Understanding 3D Printing Quotes by Technology

Recommended Resources

Additive Manufacturing Solutions for Aerospace FDM Material Tolerance 3D Printing Impact Value Chain

Breaking Down Quotes by Technology

Each 3D printing technology has unique considerations that influence quoting, from material efficiency to post-processing needs. While two quotes for the same part may look similar on the surface, the specific technology and material chosen—and how it’s applied—can make a significant difference in cost, lead time, and part quality. Below, we explore key factors for each technology to help you better understand what goes into a quote and where hidden compromises may arise.

3D printed FDM Aerospace duct in Victrex material

FDM (Fused Deposition Modeling)

FDM is widely used for functional prototypes and end-use parts, offering strong, durable components in a variety of thermoplastics. However, quoting discrepancies often stem from:

Layer Height & Stair-Stepping – A low quote may be based on the thickest possible layers, which can lead to visible layer lines and poor surface quality.
Build Orientation & Strength – Most 3D-printed parts are strongest in the XY plane. A cheaper quote may orient the part for cost efficiency rather than for optimal strength or cosmetics depending on the application, potentially compromising performance.
Support Material & Surface Quality – Some FDM parts require manual support removal, and breakaway supports may leave rough or uneven surfaces that require additional finishing.

🚩 Red Flag: A low-cost FDM quote may not actually be FDM—it could be FFF (Fused Filament Fabrication), which lacks the advantages of industrial FDM. Unlike true FDM, FFF often uses lower-quality materials, open-air systems, or lacks patented features that improve strength, repeatability, and part performance. A provider should not only offer a low-cost quote but also have the expertise and technology to ensure the part is built to industrial standards the first time.

SLS (Selective Laser Sintering)

SLS is widely used for functional prototypes and production parts, offering strong, durable components without requiring support structures. However, certain quoting factors may not fully reflect the post-processing steps or material considerations:

Powder Cleanup & Surface Finish – While SLS does not require support structures, excess powder must still be removed from the part. Fine feature areas and enclosed geometries may require additional labor for powder removal. Additionally, raw SLS parts typically have a textured surface, and achieving a smoother finish may require bead blasting or additional finishing steps.
Material Consistency & Powder Reuse – Some providers use higher levels of reused powder, which can affect part consistency, surface roughness, or mechanical properties.
Post-Processing for Aesthetics & Functionality – Dyeing, smoothing, and coatings can enhance part appearance or functionality but may not be reflected in an initial quote. If a lower-cost quote does not mention these options, additional costs could arise later.

🚩 Red Flag: A low SLS quote may be indicative of higher levels of reused powder, which can impact surface quality and consistency. If appearance, color, or post-processing are critical, confirm what’s included upfront to avoid unexpected costs or additional finishing requirements later.

PolyJet

PolyJet excels at ultra-high detail parts and multi-material prints, making it a preferred choice for medical models, intricate prototypes, and visually accurate representations. However, certain factors can impact quoting:

Photo Bleaching for Transparency – Clear PolyJet parts may require photo bleaching to achieve optimal transparency. Some providers may skip this step to reduce costs, resulting in cloudy or inconsistent optical clarity.
Surface Finish & Fine Feature Cleanup – While PolyJet uses water-soluble support material, detailed features or internal channels may require extra care in post-processing to avoid surface blemishes or material residue.
Additional Post-Processing & Surface Refinements – Clear coating, sanding of support-facing surfaces, and other finishing steps may be required to achieve a smooth, high-quality finish. Some providers may minimize or skip these refinements, affecting both the appearance and functionality of the final part.

🚩 Red Flag: A low PolyJet quote may not reflect the level of finishing required for fine details, transparency quality, or post-processing enhancements. Providers focused solely on cost may overlook critical refinements necessary for achieving cosmetic or functional requirements.

SAF (Selective Absorption Fusion) & HP MJF (Multi Jet Fusion)

Both HP MJF and SAF are powder-based fusion technologies ideal for batch production and high-volume manufacturing. While they share similarities in process efficiency and material use, their fusing methods and thermal processes differ, which can impact quoting considerations:

Packing Density & Throughput – Both technologies allow for efficient nesting to reduce per-unit cost. However, MJF uses fine thermal control for localized fusing, while SAF applies uniform infrared heating across the entire layer. Improper packing strategies in either process can increase individual part costs.
Material Consistency & Powder Reuse – As with SLS, powder reuse policies affect both quality and cost. Some providers may rely on higher levels of recycled powder, reducing pricing but potentially impacting material integrity and mechanical performance.
Surface Finish Considerations – MJF parts tend to have finer surface detail and edge definition due to its detailing agent, while SAF maintains consistent strength properties across builds thanks to its uniform infrared heating process. Additional finishing steps (such as bead blasting or dyeing) may not be reflected in an initial quote.

🚩 Red Flag: A low per-unit price may indicate that a provider is prioritizing machine throughput over part quality, leading to variability in surface finish, mechanical performance, or powder integrity. Without careful oversight, cost-cutting measures in powder reuse or part orientation could affect consistency across production runs.

SLA (Stereolithography)

SLA produces high-resolution parts with smooth surface finishes, making it a popular choice for prototypes and cosmetic models. However, the quoting process for SLA can be misleading if critical finishing steps aren’t accounted for:

Support Structures & Orientation – SLA requires supports, and if not properly oriented, supports may be generated on the A-surface (outside or preferred surface), affecting final part quality. A lower-cost quote may still not reflect the impact on surface finish or the additional labor required to restore cosmetic surfaces. Proper orientation and finishing considerations are key to achieving the best results.
Post-Curing & Resin Quality – Some providers may reduce post-curing time or use improper curing conditions, leaving parts weaker, more brittle, or dimensionally unstable. Additionally, higher levels of recycled or older resin may be used to cut costs, affecting mechanical properties. Stratasys Direct ensures all SLA parts are properly cured and built with well-managed resin to maintain long-term performance.
Finishing & Coatings – SLA parts often require additional post-processing, including sanding, coating, or clear finishing, which may not be included in an initial quote. The level of finishing required depends on support placement, surface quality expectations, and cosmetic needs.

🚩 Red Flag: A surprisingly low SLA quote may not account for labor-intensive post-processing or hidden quality risks from improper curing or material selection—leading to unexpected costs or part failure.

DLP (Digital Light Processing)

Digital Light Processing (DLP) excels at producing parts with high feature resolution and smooth surfaces, making it a strong option for tight-tolerance components, detailed prototypes, and aesthetic parts. Technologies like P3™ utilize high-resolution 5K projectors, offering greater precision than some LED-based systems used by other providers.

Resolution & Surface Quality – DLP delivers exceptional surface finish, but because supports are printed in the same material as the part, they may leave support marks or residual nubs at attachment points. These areas often require light sanding to achieve cosmetic expectations—similar to SLA.
Material Versatility – DLP supports a range of functional resins, including those designed for durability, flexibility, and heat resistance. However, even when using the same resin (e.g., Loctite), part performance can vary depending on whether it’s printed with a high-resolution projector or a lower-resolution LED system.
Build Volume Nuance – DLP systems typically have limited X/Y dimensions, but Z-height can be substantial, allowing for tall prints or vertical stacking of multiple parts. Understanding these build constraints is essential when evaluating suitability for larger parts.

🚩 Red Flag: A low DLP quote may indicate use of lower-resolution hardware, potentially affecting surface finish and dimensional accuracy. Even when the same resin is listed, differences in projection technology—such as LED vs. projector—can significantly impact final part quality.

Additional Articles in This Series

Choosing a 3D Printing Service: What to Consider

Learn how to evaluate 3D printing quotes, uncover hidden costs, and choose a provider based on transparency, in-house expertise, and production quality.

How to Spot a Transparent 3D Printing Quote—and Avoid Hidden Costs

Not all 3D printing quotes are created equal. Learn how to identify hidden costs, evaluate quality standards, and avoid project delays with a transparent quoting process.

CAD design for 3D printing on computer monitor

What Really Drives the Cost of a 3D Printing Quote?

Understand what truly impacts the cost of a 3D printing quote: material choices, build setup, post-processing, and expert engineering. Learn how to avoid misleading low prices.

Protect your IP by using Stratasys Direct 3D printing service

How to Protect Your Design Files and IP in 3D Printing

Learn how to safeguard your 3D printing files and intellectual property. Discover the risks of cloud-based systems, outsourcing, and offshore storage, and how to choose a secure provider.