Beyond Plastic: My Journey into 3D Printing with Metals, Ceramics, and Glass
Introduction
For years, I believed 3D printing (also called rapid prototyping) was limited to plastics. I had heard whispers about metal applications, but never looked deeply into them. Recently, I was surprised to learn that glass and ceramics can also be used in 3D printing — despite their high melting points, often above 2,500°C.
This discovery has changed how I think about rapid prototyping. Below, I’ll share my early experiences, lessons learned, and why I now see 3D printing as one of the most versatile tools for proof-of-concept and functional prototypes.
My First 3D Printing Experience
The first time I used 3D printing, the parts came out looking like the intended design — but only at a glance.
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The surface finish was rough and layered.
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The parts broke easily.
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They worked as display models, not functional components.
At that stage, the technology was best for visualizing shapes rather than testing real-world performance.
From FDM to PolyJet: A Big Step Forward
Later, I ordered parts through fusion deposition modeling (FDM). These were functional, but they still had a layered finish and weaknesses along the layer lines — especially in thin sections.
A few months later, I discovered PolyJet printing, which was a game-changer:
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Smoother surface finish.
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Stronger parts.
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Better accuracy for assemblies.
PolyJet made prototypes look closer to production-quality parts, while FDM remained more limited in mechanical strength.
Rubber-Like 3D Printing
One of my favorite discoveries was a rubber-like 3D printed material, similar to what you find in running shoe soles.
This soft, flexible option was excellent for projects that needed proof-of-concept elastomer parts or short-run molding. Even better, the same CAD files used for 3D printed prototypes could also be repurposed to make molds — a huge cost-saving measure.
Metal Prototyping with DMLS
The most exciting advancement for me has been metal 3D printing. A standout method is Direct Metal Laser Sintering (DMLS):
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Works with almost any powdered metal.
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Produces “full density” parts, meaning no voids like in FDM plastics.
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Strong enough for functional prototypes.
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Potentially compatible with heat treatments for improved mechanical properties.
This opens doors for aerospace, automotive, and medical prototypes where real-world testing of metal parts is essential.
Ceramics and Glass: A Surprising Discovery
What surprised me most was learning that ceramics and glass are also being used in rapid prototyping.
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Both materials normally require very high melting temperatures (>2,500°C).
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Advances in 3D printing have made it possible to create complex ceramic and glass shapes for high-temperature or biomedical applications.
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This expands the possibilities far beyond traditional plastics and metals.
Why 3D Printing Matters for Design
From plastics to metals, ceramics, and even flexible rubbers, 3D printing has grown into a tool that:
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Speeds up prototyping by cutting lead times.
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Reduces costs by eliminating expensive tooling in early stages.
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Allows rapid design changes at minimal cost.
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Provides a wide material selection for real-world testing.
What started for me as a way to make rough display models has become a serious method for functional prototypes — and even pre-production testing.
Conclusion
My early assumptions about 3D printing were wrong. I thought it was only about plastic parts. But today, we can make prototypes in metal, glass, ceramics, and flexible rubbers with surprising precision and strength.
For engineers and designers, 3D printing is no longer just a visualization tool — it’s a core part of product development, bridging the gap between design concepts and functional prototypes.
Norman T. Neher, P.E.
Analytical Engineering Services, Inc.
Elko New Market, MN
www.aesmn.org