STEP Printing

How Does STEP Work

01 Part Design & Printing Preparation

Most part designs require modifications to accommodate the shortcomings of injection molding and many types of 3D printing technology. Parts built using STEP technology can contain features like sharp corners, thin-to-thick wall transitions and no draft without restrictions. Like other 3D printing technologies, part designs must be converted into layers using “slicer” software prior to printing.

02 Part Printing

STEP technology prints the part, one layer every 6 seconds, regardless of its complexity. It’s then transferred via conveyors to the build platform, where it is precisely registered and positioned on top of the last layer placed there. The new layer is then bonded to them using heat and pressure. The result is a dense, thermoplastic part with physical characteristics similar to injection molded parts – but without the time and investment of tooling.

03 Post Processing

When cooled, the parts are removed from the build table. Little or no post-processing is required, because parts produced using STEP technology have excellent surface quality. if desired, STEP parts can be post-processed in the same ways as any thermoplastic parts, including vapor smoothing, painting and plating them. Inserts can be heat-staked into parts after they’re processed.

Advantages & Limitations of STEP Technology

Advantages

Accelerate New Product Development

Because parts can be produced quickly using the STEP technology without tooling, it can help you bring new products to market faster and expand your company’s competitive edge.
Excellent Surface Quality

The STEP technology produces parts with a smooth surface finish that doesn’t require post-processing.
Flexible Post-Processing

If it is required, parts produced using the STEP technology can be post-processed the same as any thermoplastic parts.
Fine Features

The STEP technology enables you to print part designs with fine features, small holes and complex geometries. It can accommodate thin walls without warping, which is sometimes a problem for other additive technologies.
Tight Tolerances

The STEP technology can achieve tolerances that are comparable to CNC machining – tighter than additive technologies or injection molding.
All of the Toughness of Thermoplastics

Parts produced using the STEP technology have good dimensional stability for use in hot, humid environments. They also have excellent chemical resistance to acids, bases, water and alcohol (commonly found in hand sanitizers), just like injection-molded thermoplastics.
Produce Production Parts with the Same Materials as Prototypes

STEP enables customers to go from prototype to production parts quickly and easily.
Minimal Design Restrictions

Many additive technologies require designers to convert thick wall designs to lattices to reduce print time and material use. STEP has no such restriction. It prints and deposits layers every 6 seconds, regardless of their complexity. STEP can handle sharp corners, thin-to-thick wall transitions and no draft – design features that tend to be problematic for injection molded parts.

Disadvantages

Support Removal

When printing is complete, parts are completely encased in a soluble support material. It’s easily cleaned from open surfaces, but it may be hard to remove from cavities, blind holes and trapped areas.
Build Size

The maximum build envelope for parts produced using the STEP technology is currently 24 x 12 x 4 inches, not as large as some other additive technologies. Evolve is working on expanding the build size.
Limited Materials

The STEP technology currently only produces parts from ABS. A high-performance grade of Nylon will be offered soon.

Applications of STEP Technology

Healthcare: STEP enables you to produce complex healthcare parts and products, with high new technology content or un-moldeable features at scale. STEP technology also offers opportunities for product customization with a high level of agility.

Automotive: Dimensional and form accuracy mean STEP parts can be integrated seamlessly into larger assemblies, replacing injection-molded parts. The ultra-smooth surface of STEP parts (3-6 um Ra) and zero porosity makes it possible to use them in a variety of applications. STEP parts can be painted, metalized or coated in the same way as injection-molded parts.

Electronics: The mechanical strength and toughness of STEP parts, along with their excellent surface finish, make them a strong contender to replace injection molded parts in consumer electronics. It’s especially well-suited to high-value, low-volume parts where injection molding would be impractical.

Fluid Management: For irrigation and other water systems, STEP can be used to produce water-tight screw threads and fluid control features. Its excellent dimensional accuracy delivers tolerances required for complex assemblies. Applications include internal manifolds, accumulators, retained ball valves and deep channels.

Case Studies Block

What Can STEP be Paired With?

Like any thermoplastic parts, parts produced using the STEP technology can be attached or bonded to other components. Inserts can be added to parts after they are processed.

Because parts can be produced so quickly using STEP technology, it is suitable for both prototype and production applications. Utilizing the same process for rapid prototyping and production can help you speed your new product launches.

Traditional Technologies That Can Benefit from STEP

Any engineer who’s currently using ABS, nylon or other thermoplastics for their products and new product development should investigate the STEP technology. It can help you bring your products to market faster and achieve designs that aren’t possible with injection molding and other additive technologies.