DDM Guide Direct Digital Manufacturing Guide

How plastic and metal parts are made

Plain-language guides to additive manufacturing in polymers and metals, bridge tooling, molding, machining and the engineering around them.

A 3D printer building a part layer by layer

Choosing a process

Pick the material first, then the quantity, then the process that delivers both.

The right process depends on four questions, in roughly this order: what material the part must be, how many you need, how good the surface and tolerances have to be, and how soon you need them.

  • One to a few dozen parts almost always means 3D printing or CNC machining. No tooling, short lead times.
  • Dozens to a few hundred is bridge-tooling territory: RTV silicone or epoxy molds made from a printed master.
  • Hundreds and up usually justifies an injection mold, and the per-part price drops sharply.
  • Metal parts with internal features point to selective laser melting, followed by machining of the critical faces.

Each guide explains how a process works, where it is strong, where it struggles, and the design rules that keep parts manufacturable. The writing is vendor-neutral: nothing here is a sales page, and we do not make or quote parts.

Beyond the factory floor

The same processes reach well past aerospace and medical hardware. Gaming and slot cabinets depend on injection-molded bezels, machined brackets and 3D-printed button prototypes, and a large share of that play has since moved online, where guides such as this Lucky7even casino review compare the digital equivalents (18+ only; please gamble responsibly). Marketing in that sector has shifted as well: brands increasingly find creators through resources like this iGaming influencers database.

Additive Manufacturing

Building parts layer by layer in polymers and metals.

AM01 Plastic Laser SinteringHow selective laser sintering turns nylon powder into tough, support-free parts, and …
AM02 StereolithographyThe oldest 3D printing process is still the one to beat for …
AM03 Selective Laser MeltingMetal powder bed fusion (SLM / DMLS) explained: materials, design rules and …
AM04 Fused Deposition ModelingExtrusion printing for engineering thermoplastics, big build volumes and shop-floor tooling.

Machining & Molding

Bridge tooling, molding and subtractive finishing.

MM01 RTV ToolingSilicone molds and urethane castings: the quickest route from one printed master …
MM02 Epoxy ToolingRigid epoxy molds bridge the gap between silicone tools and steel, for …
MM03 Injection MoldingTooling types, design rules and the cost logic behind the world's most …
MM04 CNC MachiningSubtractive machining for tight tolerances, real alloys and the finishing work printed …

Special Processes

Design, analysis, fixtures and composites.

SP01 Solid ModelingClean CAD is the cheapest quality tool there is. What to get …
SP02 Structural AnalysisFinite element analysis in practice: what it tells you, what it hides, …
SP03 Tools & FixturesPrinted jigs, fixtures and gauges are one of the quickest wins additive …
SP04 Resin Transfer MoldingHow RTM produces repeatable composite parts with good finish on both sides, …