A SeminarReport

On

3D PRINTING

Submitted to

SIR. ANUJ GUPTA

Submitted by

SHUBHAM SRIVASTAVA

BACHELOR OF TECHNOLOGY

InMECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERINGIEC Group of Institutions

Greater Noida (UP) 2013062016

ACKNOWLEDGEMENT

I would like to express my sincere gratitude to all those who helped in making of this seminar. I am grateful to SIR ANUJ GUPTA, for his necessary help in the fulfilment of this seminar. I would like to express my heartfelt gratitude to our seminar coordinator Mrs. RINKU YADAV for their valuable guidance, constant encouragement and creative suggestions on making this seminar.

I am also grateful to all my friends and classmates for helping me to make this seminar.

SHUBHAM SRIVASTAVA

Table Of Contents

1. Introduction- what is 3D printing.................................( i )

2. History of 3D printing..................................................( ii )

3. Sustainable Environment Friendly.............................( iv )

4. 3D Printing Material.....................................................( v )

5. Choosing Printing Inks.................................................( vii )

6. General Principles.......................................................( vii )

7. 3D Printing Application...............................................( xi )

8. Consumers...................................................... ( xv )

9. Advantages........................................................( xvi )

10. Disadvantages................................................( xvi )

11. Glossary...........................................................( xiv )

12. Reference........................................................( xvii )

ABSTRACT

Additive manufacturing, often referred to as 3D printing, has the potential to

vastly accelerate innovation, compress supply chains, minimize materials and

energy usage, and reduce waste.

Originally developed at the Massachusetts Institute of Technology in 1993. 3D

printing technology forms the basis of Z Corporation’s prototyping process.

3DP technology creates

3D physical prototypes by solidifying layers of deposited powder using a liquid

binder. By definition 3DP is an extremely versatile and rapid process

accommodating geometry of varying complexity in hundreds of different

applications, and supporting many types of materials. Z Corp. pioneered the

commercial use of 3DP technology, developing 3D printers that leading

manufacturers use to produce early concept models and product prototypes.

Utilizing 3DP technology, Z Corp. has developed 3D printers that operate at

unprecedented speeds, extremely low costs, and within a broad range of

applications. This paper describes the core technology and its related

applications.

Additive manufacturing, often referred to as 3D printing, is a new way of

making products and components from a digital model. Like an office printer

that puts 2D digital files on a piece of paper, a 3D printer creates components by

depositing thin layers of material one after another ,only where required , using

a digital blueprint until the exact component has been created.

Interest in additive techniques is growing swiftly as applications have

progressed from rapid prototyping to the production of end-use products

Additive equipment can now use metals, polymers, composites, or other

powders to “print” a range of functional components, layer by layer, including

complex structures that cannot be manufactured by other means.

By eliminating production steps and using substantially less material, ‘additive’

processes could be able to reduce waste and save more than 50% of energy

compared to today’s ‘subtractive’ manufacturing processes, and reduce material

costs by up to 90%. The use of additive manufacturing can potentially benefit a

wide range of industries including defence, aerospace, automotive, biomedical,

consumer products, and metals manufacturing.

Introduction – What is 3D printing ?

3D Printing is a process for making a physical object from a three-dimensional digital model,

typically by laying down many successive thin layers of a material. It brings a digital object

(its CAD representation) into its physical form by adding layer by layer of materials.

There are several different techniques to 3D Print an object. 3D Printing brings two

fundamental innovations: the manipulation of objects in their digital format and the

manufacturing of new shapes by addition of material.

Digital

+

Additive Manufacturing

Technology has affected recent human history probably more than any other field. These

technologies have made our lives better in many ways, opened up new avenues and

possibilities, but usually it takes time, sometimes even decades, before the truly disruptive

nature of the technology becomes apparent.

Fig (i) –simplified process of 3d printing

It is widely believed that 3D printing or additive manufacturing (AM) has the vast potential

to become one of these technologies. 3D printing has now been covered across many

television channels, in mainstream newspapers and across online resources. What really is

this 3D printing that some have claimed will put an end to traditional manufacturing as we

know it, revolutionize design and impose geopolitical, economic, social, demographic,

environmental and security implications to our every day lives?

The most basic, differentiating principle behind 3D printing is that it is an additive

manufacturing process. And this is i ndee d the key because 3D printing is a radically

different manufacturing method based on advanced technology that builds up parts,

additively, in layers at the sub mm scale. This is fundamentally different from any other

existing traditional manufacturing techniques.

History of 3D Printing

1980: The Birth of a Technology3d printing story starts in the 1980s. Cumbernauld got its big Hollywood break as the

backdrop for Gregory’s Girl, Pac-Mac was busy taking the world by storm and Taggar

started solving crimes in Glasgow.

Fig (ii) – first 3d printer by MakerBot Industries

On the other side of the world, Japan’s Dr Kodama submitted a patent for Rapid Prototyping (RP) technologies. This tech was envisaged as a means to create prototypes

faster and is the first glimpse we got of 3D printing.

Sadly Dr Kodama’s patent wasn’t actually filed because the submission exceeded the one-

year deadline.

Six years later and 11,000 miles away in South Carolina, 3D printing rears its head

again. Chuck Hull invents and patents the world’s first stereolithography (SLA) rapid prototyping system and founds the now iconic 3D Systems.

Stereolithography is the process of building an object in exceedingly thin slices from the

ground up. Sort of like stacking a pile of plastic Digestives until you’ve got a shiny new

prototype. Although the SLA technology has been largely supplanted by Selective Laster

Sintering (SLS) and Multijet Printing (MJP), it’s still used in some rapid prototyping

machines today.

This is the first proper glimpse we get at 3D printing.

  1990: 3D Printing Grows Up

While 3D Systems patented the first SLA machine during the 1980s, it would take a further

six years until the first 3D printer was actually built. In 1992 3D Systems took their first steps

into the practical world of 3D printing and actually built a SLA printer.

Their first machine used a UV laser to solidify layers of photopolymer and could gradually

build up complex objects over the course of hours. The process was slow and was far from perfect but it was – and is – ground breaking stuff.

At the end of the ‘90s things began to sound like a science fiction movie: scientists began

printing human organs. Okay, technically the organs weren’t printed but the organ in

question – a bladder – was actually grown around a 3D printed scaffold.

Nonetheless, a manmade bladder was grown around a 3D-printed mould and successfully

implanted in a person. It’s amazing stuff.

  2000: The Open-Source Era

It was during the 2000s that 3D printing technology started to gain popularity and take

off in the mainstream. A lot of that success is down to the efforts of a few people who tried

to promote open-source versions of the technology.

.A couple years later 3D printing technology starts to creep into commercial uses. The

first 3D-printed prosthetic was manufactured in 2008 and DIY printing kits targeted at

kids followed the next year.

2010s: How Far Can We Push It?

We’re only half way through the decade but we’ve already pushed back the edges of the

printing sphere.

Engineers at the University of Southampton recently designed and flew the world’s first

3D-printed aircraft. Despite including traditionally expensive features like elliptical wings,

the unmanned aircraft cost a measly £5,000. Such is the benefits of 3D printing technology.

The same year, Kor Ecologic introduced the world’s first 3D-printed car. Well, the body

was 3D-printed at least. The ultra-efficient car achieves 200 mpg – around four times fuel

efficiency of the average modern car.The year after that, Dutch doctors worked with

engineers to design a 3D-printed jaw for an 83-year-old women suffering from chronic

bone infection.

Sustainable / Environmentally Friendly

3D printing is also emerging as an energy-efficient technology that can provide

environmental efficiencies in terms of both the manufacturing process itself, utilising up to

90% of standard materials, and, therefore, creating less waste, but also throughout an

additively manufactured product’s operating life, by way of lighter and stronger design that

imposes a reduced carbon footprint compared with traditionally manufactured products.

Furthermore, 3D printing is showing great promise in terms of fulfilling a local

manufacturing model, whereby products are produced on demand in the place where they are

needed — eliminating huge inventories and unsustainable logistics for shipping high volumes

of products around the world.

3D Printing Materials

The materials available for 3D printing have come a long way since the early days of the

technology. There is now a wide variety of different material types, that are supplied in

different states (powder, filament, pellets, granules, resin etc).

Plastics

Nylon, or Polyamide, is commonly used in powder form with the sintering process or

filament form with the FDM process.

Fig (iv) – Polyamide wire

It is a strong, flexible and durable plastic material that has proved reliable for 3D printing. It

is naturally white in colour but it can be coloured — pre- or post printingLayWood is a

specially developed 3D printing material for entry-level extrusion 3D printers. It comes in

filament form and is a wood/polymer composite (also referred to as WPC).

Metals

A growing number of metals and metal composites are used for industrial grade 3D printing.

Two of the most common are aluminium and cobalt derivatives.

One of the strongest and therefore most commonly used metals for 3D printing is Stainless

Steel in powder form for the sintering/melting/EBM processes. It is naturally silver, but can

be plated with other materials to give a gold or bronze effect. In the last couple of years Gold

and Silver have been added to the range of metal materials that can be 3D printed directly,

with obvious applications across the jewellery sector. These are both very strong materials

and are processed in powder form.

Ceramics

Ceramics are a relatively new group of materials that can be used for 3D printing with

various levels of success. The particular thing to note with these materials is that, post

printing, the ceramic parts need to undergo the same processes as any ceramic part made

using traditional methods of production — namely firing and glazing.

Bio Materials

Living tissue is being investigated at a number of leading institutions with a view to

developing applications that include printing human organs for transplant, as well as external

tissues for replacement body parts. Other research in this area is focused on developing food

stuffs — meat being the prime example.

Food

An experiment with extruders for 3D printing food substances has increased dramatically

over the last couple of years. Chocolate is the most common (and desirable). There are also

printers that work with sugar and some experiments with pasta and meat. Looking to the

future, research is being undertaken, to utilize 3D printing technology to produce finely

balanced whole meals

CHOOSING PRINTING INKS

Printing inks are chosen according to the need and kind of object that has to print. Different

types of inks are available according to the size, type, resolution and function of the object.

COLLOIDAL INK

Three-dimensional periodic structures fabricated from colloidal “building blocks” may find

widespread technological application as advanced ceramics, sensors, composites and tissue

engineering scaffolds. These applications require both functional materials, such as those

exhibiting Ferro electricity, high strength, or biocompatibility, and periodicity engineered at

length scales (approximately several micrometers to millimeters) far exceeding colloidal

dimensions. Colloidal inks developed for robotic deposition of 3-D periodic structures. These

inks are also called general purpose inks.

FUGITIVE INK

These types of inks are used for creating soft devices. The type of ink is capable for self-

organizing which results in self regenerative devices.

NANOPARTICLE INK

The object that has to be printed sometimes need conductor for its function. For printing

conductors, special types of inks called Nanoparticle inks are used.

GENERAL PRINCIPLES

1. MODELLING 2. PRINTING 3. PROCESS

1. MODELLING

There are some procedures for printing. First we must create a computer model for printing

the object. For creating that, we can use Computer Aided Design Software like AutoCAD,

3DS Max etc. After the object file is created, the file need to be modified. The object file

contains numerous amount of curves. Curves cannot be printed by the printer directly. The

curves has to be converted to STL (Stereo lithography) file format.

Fig(v) – CAD Model of an object

The STL file format conversion removes all the curves and it is replaced with linear shapes.

Then the file need to be sliced into layer by layer. The layer thickness is so chosen to meet

the resolution of the 3D printer we are using. If you are unable to draw objects in CAD

software, there are many websites available which are hosted by the 3D printing companies

to ease the creation of 3D object.

2. PRINTING

Once completed, the STL file needs to be processed by a piece of software called a "slicer,"

which converts the model into a series of thin layers and produces a G-code file containing

instructions tailored to a specific type of 3D printer (FDM printers).This G-code file can then

be printed with 3D printing client software (which loads the G-code, and uses it to instruct

the 3D printer during the 3D printing process) The sliced file is processed and generates the

special coordinates. These coordinates can be processed by a controller to generate required

signal to the motor for driving extruder.

This layer by layer process generate a complete object.

Printer resolution describes layer thickness and X-Y resolution in dots per inch (dpi)

or micrometres (µm). Typical layer thickness is around 100 µm   , although some machines

can print layers as thin as 16 µm .  The particles (3D dots) are around 50 to 100 µm (510 to

250 DPI) in diameter

Fig(vi) – An overview of the printing process from 2d diagram to real 3d printed object

3. PROCESS

Several 3D printing processes have been invented since the late 1970s. The printers were

originally large, expensive, and highly limited in what they could produce.

Fig(vii) – Block diagram of 3d printer

A large number of additive processes are now available. The main differences between

processes are in the way layers are deposited to create parts and in the materials that are used.

Some methods melt or soften the material to produce the layers, for example SELECTIVE

LASER MELTING (SLM) or DIRECT METAL LASER SINTERING (DMLS), 

SELECTIVE LASER SINTERING (SLS), FUSED DEPOSITION MODELLING (FDM), ,

Each method has its own advantages and drawbacks, which is why some companies offer a

choice of powder and polymer for the material used to build the object. Others sometimes use

standard, off-the-shelf business paper as the build material to produce a durable prototype.

The main considerations in choosing a machine are generally speed, costs of the 3D printer,

of the printed prototype, choice and cost of the materials, and color capabilities.

3D Printing Applications 

The developments and improvements of the process and the materials, since the emergence of

3D printing for prototyping, saw the processes being taken up for applications further down

the product development process chain. Similarly for final manufacturing operations, the

improvements are continuing to facilitate uptake.

The following are some of the applications

Medical and Dental

Professor Leroy Cronin of Glasgow University proposed in a 2012  that it was possible to use

chemical inks to print medicine Similarly, 3D printing has been considered as a method of

implanting stem cells capable of generating new tissues and organs in living humans. With

their ability to transform into any other kind of cell in the human body, stem cells offer huge

potential in 3D bio-printing.

Fig (viii) – Real 3d printed ear

A printing based on fused filament fabrication (FFF) approach has been already implemented

for the creation of microstructures having an internal 3D microstructure geometry. These

objects can be produced without any sacrificial structures or additional support materials, just

by precisely tuning the nozzle heating, fan cooling and translation velocity parameters. The

manufactured microporous structures out of polylactic acid (PLA) can have fully controllable

porosity (20%–60%). Such scaffolds could serve as biomedical templates for cell culturing,

as well as biodegradable implants for tissue engineering.

Pills

The first pill manufactured by 3D printing was approved by the FDA in August 2015. Binder-

jetting into a powder bed of the drug allows very porous pills to be produced, which enables

high drug doses in a single pill which dissolves quickly and can be ingested easily.

Aerospace

Because of the critical nature of aircraft development, the R&D is demanding and strenuous,

standards are critical and industrial grade 3D printing systems are put through their paces.

Process and materials development have seen a number of key applications developed for the

aerospace sector — and some non-critical parts are all-ready flying on aircraft.

High profile users include GE / Morris Technologies, Airbus / EADS, Rolls-Royce, BAE

Systems and Boeing. While most of these companies do take a realistic approach in terms of

what they are doing now with the technologies, and most of it is R&D, some do get quite

bullish about the future.

Automotive

In early 2014, the Swedish supercar manufacturer, Koenigsegg, announced the One:1, a

supercar that utilizes many components that were 3D printed. In the limited run of vehicles

Koenigsegg produces

Fig(ix) – 3d printed wearable item

the One:1 has side-mirror internals, air ducts, titanium exhaust components, and complete

turbocharger assemblies that were 3D printed as part of the manufacturing process.

Urbee is the name of the first car in the world car mounted using the technology 3D printing

(his bodywork and his car windows were "printed"). Created in 2010 through the partnership

between the US engineering group Kor Ecologic and the company Stratasys(manufacturer of

printers Stratasys 3D), it is a hybrid vehicle with futuristic look.

Many automotive companies are now also looking at the potential of 3D printing to fulfill

after sales functions in terms of production of spare/replacement parts, on demand, rather

than holding huge inventories.

Jewellery

For the jewellery sector, 3D printing has proved to be particularly disruptive. There is a great

deal of interest — and uptake — based on how 3D printing can, and will, contribute to the

further development of this industry. From new design freedoms enabled by 3D CAD and 3D

printing, through improving traditional processes for jewellery production all the way to

direct 3D printed production eliminating many of the traditional steps, 3D printing has had —

and continues to have — a tremendous impact in this sector.

Construction

According to Erik Kinipper, clients usually need to see the product from all possible

viewpoints in space to get a clearer picture of the design and make an informed decision. In

order to get these scale models to clients in a small amount of time, architects and

architecture firms tend to rely on 3D printing. Using 3D printing, these firms can reduce lead

times of production by 50 to 80 percent, producing scale models up to 60 percent lighter than

the machined part while being sturdy.

The use of 3D printing in architecture is still small as logistics are being ironed out, but a

new proof of concept has just been unveiled. The 250-square-metre space (2,700 square foot)

is what Dubai's Museum of the Future project is calling the world's first 3D-printed office

building. China unveiled the world's first 3D printed office building and mansion in early

2015.

Fashion

As 3D printing processes have improved in terms of resolution and more flexible materials,

one industry, renowned for experimentation and outrageous statements, has come to the fore.

We are of course talking about fashion!

3D printed accessories including shoes, head-pieces, hats and bags have all made their way

on to global catwalks. And some even more visionary fashion designers have demonstrated

the capabilities of the tech for haute couture — dresses, capes, full-length gowns an

evensome under wear have debuted at different fashion venues around the world.

Fig(x) – Application of 3d printer

Food

Initial forays into 3D printing food were with chocolate and sugar, and these developments

have continued apace with specific 3D printers hitting the market. Some other early

experiments with food including the 3D printing of “meat” at the cellular protein level. More

recently pasta is another food group that is being researched for 3D printing food.

Fig(xi) – 3d printer printing eadable burger

Looking to the future 3D printing is also being considered as a complete food preparation

method and a way of balancing nutrients in a comprehensive and healthy way.

Consumers

The holy grail for 3D printing vendors is consumer 3D printing. There is a widespread debate

as to whether this is a feasible future. Currently, consumer uptake is low due to the

accessibility issues that exist with entry level (consumer machines). There is headway being

made in this direction by the larger 3D printing companies such as 3D Systems and

Makerbot, as a subsidiary of Stratasys as they try to make the 3D printing process and the

ancillary components (software, digital content etc) more accessible and user-friendly. There

are currently three main ways that the person on the street can interact with 3D printing tech

for consumer products:

design + print choose + print choose + 3D printing service fulfilment

ADVANTAGES

Create anything with great geometrical complexity.

Ability to personalize every product with individual customer needs.

Produce products which involve great level of complexity that simply could not be

produced physically in any other way.

Additive manufacturing can eliminate the need for tool production and therefore

reduce the costs, lead time and labour associated with it.

3D printing is an energy efficient technology.

Additive Manufacturing use up to 90% of standard materials and therefore creating

less waste.

Lighter and stronger products can be printed.

Increased operating life for the products.

Production has been brought closer to the end user or consumer.

Spare parts can be printed on site which will eliminate shipping cost.

3D printing can create new industries and completely new professions.

Printing 3D organs can revolutionarise the medical industry.

Rapid prototyping causes faster product development.

DISADVANTAGES

Since the technology is new, limited materials are available for printing.

Consumes more time for less complicated pats.

Size of printable object is limited by the movement of extruder.

In additive manufacturing previous layer has to harden before creating next layer.

Curved geometry will not be much accurate while printing.

Glossary

3DP 3D Printing AM Additive Manufacturing CAD / CAM Computer-aided design / Computer-aided manufacturing CAE Computer-aided engineering DMD Direct Metal Deposition DMLS Direct Metal Laser Sintering FDM Fused Deposition Modelling (Trademark of Stratasys) FFF Freeform Fabrication LS Laser Sintering RM Rapid Manufacturing RP Rapid Prototyping SL Stereolithography SLA Stereolithography Apparatus (Registered Trademark of 3D

Systems) SLM Selective Laser Melting SLS Selective Laser Sintering (Registered Trademark of 3D Systems) MJP Multijet Printing WPC Wood/Polymer Composite DMLS Direct Metal Laser Sintering PLA Polylectic Acid

REFERENCE

INTRODUCTION : http://3dprinting.com/what-is-3d-printing/

HISTORY : http://www.capture-all.co.uk/a-brief-history-of-3d-printing-1980-to-2015/

CHOOSING 3D PRINTER INK : http://3dprintingforbeginners.com/filamentprimer/

3D PRINTING MATERIALS : https://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/materials/

GENERAL PRINCIPLES & APPLICATION : https://en.wikipedia.org/wiki/3D_printing

ADVANTAGES AND DISADVANTAGES : https://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/global-effects-manufacturing-economy/