications. However, it is less durable and heat-resistant compared to other materials. PLA is ideal for prototypes, educational projects, and models that don’t require high mechanical strength or thermal resistance. Its environmental friendliness makes it a popular choice for eco-conscious projects. It is also compatible with cell culture and living tissues, which makes it extremely useful for laboratory settings.

ABS (Acrylonitrile Butadiene Styrene)

ABS is a strong, durable thermoplastic with high impact resistance and good heat resistance. It is ideal for functional parts and mechanical applications. However, it requires a heated bed and can be prone to warping, making it slightly more challenging to print with. One other complication are the fumes that are produced while printing with ABS, making it necessary to use closed ventilation while printing. ABS is commonly used for automotive parts, toys (like LEGO bricks), and household appliances due to its strength and durability. It can also be post-processed with acetone to achieve a smooth finish.

Teflon (PTFE)

Teflon, or PTFE, is a high-performance plastic known for its excellent chemical resistance and low friction. It is used in applications requiring high thermal and chemical stability. While not commonly used in standard 3D printing due to its high melting point, specialized printers and filaments are available for printing with PTFE. Teflon’s unique properties make it suitable for high-temperature environments and chemical processing applications. It is often used in laboratory equipment, gaskets, and seals where resistance to aggressive chemicals is essential.

Soluble 3D Printing Material (PVA and HIPS)

Soluble materials are used as support structures for complex prints. They dissolve in water or other solvents, allowing for the creation of intricate designs without the need for manual support removal.

PVA (Polyvinyl Alcohol): PVA is a water-soluble material commonly used with dual extrusion 3D printers. It is environmentally friendly and dissolves easily in water, making it ideal for printing supports for complex models. PVA is compatible with a variety of materials like PLA and PETG, allowing for clean and precise prints.
HIPS (High Impact Polystyrene): HIPS is a soluble material that dissolves in limonene, a citrus-based solvent. It is often used in conjunction with ABS, as it provides strong support structures that can be easily removed post-printing. HIPS also has good impact resistance and can be used for functional parts when not used as a support material.

In conclusion, 3D printing technology offers laboratories unparalleled flexibility and customization capabilities, enabling the creation of specialized tools and equipment that are otherwise inaccessible or prohibitively expensive. In my personal use, I design several tools for the preservation of acute brain slices for electrophysiology. You can see an example of a slice support with a socket for a bubbling stone in the image that I regularly use for my slice preparations.

I warmly invite you to explore the infinite possibilities of 3D printing!

Slice support with a socket for a bubbling stone

About the Author

Vincenzo Mastrolia is currently a research associate at the Centre for Developmental Neurobiology at King's College London. Vincenzo investigates the regulation of excitatory and inhibitory synapses by using electrophysiology and imaging in brain slices.