Report on 3D printing

3D Printing

ABSTRACT Three-dimensional printing, also known as additive manufacturing, is the process of using additives to form solid 3D objects of virtually any shape from a digital model. This is achie achieved ved using using specia specially lly formu formulat lated ed addit additive ives, s, such such as plasti plastics cs,, that that are form formed ed into into successive layers of material typically laid down on a platform in different shapes. The first published account accoun t of a printed solid model was made by Hideo odama of !agoya !ago ya "unicipal #ndustrial $esearch #nstitute in %&'(. The first working 3D printer was created in %&') by *harles +. Hull of 3D ystems *orp. f course, 3D printing in the early days was very epensive and not feasible for the general market. /s we moved into the (%st century, howeve however, r, costs costs dras drastic ticall ally y dropp dropped ed,, allow allowin ing g 3D printe printers rs to find find their their way to a mo more re affordable market. +ith the introduction of 3D printing technology, you can go for a mass production. 0ou 0ou can increase the production with less capital as they will be controlled by the same controller. controller. "edical science is also taking the help of this techni1ue. /ccording /ccording to these futurists, 3-D printing will make life as we know it today barely recogni2able in 4 to 5 years. 6$ealistically, we7re going to be living to %44 -%%4. +ith bio-printed organs, living to %%4 won7t be anything like living to that age today,6 contends 8ack 9ldrich, a technology trend epert. 6+e7re already printing skin, kidneys, a replica of a beating human heart. #f a person lose losess a limb limb,, we7l we7lll be able able to prin print, t, lay layer by laye layer, r, a repl replac acem emen ent. t. #t7s #t7s theo theore reti tica call lly y possible.6There are many companies that offer 3D services to consumers. They need to upload their design in the website and your design will be ready within a few hours. 8ust imagine you can print a solid object from a device connected to the computer. #t sounds like a world of star trek.

GTU/SCET/IT/V Semester/120420116049

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3D Printing

1. Introduction Introduction to 3D Printing /s every designer knows, there:s magic in transforming a great idea into a tangible and useful object you can hold in your hand. #t can be a consumer good on a store shelf, a critical component of an industrial machine, or even an early physical prototype that unveils your new idea to the world.

;hysical prototypes < basic and blocky or wonderfully reali2ed in shape, teture and color < go far beyond drawings or computer models to communicate your vision in a dramatic way. They empower the observer to investigate the product and interact with it rather than simply guess what it might be like. =efore the product is ever produced, people can touch it> feel it> turn it left, right and upside down> and look inside. They can test it, operate it and fully evaluate it < long before the finished product is brought to market.

9ntil recently, a quic an! a""#r!a$%e &'(sica% &r#t#t(&e has been an oymoron. btaining prototypes wasn:t 1uick. #t meant contracting with a fabricator who handcrafted handcraf ted them or used a compli complicat cated ed stere stereo o lith lithogr ograph aphy y mach machine ine.. #n eithe eitherr case, case, it took took week weeks, s, and and it wasn: wasn:tt affordable. 0ou were billed thousands of dollars for your trouble.

/nd who needs just #ne prototype? prototype? uccessful product developers revise a design repeatedly until they approach their ideal. ;hysical prototypes available on demand in sample 1uantities accelerate the design process, and more 1uickly send a better product to market.

This ideal is in fact a reality for some of the world:s most accomplished and demanding designers and engineers. /vailable within a couple of hours of hitting @printA on a 1uiet, clean and and slee sleek k mach machin inee in an ever everyd yday ay offi office ce sett settin ing, g, on-d on-dem eman and d prot protot otyp ypes es toda today y help help engineering organi2ationsB •

improve communication within the product development organi2ation>

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shorten design cycles

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put superior products produc ts on the market ahead of the th e competition

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stretch $CD dollars

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improve accuracy


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3D Printing

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eliminate costly mistakes

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trigger unepected ideas

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drive innovation and 1uality

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#mprove collaboration among engineering, sales, marketing and the eecutive team.

This paper will cover the inception and evolution of 3D printing> then eplore in depth how a 3D printer produces a physical model> and finally, eamine the defining attributes of a 3D printer and the technology techno logy decisions that produced them.

1.1 What is 3D PRINTER? 3D printing or additiv !anu"acturing A#E is any of various processes for making a

three-dimensional object of almost any shape from a 3D model or other electronic data source primarily through a!!iti)e &r#cesses in which successive layers of material are laid down under computer control 3D ;rinters are machines that produce physical 3D models from digital data by printing layer by layer. #t can make physical models of objects either designed with a */D program or scanned with a 3D canner. #t is used in a variety of industries including jewelry, footwear, industrial design, architecture, engineering and construction, automotive, aerospace, dental and medical industries, education and consumer products.


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3D Printing

$. %istor& o" 3d Printing The technology for printing physical 3D objects from digital data was first developed by *harles Hull in %&'). He named the techni1ue as tereo lithography and obtained a patent for the techni1ue in %&'F.

+hile tereo lithography systems had become popular by the end of %&'4s, other similar technologies such as Gused Deposition "odeling GD"E and elective aser intering E were introduced.

#n %&&3, "assachusetts #nstitute of Technology "#TE patented another technology, named 63 Dimensional ;rinting techni1ues6, which is similar to the inkjet technology used in (D ;rinters.

#n %&&F, three major products, 6Ienisys6 from tratasys, 6/ctua (%446 from 3D ystem ystemss and 6J)4(6 6J)4(6 from J *orporati *orporation on were introduce introduced. d. #n (44, J *orp. launched launched a breakthrough product, named pectrum J%4, which was the first high definition color 3D ;rinter in the market. /nother breakthrough in 3D ;rinting occurred in (44F with the initiation of an open source project, named $eprap, which was aimed ai med at developing a self-replicating self-r eplicating 3D printer.


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3D Printing

3. Currnt 3D Printing Tchno'ogis 3.1 Stro 'ithograph& tereo lithographic 3D printers known as /s or stereo lithography apparatusE position a perforated platform just below the surface of a vat of li1uid photo curable polymer. / 9K laser beam then traces the first slice of an object on the surface of this li1uid, causing a very thin layer of photopolymer to harden. The perforated platform is then lowered very slightly and another slice is traced out and hardened by the laser. /nother slice is then created, and then another, until a complete object has been printed and can be removed from the vat of photopolymer, drained of ecess li1uid, li1 uid, and cured. Gused Gused depositi deposition on mod modelin eling g - Here a hot thermoplast thermoplastic ic is etruded etruded from a tempera temperature ture-controlled print head to produce fairly robust objects to a high degree of accuracy.

3.$ S'ctiv 'asr sintring (S)S* This builds objects by using a laser to selectively fuse together successive layers of a cocktail of powdered wa, ceramic, metal, nylon or one of a range of other materials.

3.3 #u'ti+,t !od'ing (#-#* This again builds up objects from successive layers of powder, with an inkjet-like print head used to spray on a binder solution that glues only the re1uired granules togethe r. The K-Glash K-Glash printer, manufactured by *anon, is low-cost 3D printer. #t:s known to build layers with a light-curable film. 9nlike other printers, the KGlash builds its parts from the top down. Desktop Gactory is a startup launched by the #dea lab incubator in ;asadena, *alifornia.

3. /a0ho! #t is an eperimental project based at *ornell 9niversity, 9niversity, uses uses a syringe to deposit material in a manner similar to GD". The #nepensive syringe makes it easy to eperiment with different materials from glues to cake frosting.


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3D Printing

3.2 In,t 3D printing #t creates the model one layer at a time by spreading a layer of powder plaster plaster , or resins resinsEE and inkjet printing binder in the cross-section of the part. #t is the most widely used 3-D ;rinting technology these days and the reasons beyond that are stated below. This technology is the only one that •

/llows for the printing of full color prototypes.

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9nlike stereo lithography, lithography, inkjet 3D printing is optimi2ed for speed, low cost, and easeof-use.

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!o toic chemicals like those thos e used in stereo lithography lithogr aphy are re1uired. "inimal post printing finish work is needed> one needs only to use the printer itself to blow off surrounding powder after the printing process. proce ss.


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3D Printing

. #AN4/A # AN4/ACT4RIN5 CT4RIN5 A #6DE) WIT% T%E 3D 3D PRINTER To set up this new process, two steps are necessaryB the amount of the printed material must be reduced to a minimum, and the dosed d osed material mustn:t be a part of the th e desired object.

This will be achieved by separation of the process in information transfer and material deposition. The minimum information to create the cross section of an object is the boundary line. This outline will be printed by means of a droplet generator. Thus a thin shell of the model will be formed. Gor eample, the shell material could be a release wa with a high melting point. #n the net step the layer is filled with building material by a rapid application. This material could be also wa with a lower melting point or a fast curing resin etc.

Gigure shows the new printing method for making a three-dimensional bodyB

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/igur 8 3D Printing Procss


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3D Printing

The repeated steps areB

%E ow owerin ering g the platform platform accordi according ng to the layer layer thicknes thickness. s.

(E /pplyin /pplying g a release release wa in its its li1uid state state onto selected selected areas areas of a building building platform platform by a multi-jet printhead, using a pattern according to the cross-section of a thin-walled shell around the three-dimensional body, and a grid pattern not shown in Gigure %E across the remaining area of the building platform.

3E /fter finishing finishing of the pattern pattern of the current current layer, layer, the areas enclosed enclosed by the release release wa are filled with the building wa.

)E moothi moothing ng and planing planing of the layer layer in order order to epose epose the upper surface of the release release wa.

E $eady for the net layer layer.. $epetition $epetition of the steps steps %E to )E with with patterns patterns according according to the current cross-section of the three-dimensional body, thereby making the body itself.

FE $emovi $emoving ng the structures structures not belonging to to the body by dissolving dissolving the release release wa.


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3D P-I.TI.G

2. W6R9 /)6W 6/ 3D PRINTIN5 The workflow can be easily understood with the help of the flowchart given below. / 3-D prototype of a desired object is created in three basic steps and these steps areB •

;re-;rocess

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3-D ;rinting

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;ost-;rocess

/I54RE 2.1 Procss o" 3D Printing

GTU/SCET/IT/V Semester/120420116049 Semester/120420116049

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3D P-I.TI.G

2.1 CAD Prparat Prparation ion (Pr+Procss*8 Co!putr+aidd Co!putr+aidd dsign CADE, also known as co!putr+aidd dsign and dra"ting

CADDE, is used to prepare a 3-D or (-D model of the desired object. "odern */D packages can also fre1uently allow rotations in three dimensions, allowing viewing of a designed object from any desired angle. "ost 3D printers re1uire a special file typically .stl formatE to print. /dditionally, we need to modify the design to make up for limitations of the printer and build material.

/I54RE 2.1 Pr+Pr Pr+Procss ocss o" 3D Printing


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3D P-I.TI.G

2.$ 3D Printing8 The 3D printer runs automatically, depositing materials at layers L.443M thick. This is roughly the thickness of a human hair or sheet of paper. The time it takes to print a given object depends primarily primarily on the height of the design, but most designs take a minimum of several hours. The average cost for printing a full color prototype is somewhere between 4 - %44N.

/I54RE 2.$ Printing an 60,ct


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2.3 C'aning 3D Printouts (Post+Procss*8 (Post+Procss*8 Overy 3D printer uses some sort of material to support parts of the design that have an overhang. ome printers use a loose powder which can be blown off and reused in future models.

/I54RE 2.3 Post+Proc Post+Procss ss o" 3D Printing


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2.3.1 Po:dr R!ova'8 This is the sculpture with most of the support dust removed and it is then dipped in special glue that makes them stronger and more colorful.

/I54RE 2.3.1 Po:dr R!ova'


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2.3. 2. 3.$ $ % %at atin ing g The models are heated to set the glue. #t is funny to see the oven in this picture is a standard consumer grade.

/I54RE 2.3.$ %ating


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2.3.3 2.3 .3 /in /inish ishing ing Touch uchs s The output of all eisting 3D printers printers is rough. The tetures tetures vary from pronounced @wood grainA to merely @sandyA, +ith a little elbow grease you can get stunning results.

/I54RE 2.3.3 /ina' Touch up


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3D P-I.TI.G

7. Bn"its o" 3D Printing

The most successful companies companies have adopted 3D printing as a critical part of the iterative design process toB Incras Innovation ;rint prototypes in hours, obtain feedback, refine designs and repeat the cycle until •

designs are perfect. I!prov Co!!unication •

Hold Hold a full full color, color, realisti realisticc 3D model model in your your hands hands to impart impart infin infinite itely ly more more information than a computer image.

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Create physical 3D models quickly, easily and affordably for a wide variety of applications.

Spd Ti! to #art •

Compress design cycles by 3D printing multiple prototypes on demand, right in your office.

Rduc Dv'op!nt Costs •

Cut traditional prototyping and tooling costs.

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Identify design errors earlier.

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educe travel to production facilities.

Win Businss •

!ring realistic 3D models to prospective accounts, sponsors and focus groups


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3D P-I.TI.G

;. App'ications

;.1 Dsign Protot&ps8 •

3-Dimen 3-Dimension sional al ;rintin ;rinting g concept concept mod model, el, function functional al prototyp prototypes es and presenta presentatio tion n models mod els for evaluati evaluating ng and refining refining design, design, includin including g Ginite Ginite Olement Olement /naly /nalysis sis GO/E results and packaging.

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i2eB 3.  (  4.5 inches

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&    ( cmE

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;rinting TimeB 4. hours

!ow, here we have !okia mobile phone for demonstrationB

created a dummy of a further study and

/I54RE ;.1 D!o #od'


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;.$ Education8 •

Ongage students by bringing digital concepts into the real world, turning their ideas into real-life 3D color models that they can actually hold in their hands.

Here an electronic device circuit has come to life with the help of a 3-D ;rinterB •

i2eB '    (. inches

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(4  %3  F cmE

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;rinting TimeB 3 hours

/I54RE ;.$ an 'ctronic dvic circuit Cratd 0& 3D Printr


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3D P-I.TI.G

;.3 %a'thcar8 %a'thcar8 •

$api $apidly dly produc producee 3D mo model delss to reduce reduce opera operatin ting g time time,, enhan enhance ce patien patientt and physician communications, communicatio ns, and improve patient outcomes.

/ 3-D ;rototype of the hori2ontal crossection of a human skull has been prepared to allow its better studyB

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i2eB &.'  5.&  3.& inches

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(  (4  %4 cmE

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;rinting TimeB . hours

/I54RE ;.$ 3+D Protot&p o" a hu!an su''


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3D P-I.TI.G

<. Conc'usion !othing communicates ideas faster than a three-dimensional part or model. +ith a 3D printer you can bring */D files and design ideas to life right from your desktop. Test Test form, fit and function and as many design variations as you like P with functional parts. #n an age in which the news, books, music, video and even our communities are all the subjects subjects of digital digital demateri demateriali2 ali2atio ation, n, the developm development ent and applicat application ion of 3D printin printing g reminds us that human beings have both a physical and a psychological need to keep at least one foot in the real world. 3D printing has a bright future, not least in rapid prototyping, but also in medicine the arts, and outer space. Desktop 3D printers for the home are already a reality if you are prepared to pay for one andQor build one yourself. 3D printers capable of outputting in color and multiple materials also eist and will continue to improve to a point where functional products will be able to be output. /s devices that will will provi provide de a solid solid bridge bridge betwe between en cybers cyberspac pacee and the the phy physic sical al worl world, d, and as an important manifestation of the econd Digital $evoluti $evolution on,, 3D printing is therefore likely to play some part in all of our futures.


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3D P-I.TI.G

=.RE/RENCES R%Sen.wikipedia.orgQwikiQ3Dprinting. R(ShttpBQQwww.newscientist.comQarticleQmg(%%('(3F.%44-3d-printing-the-technologythat-changes-everything.html R3S httpBQQwww.stratasys.comQ3d-printersQdesign-seriesQdimension-%(44es R)S httpBQQreplicatorinc.comQblogQ(44'Q%(Qa-major-advance-in-3d-printing


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Report on 3D printing

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