A Mini Project Report On

STUDY OF PRODUCT DESIGN AND DEVELOLPMENT

USING 3D TECHNOLOGY BY
FUSED DEPOSITION MODELLING
IS
SUBMITTED TO THE JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY IN PARTIAL
FULFILMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
By

B. UDAY KUMAR 167R1A0308

M.VENU 177R5A0311
M.SAI PRASANNA 177R5A0305
M.SRINIVAS SAGAR 177R5A0303

Under the Guidance of

Mr. M. AJAY KUMAR, M. TECH, (Ph.D.)
ASSOCIATE PROFESSOR,
DEPARTMENT OF MECHANICAL ENGINEERING
CMR TECHNICAL CAMPUS

DEPARTMENT OF MECHANICAL ENGINEERING

CMR TECHNICAL CAMPUS
(Sponsored by CMR Technical Education Society)
UGC AUTONOMOUS
Accredited by NBA & NAAC with ‘A’ Grade
Approved by AICTE, NEW Delhi and JNTU Hyderabad
Kandlakoya (V), Medchal Road, Hyderabad - 501401
 CERTIFICATE
This is to certify that the Mini project report entitled “ STUDY OF PRODUCT
DESIGN AND DEVELOPMENT USING 3D PRINTING TECHNOLOGY BY FUSED
DEPOSITION MODEELING “ is being submitted by the following Students, in

partial fulfillment for the award of Degree of Bachelor of Technology in

Mechanical Engineering to the Jawaharlal Nehru Technological University is a
record of bonafide work carried out by them under guidance and supervision.
The results embodied in this Mini project report have not submitted to any
other University or Institute for the award of any Degree.

B. UDAY KUMAR 167R1A0308

M.VENU 177R5A0311
M.SAI PRASANNA 177R5A0305
M.SRINIVAS SAGAR 177R5A0303

Project Guide HOD-Mechanical

Mr. M. Ajay Kumar, M. Tech, (Ph.D.) Prof.Dr.D. Maneiah, M. Tech., Ph.D.

Director-CMRTC External Examiner

Dr.A. Raji Reddy, M.Tech., Ph.D.
 ACKNOWLEDGEMENT
It gives us an immense pleasure in expressing our deep sense of
gratitude to our internal guide, Mr.M.Ajay Kumar, Associate professor,
Department of Mechanical Engineering, CMR Technical Campus, for his
valuable suggestions on each and every review during the course of our project.
We sincerely express our thanks and extend our deep sense of gratitude to
the director Dr.A.RAJI REDDY and the management of CMR TECHNIAL
CAMPUS for providing us the best amenities to enable us complete our project
in the stipulated time.
We are obliged and grateful to thank Dr.D.MANEIAH, HOD, Department
of Mechanical Engineering, CMR Technical Campus, for his cooperation,
valuable guidance, sustained interest and constant encouragement at every stage
of this endeavor in all respects during the course.
It gives us an immense pleasure to acknowledge with gratitude, for the
help and patience, gracious cooperation, support received by all during the
course of the successful completion of the project “STUDY OF PRODUCT
DESIGN AND DEVELOPMENT USING 3D PRINTING TECHNOLOGY BY FUSED
DEPOSITION MODEELING”.

Finally, we own all our success to our beloved parents, friends and other
faculty of the Department of Mechanical Engineering for their unstinting
support which gave us the confidence required to overcome the obstacles that
we faced in the completion of this project.
 TABLE OF CONTENTS
CHAPTER TITLE PG.NO
ABSTRACT
LIST OF FIGURES

1 INTRODUCTION 3
1.1 Objective of the project
1.2 Process of 3d printing
1.3 Thesis
2 HISTORY OF 3D PRINTING 2
3 PRINTING METHODS 13
3.1 Fused deposition modelling
3.2 Granular material binding
3.3 selective laser sintering
3.4 selective heat sintering
3.5 selective laser melting
3.6 electron beam melting
3.7 Stereo lithography
3.8 DLP projecting
3.9 Material jetting
3.10 laminated object manufacturing process
4 PROJECT DESCRIPTION 10
5 ADVANTAGES & DISADVANTAGES, APPLICATIONS
6 RESULTS, CONCLUSIONS & FUTURE PROSPECTS
REFERENCES
 ABSTRACT
3D printing is a form of additive manufacturing technology where a three-
dimensional object is created by laying down successive layers of material. It is
also known as rapid prototyping, is a mechanized method whereby 3D objects
are quickly made on a reasonably sized machine connected to a computer
containing blueprints for the object. The 3D printing concept of custom
manufacturing is exciting to nearly everyone.
This revolutionary method for creating 3D models with the use of inkjet
technology saves time and cost by eliminating the need to design; print and glue
together separate model parts. Now, you can create a complete model in a single
process using 3D printing. The basic principles include materials cartridges,
flexibility of output, and translation of code into a visible pattern.
3D Printers are machines that produce physical 3D models from digital
data by printing layer by layer. It can make physical models of objects either
designed with a CAD program or scanned with a 3D Scanner. It 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.
 LIST OF FIGURES
FIGURE NO TITLE PG.NO

1 Basic method of fdm 12

2 Granular material binding 13

3 llustration of granular material 14

4 Selective Laser Sintering Citation Process 15

5 llustration of a Blue Printer Citation 15

6 A model created by Blue Print Citation 16

7 Illustration of selective laser sintering method 16

8 Selective laser sintering in action 17

9 Illustration of an EBM process citation 17

10 Diagram of SLA printing process 18

11 Illustration of DLP Projection 19

12 Illustration of material jetting process citation 20

13 Laminated Object Manufacturing process 21

14 FDM PROCESS 23

15 Representations of Process parameters 25

16 Necking Phenomenon’s 25

17 Picture Representing Cusp Heights 26

18 Representation of Orientation in FDM 27

19 Effect of Layer Thickness on Surface Finish 28

20 Containment Issue in Layered Manufacturing 28

 CHAPTER 1
1.1. INTRODUCTION:

3D printing called as desktop fabrication. It is a rapid prototyping process whereby a real

object can be created from a 3D design. A 3D printer machine uses a CAD model for rapid
prototyping process. [1]
3D printing is called as desktop fabrication which is a process of prototyping where by a
structure is synthesized from its 3d model. The 3d design is stored in as a STL format and
after that forwarded to the 3D printer. It can use a wide range of materials such as ABS, PLA,
and composites as well.3D printing is one kind of rapidly developing and cost optimized form
which is used for rapid prototyping. The 3D printer prints the CAD design layer by layer
forming a real object. 3D printing process is derived from inkjet desktop printers in which
multiple deposit jets and the printing material, layer by layer derived from the CAD 3D
data.3D printing is diversifying and accelerating our life, letting various qualities of products
to be synthesized easier and faster[2].Three dimensional (3D) printing has the ability to
impact the transmission of information in ways similar to the influence of such earlier
technologies as photocopying. This identifies sources of information on 3D printing, its
technology, required software and applications. Along 3D printing, companies are able to
extract and innovate new ideologies and various design replications with no time or tool
expense. 3D printing possibly challenges mass production processes in future. 3D printing
influences many industries, such as automotive, architecture, education, medical, business
and consumer industries [3].

MOTIVATION FOR THE PRESENT RESEARCH WORK:

Since over a century the visual world of printed scriptures has been dominated by the 2-D
printing methods. Be that easy to read or comprehend but when it comes to imaging of
definite and real-life models it is sorely outsourced. Any 3-D model cannot be represented
and displayed easily in a 2-D workplace. The only thing worth mentioning for likable
perception is the rendering of the image. This ushered in the era of the much-needed idea of
“3-D” printing.
Basically, the singular purpose for the division of 3-D printer was to prepare 3-D samples
directly on the bed of the printer. It has been an effective way of manufacturing since many
companies are now opting for this type of method for their production operations.

1.1 OBJECTIVE:

1. To study different methods of 3d printing and their applications.

2. To study the working procedure of each component of a 3d printer and the evolution
of 3d printer.
3. To design and fabricate a 3d printer using tool kit.

1.2 PROCESS OF 3D PRINTING:

3D printing process can be described and defined in the following steps:

CAD Model Creation: Initially, the item to be 3D printed is designed utilizing a Computer-
Aided Design (CAD) software. Solid modelers, for example, CATIA, and SOLID WORKS
have a tendency to represent 3-D objects more precisely than wire-frame modelers, for
example, AutoCAD. This procedure is comparative for the majority of the Rapid Prototyping
building methods [6].
Conversion to STL Format: The different CAD models use different methods to present
solid parts. To have consistency, the stereo lithography format has been followed as the
standard of the 3D printing industry.
Slice the STL File: A preprocessing computer program is done which readies the STL format
going to be built. Numerous programs are there, which permit the user to tweak the model.
The preprocessing program cuts the Stereo lithography model into numerous layers from 0.01
mm to 0.7 mm thickness, in view of the building method. The program likewise makes an
auxiliary structure to help the model amidst of building. Sophisticated structures are bound to
use auxiliary support [7].
Layer by Layer Construction: The fourth step is the actual construction of the part. Using
one of various techniques RP machines build one layer at a time from polymers, or powdered
metal [7].
1.3 THESIS:
The thesis explains the implantation of “ “. The organization of the
thesis is explained here with:
Chapter 1: Presents introduction to the overall thesis and the
overview a brief introduction of
Chapter 2: Presents the history of 3d printing
Chapter 3: Presents the different printing methods
Chapter 4: Presents the Project description along with designing
software’s used for 3d printing and materials used for FDM
technology
Chapter 5: FDM manufacturers, advantages and disadvantages
Chapter 6: Presents the Result,conclusions and future scope of the
project and References
 CHAPTER 2
HISTORY OF 3-D PRINTING:
1974 :
David E. H. Jones laid out the concept of 3D printing in his regular column Ariadne in the
journal New Scientist
1981:
Early additive manufacturing equipment and materials were developed in the 1980s. In 1981,
Hideo Kodama of Nagoya Municipal Industrial Research Institute invented two additive
methods for fabricating three-dimensional plastic models with photo-hardening thermoset
polymer, where the UV exposure area is controlled by a mask pattern or a scanning fibre
transmitter.
1984 :
On 16 July 1984, Alain Le Méhauté, Olivier de Witte, and Jean Claude André filed their
patent for the stereolithography process. The application of the French inventors was
abandoned by the French General Electric Company (now Alcatel-Alstom) and CILAS (The
Laser Consortium). The claimed reason was "for lack of business perspective".
Three weeks later in 1984, Chuck Hull of 3D Systems Corporation[18] filed his own patent
for a stereolithography fabrication system, in which layers are added by
curing photopolymers with ultraviolet light lasers. Hull defined the process as a "system for
generating three-dimensional objects by creating a cross-sectional pattern of the object to be
formed," Hull's contribution was the STL (Stereolithography) file format and the digital
slicing and infill strategies common to many processes today.
1988:
The technology used by most 3D printers to date—especially hobbyist and consumer-
oriented models—is fused deposition modelling, a special application of plastic extrusion,
developed in 1988 by S. Scott Crump and commercialized by his company Stratasys, which
marketed its first FDM machine in 1992.
1993 :
The term 3D printing originally referred to a powder bed process employing standard and
custom inkjet print heads, developed at MIT by Emanuel Sachs in 1993 and commercialized
by Soligen Technologies, Extrude Hone Corporation, and Z Corporation.
The year 1993 also saw the start of a company called Solidscape, introducing a high-
precision polymer jet fabrication system with soluble support structures.
1995:
In 1995 the Fraunhofer Institute developed the selective laser melting process.
2009:
Fused Deposition Modelling (FDM) printing process patents expired in 2009.
2010:
were the first decade in which metal end use parts such as engine brackets and large nuts
would be grown in job production rather than obligately being machined from bar stock or
plate. It is still the case that casting, fabrication, stamping, and machining are more prevalent
than additive manufacturing in metalworking, but AM is now beginning to make significant
inroads, and with the advantages of design for additive manufacturing, it is clear to engineers
that much more is to come.
As technology matured, several authors had begun to speculate that 3D printing could aid
in sustainable development in the developing world.
2012:
Filabot develops a system for closing the loop with plastic and allows for any FDM or FFF
3D printer to be able to print with a wider range of plastics.
2014:
Georgia Institute of Technology Dr. Benjamin S. Cook, and Dr. Manos M. Tentzeris
demonstrate the first multi-material, vertically integrated printed electronics additive
manufacturing platform (VIPRE) which enabled 3D printing of functional electronics
operating up to 40 GHz.
 CHAPTER 3

3 PRINTING METHODS:
3.1 FUSED DEPOSITION MODELLING:

In this process the thermoplastics; which constitute ABS (Acrylonitrile butadiene styrene),
wax and nylon were utilized. The introductory venture of the FDM procedure were to warmth
up the thermoplastic constituent until it is at an intertwined state .Then, the 3D printer uses
advanced demonstrating information from a CAD record to create the 3D item layer by layer,
The printers join a much weaker bolster composite. The bolster material goes about as
framework to the test item. This is valuable amid the building procedure when parts have
overhangs that could not bolster it. The thermoplastic for the most part has a filamentous
structure which benefits warmth exchange and serves to move with a print head that
navigates in the x and y bearings. After every layer is printed, a cylinder navigates the stage
beneath (z-hub) the separation of thickness of printed layer. There are numerous benefits of
FDM innovation; it is anything but difficult to control, use, and fix. The expense of the
machine and material are generally low.

BASIC METHOD OF FDM TECHNOLOGY

3.2 GRANULAR MATERIAL BINDING (USING HEAT/ ENERGY):

The joining of granular materials involves specifically fusing powder, layer by layer.
The elemental constitution of the powder and binding process relies on the machine.

Granular material binding

GRANULAR MATERIAL BINDING (USING BINDING AGENT):

This methodology utilized fluid binding material for the binding procedure of the powder
together, instead of a laser. Zcorp, has a copyright of this innovation around the world. 3D
printing is also called fundamental inkjet printing procedures. As opposed to utilizing paper
like as a part of the instance of a 2D printer, a 3D printer moves the print heads over a bed of
powder whereupon it printed information sent from the product. The fluid binding materials
here utilized is much the same as super glue. Composite material or mortar is utilized as
powder here.
 Illustration of granular material

3.3 SELECTIVE LASER SINTERING (SLS):

One of the sorts of binding processes is Selective Laser Sintering, or SLS. It utilizes a high-
powered laser to sinter the powder. Once the first layer is made, the whole granular plate, in
which the powder (and the "print") is found, is cut down. As seen in Figure 6, this procedure
is supplemented by the vertical development of a cylinder. Moreover, cylinders are
additionally utilized as a part of a few printers to send the coupling powder up so that the
moving instrument would continue working adequately and the sintering can proceed. A
mirror is integrated to control the laser bar into the foreordained "cut" of the CAD model.
When the greater part of the layers is appropriately sintered, the item is removed from the
build chamber.
 Selective Laser Sintering Citation Process

3.4 SELECTIVE HEAT SINTERING:

SHS is indistinguishable to SLS. Selective Heat Sintering utilized a thermal print head. This
new strategy uses concentrated heat to fuse the binding powder.

Illustration of a Blue Printer Citation

 A model created by Blue Print Citation

3.5 SELECTIVE LASER MELTING (SLM):

SLM is almost as same as SLS. A more powerful laser is generally used. It required more
energy for the metal to be melted.

Illustration of selective laser sintering method

 Selective laser sintering in action

3.6 Electron Beam Melting (EBM):

Electron Beam Melting is some cases similar to SLM; an electron beam was used to melt the
powder. Unlike models produced by SLM, EBM models are fully accurate, void-less, and
extremely powerful.

Illustration of an EBM process citation

Photo Polymerization:
This is an additive manufacturing process. This methodology utilizes UV light for the
hardening of the photograph polymer. There are diverse sorts of photopolymers which are
accessible today. Photograph polymerization is really same as FDM and Granular Material
binding process. The fundamental contrasts are the material sand the system utilized for the
printing systems.

3.7 Stereo Lithography:

A stereo lithographic printer is regularly known as a SLA. A perforated platform was put just
beneath the surface of a carriage of fluid polymer.
The UV-treatable fluid solidifies quick, shaping the essential layer of the 3D-printed item.
Next, the stage was brought down, uncovering another surface layer of the fluid substance.
This procedure is rehashed more till the whole question is framed and is completely
submerged in the tank [10]. Regularly, the utilization of the UV stove issued for the ensuing
cure of the photograph polymer.
 3.8 DLP Projecting:

DLP (Digital Light Processing) is one kind of stereo lithographic procedure. It utilizes a
projector to solidify a layer of photopolymer at once, as opposed to utilizing a laser for the
following of distinctive layers. A mirror was most normally used to position and size the
replication precisely onto layer of photopolymer.

Illustration of DLP Projection

Digital Light Processing is a 3D printing technology know as DLP, used in DLP 3D

printers. The object is formed by the solidification of a photo-reactive resin using a digital
light projector as the UV light source. The projector used in a DLP 3D printer can be a
regular video projector, its resolution will determine the 3D print resolution. DLP 3D printers
are gaining traction, notably because of their superior print speed thanks to the light projector
which hardens the resin layer by layer and not point by point, as lasers used in SLA 3D
printers do.
 3.9 Material Jetting:
Material Jetting is much the same as the FDM process, yet it works absolutely in an alternate
manner than the basic plastic extrusion system. Layers were made by emanating fluid
photopolymer into a specific example. These sorts of printers utilize a bolster material
alongside the model material. When every layer is shaped, an UV laser is utilized for the
solidification of the photopolymer. The platform is then moved down, and the model is
printed layer by layer.

Illustration of material jetting process citation

3.10 Laminated Object Manufacturing (LOM):

Covered article assembling can give great results. Other than the laser (carbon dioxide) that is
involved for following the patterns in the material. It is a less prevalent rapid prototyping
process yet looks into are continuing for its future actualizes.
 Depiction of Laminated Object Manufacturing process

In this technique the chose printing material is initially covered with a sticky material. The
material supply roll turns simply enough with the goal that there is another layer of substance
which is prepared to be cut with the assistance of the laser. The warmth and weight from the
roller join so that the following layer is safely stuck to the past layer. The laser is being
customized in a manner that it cuts the material so that the abundance material is effortlessly
expelled from the setup. After the "print" is expelled from the stage, the abundance material
and backings are to be uprooted. In this technique at last, regularly there is requirement for
devices, for example, etches, to pry the additional parts far from the set up.
 CHAPTER 4
FUSED DEPOSITION MODELLING
INTRODUCTION:
Fused Deposition Modeling (FDM) process comes under additive process. It is one among
the several additive processes like Stereo lithography (SL), Selective Laser sintering (SLS)
etc. Additive Manufacturing follows building components by addition of material. In order to
visualize the approach used, stacking a pack of cards can be considered as an example
FDM, the name itself gives the idea that the parts are formed by deposition of the fused
material in layers. This RP technique is used in modeling, prototyping and production
applications. FDM was developed by S. Scott Crump in the late 1980s and was
commercialized in 1990 by Stratasys.
Working of FDM machine:
In the FDM process, a gantry-robot which is fitted with the extruder head moves in X & Y
directions. The table moves in vertical Z-axis. When a layer gets deposited on the table, it
goes down according to the layer thickness and the subsequent layers are built in the same
way.

FDM PROCESS
Materials used in making FDM parts:
Most of the existing FDM machines use thermoplastic materials which are in a filament form
for the extrusion and deposition purpose. Acrylonitrile Butadiene styrene (ABS) and
Polylactide (PLA) thermoplastics are predominantly used in the process.
The above-mentioned materials are used in following forms:
i. Build material: This material is used to obtain actual part.
ii. Support material: This material is used to construct support structures for the actual part.
The support material is otherwise called as dissolvable material if it is dissolvable.
Table 1: Properties of materials
S.No. Name of the Normal melting Temperature
material point used in FDM
1 ABS 105oC 230 oC

2 PLA 65oC 180oC

Steps to be carried out to build a model:

Create a CAD model of the product.
1. Save it in the Stereolithography (STL) file format
2. Load the .stl file in to the slicing software or the interface platform between the specific
machine and the computer.
3. Upload the sliced file into the FDM machine.
4. Run the machine with required settings.
5. Detach the part from the table after completion.
VARIOUS PARAMETERS IN FDM
It is found from the literature review that the quality of the FDM prototype produced is
influenced by different parameters. Reference [10] defines these parameters as follows:
Orientation: Part build orientation or orientation refers to the inclination of the part in the
build platform with respect to X, Y, and Z axis, where X and Y-axis are considered parallel to
build platform and Z- axis is along the direction of part build.
Layer thickness: It is the thickness of layer deposited by nozzle and depends upon the type of
nozzle used.
Raster angle: It is a direction of raster relative to the
X-axis of the build table.
Part raster width (raster width): It is the width of raster pattern used to fill interior regions of
part curves.
Raster to raster gap (air gap): It is the gap between two adjacent rasters on same lay

Figure 3: Representations of Process parameters

Necking: Necking is a shape formed due to molecular bonding between two rasters

Figure 4: Necking Phenomenon’s

Figure 5: Neck Growth Evolutions at Constant Temperature for ABS at 200˚C

Cusp height: It is calculated as the maximum normal distance between facet and the
deposited part considering the edges of the slices to be rectangular

Figure 6: Picture Representing Cusp Heights

Speed of deposition: It is the rate at which the nozzle deposits the raster.
Other parameters:
Shell: It refers to the outermost boundary of the layer.
Infill: Everything that is neither shells, nor roof, nor floor is filled with an internal lattice
called infill.
CHARACTERISTICS CONSIDERED IN An FDM BUILT PART
Products manufactured using Fused Deposition Modeling technology can be characterized by
technical indices – strength of certain kind (tensile, flexural strength or impact resistance),
dimensional accuracy, as well as economic indices, such as manufacturing time and amount
of support and build material used. Many parameters mentioned above have direct and
indirect influence on these indices.
Characteristics that are predominantly considered in FDM built parts are as follows:
A. Dimensional Accuracy.
B. Surface roughness.
C. Mechanical strength characteristics.
Dimensional Accuracy:
According to[12],dimensional accuracy is understood as degree of compatibility of basic
dimensions of the obtained product with dimensions of the ideal product (nominal
dimensions).With respect to the parameters affecting the dimensional
accuracy,partorientation plays a major in obtaining the dimensional accuracy of the part.

Orientation of the model in the working chamber during layered manufacturing process can
be described as an angular difference between plane determining direction of the object
division into layers and selected, basic plane of the manufactured object. Orientation can be
defined by three angular values. One of them – rotation in the Z axis (around vertical
direction) has no importance from the viewpoint of technical and economical indexes, as it
has no influence on how the object is divided into layers.
It has been understood from the experiments conducted by
[12] that the coefficient of accuracy increases with lower orientations therefore orientation
the part should be as low as possible in order to get accurate as well as strengthened parts.

Figure 7: Representation of Orientation in FDM [12]

Orientation of the part not only affects the accuracy of the part it also play role in the usage of
the build material, build time. (Discussed in strength characteristics).

Surface roughness:

As it is considered as one of the important characteristics in any functional part manufactures

by conventional and un- conventional processes it does the same with the FDM built parts.
Surface Roughness is considered as one major challenging quest for the researches today and
many of them are working on the ways to produce products with less surface roughness
which will be a great addition to the functional prototypes.
The increase in the surface roughness of the prototypes is due to the inherent disadvantages in
the layered manufacturing processes. They can be grouped as follows:
i. Layer thickness.
ii. Stair case effect.
 i. Layer thickness:
As the thickness of the layer increases, the roughness increases. This is clearly illustrated

Figure8: Effect of Layer Thickness on Surface Finish

ii. Stair case effect:

According to [14],in any RP process, the layer by layer building process introduces an error
on the amount of material used compared to the volume specified by the computer aided
design model. This error causes the staircase effect on the surface and adversely affects the
dimensional accuracy as well as surface finish for different part build orientations. Inclined
and curved surfaces show staircase effects more predominantly than other surfaces.

The orientation, at which the part is built, has a significant effect on the quality of various
surfaces of the part. The orientation of part also affects other factors such as the build time,
the complexity of support structure, shrinkage, curling, trapped volume, and material flow in
many rapid prototyping processes. There is no way the staircase effect can be completely
eliminated. However, the effect can be reduced by decreasing the layer thickness and by
orienting the part such that the effect of overall staircase error is greatly reduced. It is because
of the staircase the edges of the slices may be completely out of the CAD model or they may
be completely inside the CAD model as shown in figure 9.

Containment Issue in Layered Manufacturing

Adaptive Slicing: -
It is the technique followed to decrease the surface roughness of the prototypes produced in
FDM. In this process the slicing software doesn’t slice the CAD model into equal layers
instead slices the CAD model according to the profile where in the minimum surface
roughness can be achieved. The software is equipped with special algorithms that can identify
the complex profiles and change the slicing pattern in order to achieve the required surface
roughness.
Chemical Processing: -
Reference [7] manufactured the specimens considering the parameters; tip size, raster width
and slice height by studying previous literatures and also implemented a chemical cleaning
process to improve the surface finish of the build parts. Approach workflow was used as
shown in figure 10.

Approach Workflow
In the second phase of the experimentation, the specimens were subjected to a chemical
finishing process. The chemical bath was chosen according to the following considerations:
ABS is a polymer with a low reticulation degree, including nitrile functionality having weak
interaction with polar solvents such as dimethyl ketone (acetone), ester and chloride solvents.
Dimethyl ketone was chosen due to its low cost, very low toxicity and to his very high
diffusion. Because the process resulted to be difficultly controlled using pure acetone, the
bath was added with water due to its very high mix ability with acetone. An accurate trial and
error procedure were carried out to detect suitable values of the independent variables:
concentration and immersion time. The process consisted of immersion in a volume of 90%
dimethyl ketone and 10% water for 300s. All the specimens’ sizes were measured before and
after the chemical finishing, in order evaluate any variations. The roughness of specimens
was then measured again using the conoscopic sensor in order to evaluate any differences in
terms of improvement of the roughness. The three specimens with the best and with the worst
surface finish (totally six) before the chemical process were assessed.
Mechanical Strength Characteristics: - [10] [9] [6] [4]
Strength of the parts made in FDM process depends on the bonding between the individual
rasters. The strength characteristics are directly proportional to the bonding of the filaments
and the type of the fill used to fill the space of the part which is related to the density of the
part. The type of infill used by different manufactures may differ in their shapes. Density of
the infill is also a major factor in determining the strength of the built part.
Reference [15] envelope temperature and variations in the convective conditions within the
building part will lead to the distortion of the part. This is mainly due to accumulation of
residual stresses at the bottom of the surface of the part during fabrication.

Bonding between two neighbouring fibers:

The bonding between neighboring fibers takes place via thermally driven diffusion
welding. The formation of bonds between polymer filaments in the FDM process can
be described as shown in figure4.The cross sections of filaments are idealized as
circles in the figure. The first step of the process is the establishment of interfacial
molecular contact by wetting. The molecules then undergo motions toward preferred
configurations to achieve the adsorptive equilibrium. Molecules diffuse across the
interface, forming an interfacial zone, and/or react to form primary chemical bonds
across the interface. The randomization can be reached only after extensive inter
diffusion of chain segments under critical conditions. The dimensionless sintering
neck growth is calculated as the ratio of neck radius y with the filament’s radius a, as
indicated in figure 4.
Quantitative predictions of the degree of bonding achieved during the filament
deposition process were made based on experimental data used in conjunction with
heat transfer and sintering models.
When material is extruded from nozzle of the FDM machine, it cools from glass
transition temperature to chamber temperature resulting in inner stresses to be
developed because of uneven deposition speed causing interlayer and intra-layer
deformation of the parts appearing in the form of cracking, de- lamination or even part
fabrication failure. Such phenomenon affects the part strength and size of build parts.
It has been observed that deformation is more in bottom layers than upper layers.
 CHAPTER 5
FDM MANUFACTURERS
With the 3D printing technology gaining popularity day by day, many players are jumping
into the manufacturing business of 3D printing machines. The following list contains the
names of manufacturers involved in the manufacturing of FDM/3D Printing machines.
i. MakerBot, USA
ii. 3D Systems, USA
iii. Fabbster, Germany)
iv. Envision Tec, Germany
v. Aleph Objects, USA
vi. Beijing Tier Time Technology Co.Ltd., China
vii. Beijing Yinhua Laser Rapid Prototype Making and Mould Technology Co. Ltd.,
China
Vendors selling using open source technology:
i. Solidoodle
ii. Stratasys Ltd., USA
iii. Tinkerine Studios Ltd., Canada
iv. Ultimaking Ltd. Netherlands
Apart from the above, there are several other companies which provide assembled kits and
indigenously manufactured ones. The cost of the machines depends upon the quality of the
product that is being obtained with respect to above stated input parameters and the
characteristics of the parts.

ADVANTAGES
1. Complex parts can be produced with good accuracy and with low cost when
compared to conventional manufacturing process.
2. No need for special tooling’s.
3. As simple as printing of copy from normal inkjet printer.
DISADVANTAGES
1. FDM is a costlier process.
2. The size of the output product is limited to a very small size.
3. Raw material limitations. (No metal-based filaments can be used due to requirement
of high temperatures).
4. FDM is a developing process.
APPLICATIONS OF 3D PRINTING:

3-D printing was originally developed for rapid prototyping purposes, making less
complicated physical samples. It allowed designers to identify and rectify design flaws
quickly and cheaply, thereby speeding up the product development process and minimizing
commercial risks. Here are some applications of a 3D printer described below:

Aerospace and Automotive sector

With the help of 3-D-printed components which are used for aircrafts and parts are 70% less
weighing but identically tough as conventional parts, indicating cost reduction and carbon
reduction and emissions of unwanted particle. It uses less raw constituents and manufactures
parts which are less weight, complicated but possess more strength [4].

Medical
Medical sector is one of the most promising areas of usage. It is being applied to face many
medical situations, and develop medical research, also combining the field of “regenerative
medicine”. In 2012, using a 3-D printer, engineers and doctors at Hasselt successfully
experimented the very first patient-specific instrument of prosthetic jaw transplant [4].

Rapid manufacturing:
Advancements in Rapid Prototyping have presented materials those are necessary for final
manufacturing, leading to the possibility of manufactured finished components and parts [5].

Mass customization:
Many industries have provided services where people can recreate their desirables
implementing simple web-based customizing software. This now enables customers to
replicate cases of their mobiles. Nokia has displayed the 3D designs of their mobiles so that
owners will be able to recreate their own phone case [5].
 CHAPTER 6
RESULT:

The Project “STUDY OF PRODUCT DESIGN AND

DEVELOPMENT USING 3D PRINTING TECHNOLOGY BY FUSED
DEPOSITION MODEELING “.We have learnt how to design a 3d model by using
different software’s used for 3d printing and also we have learnt about the machines
used in 3d printing technology .

CONCLUSION AND FUTURE ENHANCEMENT

This paper presents brief insight into one of the emerging Rapid-Prototyping
technique called Fused Deposition Modeling. It lays emphasis on the working process of
the FDM and various parameters involved in it and their effects on physical properties
like Dimensional accuracy, surface roughness, strength of the components made through
the process. From the study it has been understood that the parameters like orientation,
layer thickness, bond formation and the infill and temperature profile are the primary
parameters that directly affects the quality of the part. Also, some of the existing
methodologies like adaptive slicing, machining, and chemical processing are discussed
for the minimization of the problem.
It can be concluded on the basis of literature review that there is still enough space for
the research in order to improve the surface roughness and strength of the parts by
optimizing the parameters used in the building of the part. Also, there is a scope for
study and optimization of temperature profile during the deposition so that distortion
effect and the sliding wear can be reduced with increased mechanical strength. Future
work is proposed to be carried out in optimization of overall parameters to manufacture
a part to specific level of characteristics.
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