The BritForge3D Technical Knowledge Hub
Technical Knowledge Hub
The BritForge3D Technical Knowledge Hub
Welcome to the BritForge3D Technical Knowledge Hub — a structured, in-depth learning library designed to help you understand 3D printing properly.
Whether you are designing functional components, producing prototypes, or commissioning professional 3D printing in the UK, these guides explain not just what to do, but why it works.
This is not a collection of surface-level tips. It is a complete educational pathway covering strength, tolerances, materials, motion control, efficiency, repeatability, and file preparation.
Each guide builds on the previous one. If you are new, start at the beginning. If you are refining professional workflows, jump to the advanced sections.
Start Here – Core Foundations of 3D Printing
Guide 1 – The Basics of 3D Printing
Understand how 3D printing works from digital model to finished part. Learn how slicing software converts models into layers and why layer-by-layer construction affects strength and reliability.
Recommended starting point for all readers.
Guide 2 – Layer Height, Infill, and Strength
Discover how strength is actually created inside a printed part. Learn why wall thickness often matters more than infill, why thinner layers are not automatically stronger, and how print orientation dramatically affects performance.
Essential reading for functional components.
Guide 3 – Tolerances and Dimensional Accuracy
Understand why printed parts do not always fit first time. Learn about shrinkage, hole sizing, axis accuracy, and how to design with predictable clearances.
Critical for assemblies, enclosures, and precision parts.
Advanced Functional Printing & Material Control
Guide 4 – Material Selection for Functional Parts
Explore how PLA, PETG, ASA, ABS, nylon and composites behave under heat, load, UV exposure and long-term stress. Learn why there is no “best filament” — only the correct material for the application.
Key to durability and reliability.
Guide 5 – Print Speed, Acceleration, and Motion Control
Learn how speed affects bonding, surface quality, and dimensional accuracy. Understand why controlled motion produces stronger and more predictable parts than simply printing faster.
Important for consistency and professional results.
Guide 6 – Surface Finish and Post-Processing
Understand how professional finishes are achieved through proper orientation, sanding, chemical smoothing and coatings. Learn why surface finish should be planned before printing begins.
Ideal for presentation-ready or customer-facing parts.
Design Strategy & Production-Level Thinking
Guide 7 – Designing for Efficiency and Cost Control
Learn how hollow structures, wall optimisation, support-free design and modular components reduce failures and improve scalability.
Essential for repeat projects and controlled production costs.
Guide 8 – Repeatability and Production Printing
Discover what makes 3D printing reliable over time. Learn about calibration discipline, material storage, environmental control and batch consistency.
Foundational knowledge for production printing and repeat orders.
Digital File Preparation & Workflow Control
Guide 9 – Understanding 3D Printing File Types: STL, 3MF, OBJ and G-code
Before printing begins, the correct file format must be chosen.
This guide explains:
- The differences between STL and 3MF
- When OBJ is appropriate
- Why G-code is machine-specific
- How file types affect scaling, colour, materials and collaboration
- Why 3MF is increasingly preferred in modern workflows
Understanding 3D printing file formats improves reliability, reduces scaling errors, and supports better collaboration between designers and professional 3D printing services.
Essential reading before uploading files for printing.
3D Scanning and Digital Capture
Guide 10 – Why Doesn’t My 3D Scanner Capture Detail as Small as 0.02 mm?
Many 3D scanners advertise extremely high resolution values, such as 0.02 mm, but users often find that real scans do not appear to capture detail at that level.
This guide explains why this happens.
It explores the difference between scanner resolution and measurement accuracy, and how real-world factors influence scan quality.
Topics covered include:
- Resolution vs accuracy in scanning
- Surface reflectivity and material effects
- Scanner distance and focus range
- Movement and tracking stability
- Lighting conditions
- Mesh processing and software smoothing
Understanding these factors helps users achieve better scan results and set realistic expectations for scanning technology.
How to Use This Knowledge Hub
You can follow the guides in order for a complete structured learning pathway, or explore individual topics based on your current challenges.
Together, these guides provide a comprehensive understanding of:
- 3D printing strength optimisation
- Dimensional accuracy and tolerances
- Material performance
- Motion control and print quality
- Production reliability
- File preparation and workflow best practice
This structured knowledge allows you to move from trial-and-error printing to predictable, professional results.
Need Professional 3D Printing in the UK?
If you prefer to focus on design while leaving production to calibrated, professionally managed equipment, BritForge3D offers reliable UK-based 3D printing services.
We optimise:
- Material selection
- Print orientation
- Strength settings
- Dimensional accuracy
- Production consistency
Upload your file here and receive a quote.
Continue Learning
We regularly expand this hub with new technical guides covering:
- Advanced mechanical design
- Multi-material printing
- File repair and mesh optimisation
- Engineering applications
- Real-world case studies
You can also join our email education series to receive these guides directly.
Continue Learning
We regularly expand this hub with new guides and updates.
Download printable PDF versions of each guide
Support
The Basics of 3D Printing
What Every Beginner Should Know
Have you ever wanted to turn a digital idea into a real, physical object? That’s exactly what 3D printing allows you to do — and it’s more accessible than ever. Whether you’re a designer, student, hobbyist, or engineer, understanding the basics of 3D printing can open up exciting opportunities for creativity and innovation. In this comprehensive guide from BritForge 3D, you’ll learn how 3D printing works, what materials you can use, and why it’s changing the way we make things.
What is 3D Printing?
3D printing, also called additive manufacturing, is a process where objects are created layer by layer from digital designs. Unlike traditional methods that cut, drill, or cast shapes, 3D printing adds material exactly where it’s needed. This makes it possible to produce complex geometries that would be impossible or very expensive with conventional manufacturing.
How Does 3D Printing Work?
Here’s a simple breakdown of the process:
- Design: Create your 3D model using CAD software, or download it from sites like Printables or Thingiverse.
- Slicing: Use slicing software (e.g., Cura or PrusaSlicer) to convert your model into layers. The software also generates instructions for the printer.
- Printing: The printer follows these instructions, depositing material layer by layer until the part is complete.
This process can take anywhere from minutes to days, depending on the size, complexity, and printer settings.
Common Types of 3D Printing Technologies
For beginners, the two main types of 3D printing are:
- FDM (Fused Deposition Modelling): The most common and affordable option. FDM printers work by melting and extruding plastic filament through a nozzle, building parts one layer at a time. They’re great for prototyping, mechanical parts, and everyday items.
- SLA/DLP (Resin Printing): These use liquid resin cured by UV light for extremely detailed, smooth prints. SLA is ideal for jewellery, miniatures, or objects requiring fine detail, though it involves more post-processing.
Materials for 3D Printing
Choosing the right material is critical for your project’s success. The most popular beginner materials include:
- PLA: Easy to print, eco-friendly, and perfect for visual models or prototypes.
- PETG: Durable, flexible, and resistant to moisture, making it ideal for functional parts.
- ABS: Tough and heat-resistant, but more challenging to print due to warping.
- Resin: Used in SLA printing for high-detail parts with smooth surfaces.
Each material has its pros and cons depending on strength, flexibility, and appearance. Knowing these differences will help you select the best option for your project.
Benefits of 3D Printing vs. Traditional Manufacturing
3D printing offers several advantages over traditional manufacturing techniques:
- Faster prototyping reduce design cycles from weeks to days.
- Lower costs for small batches or one-off items.
- Freedom to design complex shapes and internal structures impossible with subtractive methods.
- Reduced material waste since only the needed material is used.
This flexibility makes 3D printing a powerful tool for startups, inventors, and anyone wanting to innovate on a budget.
Why Order 3D Prints Instead of Buying a Printer?
While owning a 3D printer can be rewarding, it requires time, maintenance, and knowledge to keep running smoothly. For many individuals and businesses, ordering prints from professionals like BritForge 3D saves time and ensures better quality. We use industrial-grade machines and provide a range of materials and finishes without you needing to worry about calibration, failures, or post-processing.
How to Get Started with BritForge 3D
Ready to turn your ideas into reality? Start by uploading your 3D model on our website. Our online tool gives you instant pricing, allows you to choose materials and finishes, and guides you through the process. Our experienced team will review your design, print your part with precision, and deliver it quickly — anywhere in the UK.
Conclusion
3D printing is revolutionising how we create, prototype, and manufacture. By learning the basics, you open doors to endless creative and professional possibilities. Whether you need help choosing materials, fixing your 3D model, or getting a part printed with industrial precision, BritForge 3D is here to support you every step of the way.
Technical guide
A Technical Guide – Part Nine
Understanding 3D Printing File Types: STL, 3MF, OBJ and G-code Explained
When a customer uploads a file for 3D printing, the first question we consider is not how large the part is or what material it requires. The first question is much simpler: what file format are we working with?
File type plays a significant role in print reliability, geometry accuracy, material settings, and even colour information. Many users treat file formats as interchangeable, but they are not. Each format exists for a reason, and choosing the correct one can improve workflow efficiency and reduce print errors.
In this lesson, we will explore the four most common file types used in 3D printing: STL, 3MF, OBJ, and G-code. More importantly, we will examine when to use each one and why.
Why File Format Matters in 3D Printing
A 3D printer does not understand design software files such as SolidWorks, Fusion, or Blender files directly. Instead, those designs must be exported into a format that slicing software can interpret.
The file you export determines:
- How geometry is stored
- Whether units are preserved
- Whether colour and material data are included
- Whether slicing settings travel with the model
- How easily the file can be repaired
Using the wrong format can introduce scaling issues, lost metadata, corrupted geometry, or unnecessary workflow steps.
Understanding file formats allows you to control your process rather than react to problems later.
STL – The Industry Standard
The STL file (Standard Tessellation Language or StereoLithography) is the oldest and most widely recognised format in 3D printing.
STL files describe geometry using triangles. Every curved surface is approximated by a mesh of small triangular faces. The smaller and more numerous the triangles, the smoother the surface appears.
However, STL files contain only geometry. They do not store:
- Units (mm or inches)
- Colour
- Material data
- Print settings
This simplicity is both a strength and a limitation.
Benefits of STL
STL is universally supported. Nearly every slicer, CAD package, and 3D printer workflow accepts STL files. Because the format is simple, files are generally stable and predictable.
For single-material functional parts, STL is often perfectly adequate.
Limitations of STL
Because STL does not store units, scale errors are common. A part designed in millimetres may open as inches in another system.
STL also cannot store multiple bodies intelligently, colour data, or advanced metadata.
For simple prints, STL works well. For more complex workflows, it begins to show its age.
3MF – The Modern Alternative
3MF (3D Manufacturing Format) was developed to solve the limitations of STL.
Unlike STL, 3MF files store:
- Units
- Multiple bodies
- Colour information
- Material assignments
- Print settings (when exported from slicers)
This makes 3MF far more powerful for modern workflows.
Why 3MF Is Often Better for 3D Printing
Because 3MF preserves units, scaling errors are eliminated. What you design is what opens in the slicer.
3MF also allows multi-material and multi-colour information to travel with the file. If you are using a multi-material printer, this is critical.
Additionally, some slicers store support placement and slicing profiles inside the 3MF file. This makes collaboration easier because another user can open the file exactly as intended.
When to Choose 3MF
If you are working in a modern slicer and want to preserve configuration, or if you are printing multi-material parts, 3MF is usually the better choice.
For professional workflows, 3MF is increasingly becoming the preferred format.
OBJ – Geometry with Visual Data
OBJ files are commonly used in animation and 3D modelling rather than manufacturing, but they also have applications in 3D printing.
Like STL, OBJ files describe geometry through mesh data. However, OBJ files can also store:
- Colour data
- Texture references
- Surface information
This makes OBJ useful for full-colour printing systems.
When OBJ Makes Sense
If you are printing artistic models, figurines, or textured parts that require colour mapping, OBJ can be valuable.
However, OBJ files can be larger and more complex than STL. They may also include unnecessary data for simple functional prints.
For most engineering parts, OBJ is not required.
G-code – The Machine Instruction File
G-code is very different from STL, 3MF, or OBJ.
While those formats describe geometry, G-code describes movement instructions for the printer.
Once a file is sliced, the slicer converts the model into G-code. This file contains:
- Exact nozzle movements
- Extrusion rates
- Temperature commands
- Fan speeds
- Layer heights
G-code is printer-specific. It is generated for a particular machine, with specific settings.
Why You Don’t Share G-code as a Design File
Because G-code contains machine instructions, it is not portable in the same way geometry files are.
A G-code file created for one printer may not work correctly on another due to:
- Different bed sizes
- Firmware differences
- Extruder configurations
- Temperature limits
For this reason, when sending a file to a professional 3D printing service, you should always send geometry files (STL or 3MF), not G-code.
Choosing the Right File Type
So how do you decide?
If you are printing a simple single-material part and need universal compatibility, STL is safe and reliable.
If you want to preserve units, materials, and advanced data, 3MF is the superior modern option.
If you are working with colour textures or artistic models, OBJ may be appropriate.
If you are printing directly from your own slicer to your own machine, G-code is the final production file — but not something to share externally.
Professional Workflow Recommendation
At BritForge3D, we recommend:
- 3MF for most modern workflows
- STL for compatibility and simple parts
- Avoid sending G-code unless specifically requested
We re-slice all files to ensure compatibility with calibrated machines and optimised material profiles.
Sending geometry files instead of machine code allows us to ensure print strength, dimensional accuracy, and material suitability.
Common Mistakes to Avoid
One of the most common mistakes is exporting STL with extremely low mesh resolution. This results in visible flat facets on curved surfaces.
Another mistake is forgetting to check units before export.
Finally, some users send G-code assuming it guarantees identical results. In reality, it can introduce compatibility risks.
Final Thoughts
Understanding file formats is not just about software preference. It is about workflow control.
Choosing the correct file format improves reliability, reduces errors, and supports better collaboration between designers and print services.
As 3D printing evolves, 3MF is increasingly replacing STL for professional workflows. However, STL remains deeply embedded in the ecosystem.
In the next guide, we will explore how to prepare files properly before upload — including mesh repair, manifold checks, and design validation.
Guides
The Basics of 3D Printing – A Beginner’s Guide
3D printing is transforming how we prototype, design, and manufacture
Making it more accessible than ever. Whether you’re a hobbyist, entrepreneur, or engineer, understanding the fundamentals of 3D printing is the first step toward creating high-quality prints that solve real-world problems. In this beginner’s guide, BritForge3D walks you through how 3D printing works, what you need to get started, and why it’s revolutionising design in the UK and beyond.
What Is 3D Printing?
3D printing, or additive manufacturing, is the process of building three-dimensional objects layer by layer using digital models. Unlike traditional manufacturing, which often removes material (e.g., cutting or milling), 3D printing adds material only where it’s needed, resulting in less waste and more freedom in design.
How Does It Work?
The process starts with a 3D model usually created in CAD (Computer-Aided Design) software or downloaded as an STL file. This model is then sliced into layers using software like Cura or PrusaSlicer. Each layer is converted into instructions (G-code) that guide the printer to lay down material typically plastic filament one layer at a time.
Popular 3D Printing Technologies
- FDM (Fused Deposition Modelling) – Melts and extrudes plastic filament; most common and beginner-friendly.
- SLA (Stereolithography) – Uses UV light to cure liquid resin; ideal for fine detail and smooth surfaces.
- SLS (Selective Laser Sintering) – Uses a laser to fuse powdered material; used more in industrial settings.
What You Need to Start 3D Printing
To begin your journey, you’ll need:
- A 3D printer (FDM is a great start)
- Filament (like PLA or PETG)
- Slicing software
- A 3D model file (you can design your own or download from sites like Thingiverse)
No workshop required many home printers fit on a desk and plug into a standard socket.
What Can You Print?
From mechanical prototypes and functional tools to cosplay props and custom gifts if you can design it, you can likely print it. The possibilities include:
- Phone holders and mounts
- Replacement parts and brackets
- Custom enclosures for electronics
- Educational models and architectural prototypes
Common Beginner Mistakes (and How to Avoid Them)
Getting a good print often comes down to careful preparation. Common beginner issues include poor bed adhesion, incorrect temperature settings, or using the wrong material. Take time to level your bed, experiment with slicer settings, and start with reliable filaments like PLA. Don’t worry every failed print is a step toward mastery!
Why 3D Printing is Growing in the UK
With the rise of small-scale makers, startups, and local manufacturing, 3D printing is booming in the UK. Services like BritForge3D empower individuals and businesses to upload designs and receive high-quality prints without needing their own equipment. We help turn ideas into reality, quickly and professionally.
Start Your First Print with BritForge3D
Not ready to buy a printer yet? No problem. At BritForge3D, you can simply upload your design, choose your material, and get a quote instantly. We’ll handle the printing and ship it right to your door hassle-free.
Conclusion
3D printing opens a world of possibility. Whether you’re experimenting with your first model or looking to scale up to commercial prototyping, the basics outlined in this guide will get you on the right path. BritForge3D is here to support your creative journey one layer at a time.
Technical Knowledge Hub
A Technical Guide – Part Ten
Why Doesn’t My 3D Scanner Capture Detail as Small as 0.02 mm?
One of the most common questions people ask after purchasing or using a 3D scanner is why the scanner does not capture detail as precisely as the specification suggests. Many scanners advertise resolutions such as 0.02 mm, yet when scanning real-world objects the captured model appears far less detailed.
This can be confusing and sometimes disappointing, especially for users expecting extremely fine detail. However, the answer usually lies not in the scanner being faulty, but in how scanner specifications, resolution, accuracy, and real-world conditions actually work.
Understanding these factors helps you get the best results from your scanner and avoid unrealistic expectations.
Resolution vs Accuracy – The First Source of Confusion
When a scanner advertises a resolution of 0.02 mm, this does not mean it can reliably measure every feature at that size.
In most scanners, resolution refers to the smallest point spacing the scanner can record, not the true measurement accuracy.
These are two very different things.
Resolution describes the density of points in the captured mesh.
Accuracy describes how close those points are to the true dimensions of the object.
For example, a scanner may generate points every 0.02 mm, but the true dimensional accuracy may only be ±0.05 mm or ±0.1 mm depending on the scanning conditions.
This distinction explains why extremely fine features may not appear clearly even though the specification seems capable of capturing them.
Surface Properties of the Object
Another major factor affecting scan detail is the surface of the object being scanned.
3D scanners rely on reflected light or structured light patterns to detect geometry. Certain surface types interfere with this process.
Highly reflective surfaces can scatter the projected light pattern, making it difficult for the scanner to calculate depth accurately. Similarly, very dark or matte surfaces may absorb too much light, reducing contrast.
Transparent or glossy materials are particularly challenging because the scanner may detect reflections rather than the actual surface.
This is why professional scanning workflows often use temporary scanning sprays to create a uniform matte surface that improves data capture.
Distance from the Scanner
3D scanners operate within an optimal working distance. If the object is too close or too far away, the scanner cannot resolve small details properly.
Most scanners have a focus range or optimal capture distance, and fine detail is only captured when the object sits within this range.
If the scanner is held too far away, point density decreases and small features are lost. If it is too close, the scanner may struggle to maintain tracking or capture complete geometry.
Maintaining a consistent scanning distance is therefore critical for achieving the best resolution.
Movement and Tracking Stability
Handheld scanners rely on stable tracking of the object’s surface while scanning. If tracking is lost or unstable, the software may smooth or average data during reconstruction.
This smoothing can remove small details that technically fall within the scanner’s resolution.
Even small hand movements or vibrations can affect point alignment. Professional scanning often uses tripods, turntables, or fixed scanning rigs to minimise movement and maximise accuracy.
Lighting Conditions
Ambient lighting also influences scan quality.
Strong sunlight or bright studio lighting can interfere with structured light patterns used by many scanners. Excessive ambient light reduces contrast between projected patterns and the object’s surface.
Most scanners perform best in controlled indoor lighting where the projected pattern remains clearly visible to the sensors.
Mesh Processing and Software Filtering
After scanning, software converts raw point cloud data into a mesh. During this process the software may apply smoothing, noise reduction, and hole filling.
These algorithms are designed to produce clean models but can unintentionally remove small features.
Many scanning applications include adjustable settings for mesh smoothing or detail preservation. Lower smoothing levels often retain more fine geometry.
Understanding these processing settings can significantly improve the final result.
Object Size vs Feature Size
Resolution specifications are also influenced by the overall size of the object being scanned.
Scanning a large object spreads the available point density across a wider area. This means fewer points represent small features.
In contrast, scanning a smaller object concentrates point density and improves feature capture.
For this reason, some scanners perform better when scanning smaller sections individually rather than attempting to capture a large object in one pass.
Calibration and Scanner Setup
Just like 3D printers, scanners require proper calibration.
Calibration ensures that cameras, sensors, and projection systems align correctly. If calibration drifts over time, accuracy can decrease.
Manufacturers typically provide calibration boards or routines. Running these periodically helps maintain optimal scanning performance.
Understanding Real-World Scanner Performance
In practice, the advertised resolution of a scanner represents the best-case scenario under ideal conditions.
Real-world scanning involves variables such as lighting, object surface properties, movement, and software processing. Each of these factors can reduce the amount of detail captured.
This does not mean the scanner is performing poorly. It simply reflects the difference between laboratory specifications and practical operation.
Improving Your Scan Results
While scanners cannot always achieve their theoretical limits, several techniques can significantly improve results.
Using matte scanning spray, maintaining the correct distance, scanning in stable lighting conditions, and adjusting mesh processing settings can all enhance detail capture.
Additionally, scanning smaller sections and combining them later often yields better results than scanning a large object all at once.
These practical adjustments often make the difference between an average scan and a highly detailed one.
Final Thoughts
The advertised resolution of a 3D scanner represents the maximum point density it can achieve under ideal conditions, not the guaranteed detail level in every scan.
Factors such as surface reflectivity, lighting, distance, motion, calibration, and software processing all influence the final result.
Once you understand these variables, scanning becomes far more predictable and far less frustrating.
With the right setup and expectations, modern 3D scanners are capable of producing highly detailed and accurate models suitable for reverse engineering, product design, and digital archiving.
Next Technical Guide
In the next guide, we will explore how to prepare scanned models for 3D printing, including mesh repair, hole filling, and converting scan data into usable CAD geometry.