FDM/FFF (Fused Deposit Modeling/Fused Filament Fabrication)

This is the cheapest and most widely available 3D printing technique, wherein a spool of plastic is additively melted to create a form. Materials: PLA (polylactic acid), ABS (acrylonitrile butadiene styrene), Nylon (polyamide), Polycarbonate, etc.

Potential Applications

• Soul Plates
• Buckles
• Frames
• Boots

PRO

• Inexpensive printer hardware
• Widely available
• Easy to use/learn/get started with
• Cheap consumables

CON

• Not that strong without heat treatment/chemical post-processing. Still less durable than injection molded plastic.
• Slow: 10+ hours for a frame

SLS (Selective Laser Sintering)

Plastic (usually nylon/polyamide) powder is mechanically spread and built into fine layers that are melted together by a laser.

Potential Applications

• Soul Plates
• Buckles
• Frames
• Boots

PRO

• Potentially stronger/less prone to delamination than FDM/FFF plastic prints
• High resolution finish

CON

• Not widely available as an end-consumer process; parts must be printed by/ordered from a third party
• Somewhat expensive; very expensive printer hardware

SLM (Selective Laser Melting)

Metal powder is mechanically spread and built into fine layers that are melted together by a laser.

PRO

• Printed metal??!?!?!?

CON

• Parts must be printed by/ordered from a third party
• Requires an expensive high power laser; very expensive, even when provided as a service

SLA/SL (Stereolithography)

Photoreactive resin is continuously cured by UV light and fixed in a post-printing chemical bath.

Potential Applications

• Small parts: buckles, antirocker wheels

PRO

• Parts are high resolution, have a smooth finish without cleanup and are dimensionally accurate

CON

• Not that strong
• Most machines cannot print large parts

CNC (Computer Numerical Control) Milling

The opposite of printing: material is programmatically, subtractively sculpted by a drill bit.

PRO

• Much faster than printing

• Can shape virtually any type or strength of material

CON

• Steep, less lazy learning curve than printing: requires an understanding of manual operations
• Expensive relative to FDM/FFF printing, with some affordable turnkey/DIY options becoming available
• Some designs are not possible to produce, such as those with enclosed cavities