Open Printing Systems and Key Parameters for Each Technology

In the constant evolution of 3D printing, open systems have marked a turning point for professional users, engineers, and R&D departments. Unlike closed systems – which limit the user to manufacturer-specific materials and configurations – open systems offer technical freedom that favors customization, innovation, and cost savings. In this article, we explore how these open ecosystems work in FDM, SLA/DLP, and SLS, and what technical parameters are essential to get the most out of them.

What defines an open printing system?

An open system in 3D printing allows modifying both hardware and software, using materials from any provider, and adjusting technical parameters in detail. This freedom is key in environments that require adaptability, whether to print new experimental filaments, optimize processes, or incorporate customized components. Compared to closed systems, where the experience focuses on ease of use, open systems prioritize technical control and material versatility.

Reprap printer, epitome of open and open source systems. Source: Hackday.com.

FDM: Freedom to innovate with open filaments

FDM (or FFF) technology is historically the most linked to the open-source movement. From its origins with RepRap, many current FDM printers – such as the Prusa i3 series, Creality Ender, or BCN3D Sigma – offer open designs, allowing components to be modified, sensors added, and a wide variety of filaments to be used.

What parameters are most determining in FDM?

• Extruder and bed temperature: All-metal hotends allow reaching 300–450 °C, essential for advanced thermoplastics like polycarbonate or PEEK. Heated beds, up to 100 °C or more, improve adhesion and prevent warping.
• Print volume and kinematics: From compact sizes (220×220×250 mm) to large industrial formats (>1 m). CoreXY or Delta configurations directly influence speed and precision.
• Resolution and speed: Layers of 0.1–0.2 mm are standard, but open systems allow fine-tuning from 0.05 mm to over 1 mm, adapting quality to production pace.
• Multi-component compatibility: IDEX systems or multiple extruders allow printing with soluble materials or in multiple colors, which requires precise calibration and synchronization control.

Filament in cartridges, a closed and proprietary system. Source: XYZPrinting.com.

What advantages does the open ecosystem offer in FDM?

• Unrestricted materials: Technical, flexible, conductive, or flame-retardant filaments can be used without compromising warranties or relying on proprietary cartridges.

Example of a closed FDM system with proprietary filaments. Source: All3D.com.

• Free and customizable software: From firmwares like Marlin or Klipper, to slicers like Cura or PrusaSlicer, open systems accept standard G-code, allowing accelerations or printing routines to be modified.

• Modular accessories: From hardened nozzles to video cameras for remote control and auto-leveling sensors, open systems facilitate customizations according to project needs.

SLA/DLP: Precision and flexibility with open resins

Traditionally, resin printers were closed systems. However, brands like Anycubic, Elegoo, or Prusa have driven open printers that use low-cost light sources like LCDs or projectors, and accept any 405 nm UV resin, allowing professionals to choose the most suitable formulation for the project: from biocompatible resins to ceramic compounds.

Open resin printers allow experimenting with different brands and formulations. Source: All3D.com.

What parameters are critical in resin printing?

• XY resolution and layer thickness: Determined by screen resolution (2K, 4K, 8K). Details up to 30 μm can be obtained with layers of 10–100 μm.

• Exposure and separation time: Each resin requires different curing times, power adjustments, and lift speeds to avoid adhesion failures.

• Vat and build plate compatibility: An open system allows replacing vats, films, or print surfaces to adapt the process to the type of resin and improve results.

Why choose an open resin ecosystem?

• Wide material compatibility: From ABS-like resins to dental or elastic formulations, without the need for RFID cartridges or additional licenses.

• Non-proprietary software: Slicers like Lychee or ChituBox allow generating compatible files for different brands, with full control over supports and parameters.

• Free post-processing: Universal washers and curing stations, accessible spare parts, and interchangeable components increase the professional user's autonomy.

SLS: New possibilities with open sintering

SLS technology, once reserved for large industries, has made the leap to compact formats with printers like Sinterit Lisa or Sharebot SnowWhite. These machines allow the use of powders like PA12, TPU, or even experimental mixtures, offering control over temperature, laser power, and cooling cycles.

What technical aspects should be considered in SLS?

• Laser type and scanning: From IR diodes (~5 W) to industrial CO₂, the laser type and its spot size (0.1–0.2 mm) determine resolution and efficiency.

• Thermal control: The bed temperature (~180 °C for PA12) must be kept stable. Some printers offer controlled atmospheres with nitrogen for sensitive polymers.

• Material refresh rate: Powder can be partially recycled; open systems allow adjusting parameters to maximize reuse and reduce costs.

What does an open SLS system provide?

• Use of alternative powder materials: From commercial materials to experimental formulations, access to parameters allows sintering officially non-approved materials.

• Software with exposed parameters: Allows modifying temperature curves, energy per layer, or scan density, essential for research and validation of new materials.

• Compatible post-processing: The use of universal accessories – cleaning cabinets, sieves, safety tools – reduces reliance on proprietary solutions.

Example of a proprietary and closed technology printer. Source: Stratasys.com.

Emerging technologies: pellet extrusion, binder jetting, and more

Innovation in additive manufacturing does not stop at consolidated technologies. In recent years, open systems have emerged in fields such as direct pellet extrusion or binder jetting, offering new possibilities in both scale and material diversity. These emerging technologies expand the scope of 3D printing towards industrial, sustainable, and experimental applications, always maintaining the philosophy of technical openness and operational freedom.

Pellet extrusion (FGF): print directly from granules

Pellet extrusion, also known as FGF (Fused Granulate Fabrication), allows printing parts from plastic in granular form, instead of traditional filament. This technology is ideal for high-volume jobs or experimenting with materials not available in filament format.

What does pellet extrusion offer?

• Feeding versatility: Commercial PLA, ABS, PC pellets or even mixtures with fibers, metal powders, or wood can be used.

• Cost reduction: Pellet material is significantly cheaper per kilo than filament.

• Sustainability: It is possible to print directly with recycled plastics, such as shredded PET bottles or reprocessed industrial waste.

• Total control: Open systems allow adjusting critical parameters such as screw speed, temperature zones, or cooling strategies, which is essential when working with unconventional materials.

Brands like Tumaker (with models like NX Pro or BigFoot Pro) offer interchangeable extruders between filament and pellet, while manufacturers like Piocreat and CEAD lead in industrial printers for automotive or aerospace prototyping. These solutions allow printing large format parts with high extrusion flows and heated chambers, adapting to the performance of technical or recycled thermoplastics.

Binder Jetting: heat-free printing for industrial powders

Binder jetting is an additive technology where a liquid binder is deposited onto a powder bed (ceramic, metal, sand), creating parts layer by layer without the need for heat during printing. Subsequently, the part is cured or sintered to acquire strength.

What characterizes open binder jetting?

• Material flexibility: With a single system, you can work with gypsum, technical ceramics, metals, or even biomaterials, changing the powder and binder according to the application.

• Parameter adaptability: Open systems allow adjusting binder viscosity, drop resolution (DPI), layer thickness, or even replacing the printhead with a compatible one.

• Advanced applications: From technical ceramics to functional food, open binder jetting allows experimenting with custom mixtures and alternative curing processes (UV, thermal).

Examples like CONCR3DE or open kits from Tethon 3D show how this technology allows manufacturing structures with volcanic powder, silicon carbide, or alumina. There are even DIY projects that demonstrate the feasibility of building basic binder jetting systems for research.

Hybrid technologies and material jetting

The open ecosystem also extends to hybrid machines and less common processes:

• 3-in-1 printers, like Snapmaker, combine FDM, laser engraving, and CNC in a single chassis, with open firmware and standard software.

• Open toolchangers allow exchanging printheads, for example, to combine FDM with inkjet or paste extrusion.

• Paste and ink extrusion (Direct Ink Writing) enables the printing of ceramics, silicone, or biomaterials on modified platforms with open syringe pumps.

These advances allow exploring areas such as biomedicine, functional food, or soft component manufacturing, always with a modular and open approach.

Conclusion: the future is open and adaptive

Emerging technologies like FGF, binder jetting, or hybrid systems represent the natural evolution of additive manufacturing towards greater technological freedom. The common denominator is clear: open ecosystems that allow experimenting, customizing, and scaling according to project needs.

Whether it's printing with recycled plastics in large format, developing new technical ceramics, or exploring biomaterial jetting, the openness of the system is what allows R&D teams to advance without limitations imposed by the manufacturer.

At Filament2Print, we support this approach with a growing range of pellet materials, drying solutions, specialized extruders, and accessories compatible with open printers. Because we understand that every user, from a laboratory to a digital manufacturing center, needs tools that evolve with their creativity and technical ingenuity.

Investing in open 3D printing means betting on autonomy, continuous innovation, and truly customized manufacturing.