1

3D PRINTING AND ITS APPLICATIONS

INTERNSHIP REPORT

INTERNSHIP CARRIED OUT AT

KIET GROUP OF INSTITUTIONS

GHAZIABAD

SUBMITTED BY

RISHABH TOMAR (1702940129)

in partial fulfillment for the award of the degree

of

BACHELORS OF TECHNOLOGY
IN

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

K.I.E.T. Group of institution

Ghaziabad

JUNE-JULY (2020)
 2

BONAFIDE CERTIFICATE

Certified that this Internship report “3D PRINTING AND ITS APPLICATION”

is the bonafide work of “RISHABH TOMAR” who carried out the Internship work under my supervision.

<<MR.SONENDRA SHARMA>>

SIGNATURE
 3

ACKNOWLEDGEMENT

I feel much honored in presenting this dissertation report in such an authenticable form of sheer endurance
and continual efforts of inspiring excellence from various coordinating factor of cooperation and sincere
efforts drawn from all sources of knowledge.

I express my sincere gratitude to

FIC Name- MR SONENDRAA SHARMA, ASSIST PROFESSOR, M.E.,AKTU

I wish to express my profound gratitude to DR.K.L.A. KHAN, MECHANICAL ENGINEERING , for his
support and providing all the facilities, which would have made it possible for me to complete the
dissertation report. The cooperation he gave is greatly appreciated.
I extend my thanks to all classmates who have given their full cooperation and valuable suggestion for my
dissertation report work.

Place: Ghaziabad RISHABH TOMAR

 4

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.
 5

CONTENTS
TITLE PAGE NO.

COVER PAGE 1

CERTIFICATE 2

ACKNOWLEDGEMENT 3

ABSTRACT 4

CONTENTS 5

LIST OF FIGURES 6

1. INTRODUCTION 7

2. 3D-PRINTER 8

3. ARCHITECTURE 9

4. ADDITIVE MANUFACTURING 11

4.1EXTRUSION DEPOSITION 12

4.2GRANULAR MATERIAL BINDING 13

4.3PHOTOPOLYMERISATION 14

4.4LAMINATION 15

5. PROCEDURES 16

6. APPLICATIONS 18

7. ADVANTAGES 20

8. DISADVANTAGES 21

9. FUTUTRE SCOPE 21

10. CONCLUSION 22

11. REFRENCES 23
 6

LIST OF FIGURES

TITLE PAGE NO.

Fig.1 Block Diagram 9

Fig.2 Architecture 9

Fig.3 Additive Manufacturing 11

Fig.4 Extrusion Deposition 12

Fig.5 Granular Deposition 13

Fig.6 Photo polymerisation 14

Fig.7 Laminated object manufacturing 15

Fig.8 Procedures for 3D printing 16

Fig.9 Printing inks 17

Fig.10 Motor Prototype 18

Fig.11 Customized products 19

Fig.12 CAD model of 3D printed motor bike 19

Fig.13 3D printed foot wear 20

 7

INTRODUCTION

3D printing or additive manufacturing (AM) 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 additive
processes in which successive layers of material are laid down under computer control. A 3D printer is a
type of industrial robot.

Early AM equipment and materials were developed in the 1980s. In 1984, Chuck Hull of 3D Systems
Corp, invented a process known as stereo lithography employing UV lasers to cure photopolymers. Hull
also developed the STL file format widely accepted by 3D printing software, as well as the digital slicing
and infill strategies common to many processes today. Also during the 1980s, the metal sintering
forms of AM were being developed (such as selective laser sintering and direct metal laser sintering),
although they were not yet called 3D printing or AM at the time. In 1990, the plastic extrusion
technology most widely associated with the term “3D printing” was commercialized by Stratasys under
the name fused deposition modelling (FDM). In 1995, Z Corporation commercialized an MIT-developed
additive process under the trademark 3D printing (3DP), referring at that time to a proprietary process
inkjet deposition of liquid binder on powder.

AM technologies found applications starting in the 1980s in product development, data visualization,
rapid prototyping, and specialized manufacturing. Their expansion into production (job
production, mass production, and distributed manufacturing) has been under development in the
decades since. Industrial production roles within the metalworking industries achieved significant
scale for the first time in the early 2010s.
 8

3D PRINTER

3D-Printer is a machine reminiscent of the Star Trek Replicator, something magical that can create
objects out of thin air. It can “print” in plastic, metal, nylon, and over a hundred other materials. It can
be used for making nonsensical little models like the over-printed Yoda, yet it can also print
manufacturing prototypes, end user products, quasi-legal guns, aircraft engine parts and even human
organs using a person’s own cells.

3D printers use a variety of very different types of additive manufacturing technologies, but they all share
one core thing in common: they create a three dimensional object by building it layer by successive
layer, until the entire object is complete. It’s much like printing in two dimensions on a sheet of paper,
but with an added third dimension: UP. The Z-axis.

Each of these printed layers is a thinly-sliced, horizontal cross-section of the eventual object. Imagine a
multi-layer cake, with the baker laying down each layer one at a time until the entire cake is formed. 3D
printing is somewhat similar, but just a bit more precise than 3D baking.

In the 3D world, a 3D printer also needs to have instructions for what to print. It needs a file as well. The
file, a Computer Aided Design (CAD) file is created with the use of a 3D modeling program, either
from scratch or beginning with a 3D model created by a 3D scanner. Either way, the program creates a
file that is sent to the 3D printer. Along the way, software slices the design into hundreds, or more
likely thousands, of horizontal layers. These layers will be printed one atop the other until the 3D object
is done.
 9

ARCHITECTURE AND STRUCTURE

EXTRUDER

X MOTOR X AXIS
MOTOR DRIVER
CONTROLLER
Y MOTOR Y AXIS

LEVEL SHIFTER TABLE

Z AXIS

Fig:1
 10

The picture shows the structure of a typical 3D printer. The print table is the platform
where the objects for printing has been situated. It provides the basic support for
manufacturing objects layer by layer.

The extruder is the most important part of a 3D-Printer. As the extruders in the normal paper
printers, this extruder is also used to pour ink for printing. The movement of extruder in various
dimensions create the 3D print. For printing a 3d object, the extruder has to access X, Y and Z
coordinates. For achieving this, many techniques are used according to the printer specification
required for various applications.

If the 3D-Printer is a desktop printer, the Z axis movement of the extruder can be avoided and that
function can be transferred to the print table. This will avoid complexity in 3D printing as well
as time consumption.

When the STL file is input to the printer, the microcontroller extracts each layer from it and also
extracts each line segment from each layer. Then it gives controls to the movement of the extruder
at required rate. The X-direction movement of extruder is made possible by the X- motor. When
the X motor rotates, the shaft also rotates and the extruder moves in X direction. The Y-direction
movement of extruder is made possible by the Y-motor. When the Y motor rotates, the shaft also
rotates and the extruder moves in Y direction. The X direction movement is made by the print table.

Consider printing larger objects like house using 3D printer. There will not be any X motor or Y
motor in that case. An extruder which can pour concrete mix is fixed on the tip of a crane. The
crane is programmed for the movement of extruder in X, Y and Z axis. The concept and structure
of 3d printer changes according to the type, size, accuracy and material of the object that has to be
printed.
 11

ADDITIVE MANUFACTURING

Additive manufacturing is a truly disruptive technology exploding on the

manufacturing scene as leading companies are transitioning from “analog” to “digital”
manufacturing. Additive manufacturing uses three dimensional printing to transform
engineering design files into fully functional and durable objects created from sand, metal and
glass. The technology creates products layer by layer – after a layer’s particles are bound by
heat or chemicals the next layer is added and the binding process is repeated. It enables
geometries not previously possible to be manufactured. Full-form parts are made directly from
computer-aided design (CAD) data for a variety of industrial, commercial and art applications.

Manufacturers across several industries are using this digital manufacturing process to
produce a range of products, including: engine components for automotive applications,
impellers and blades for aerospace use, pattern less sand moulds for pumps used in the oil and
energy industry, and medical prosthetics which require easily adaptable design modifications.
This advanced manufacturing process starts with a CAD file that conveys information about how
the finished product is supposed to look. The CAD file is then sent to a specialized printer where
the product is created by the repeated laying of finely powdered material (including sand, metal
and glass) and binder to gradually build the finished product.

There are tremendous cost advantages to using additive manufacturing. There is little to no waste
creating objects through additive manufacturing, as they are precisely built by adding material
layer by layer. In traditional manufacturing, objects are created in a subtractive manner as metals
are trimmed and shaped to fit together properly. This process creates substantial waste that
can be harmful to the environment. Additive manufacturing is a very energy efficient and
environmentally friendly manufacturing option.
 12

Major global companies, including Ford, Sikorsky and Caterpillar, have recognized that
additive manufacturing can significantly reduce costs while offering design freedoms
not previously possible. They have begun to implement the technology into their
manufacturing processes. Additive manufacturing has robust market capabilities ranging
from aerospace to automotive to energy, and it is not uncommon to find 3D printers in
use at metal-working factories and in foundries alongside milling machines, Companies
that use additive manufacturing reduce costs, lower the risk of trial and error, and
create opportunities for design innovation. A serious limitation of subtractive
manufacturing is that part designs are often severely comprised to
accommodate the constraints of the subtractive process. Additive manufacturing
enables both the design presses and plastic injection moulding equipment.

4.1 EXTRUSION DEPOSITION

In extrusion deposition, Fused Deposition technique is used. Fused Deposition Modelling

(FDM) was developed by Stratasys in Eden Prairie, Minnesota. In this process, a plastic or wax
material is extruded through a nozzle that traces the part's cross sectio nal geometry layer by
layer. The build material is usually supplied in filament form, but some setups utilize plastic
pellets fed from a hopper instead. The nozzle contains resistive heaters that keep the plastic at a
temperature just above its melting point so that it flows easily through the nozzle and forms the
layer. The plastic hardens immediately after flowing from the nozzle and bonds to the layer
below. Once a layer is built, the platform lowers, and the extrusion nozzle deposits another
layer. The layer thickness and vertical dimensional accuracy is determined by the extruder
die diameter, which ranges from 0.013 to 0.005 inches. In the X-Y plane, 0.001-inch resolution is
 13

achievable. A range of materials are available including ABS, polyamide, polycarbonate,

polyethylene, polypropylene, and investment casting wax.

4.2 GRANULAR MATERIAL BINDING

Another 3D printing approach is the selective fusing of materials in a granular bed. The technique
fuses parts of the layer, and then moves the working area downwards, adding another layer of
granules and repeating the process until the piece has built up. This process uses the unfused
media to support overhangs and thin walls in the part being produced, which reduces the need for
temporary auxiliary supports for the piece.

A laser is typically used to sinter the media into a solid. Examples include selective laser
sintering (SLS), with both metals and polymers and direct metal laser sintering (DMLS).
Selective Laser Melting (SLM) does not use sintering for the fusion of powder granules but will
completely melt the powder using a high-energy laser to create fully dense materials in a layer
wise method with similar mechanical properties to conventional manufactured metals. Electron
(EBM) is a similar type of additive manufacturing technology for metal parts (e.g. titanium
alloys).

4.3 PHOTOPOLYMERISZATION
Stereolithography was patented in 1986 by Chuck Hull. Photopolymerization is
primarily used in stereolithography (SLA) to produce a solid part from a liquid. This
process dramatically redefined previous efforts, from the "photosculpture" method of
 14

François Willème (1830–1905) in 1860 (which consisted of photographing a subject from a

variety of angles (but all at the same distance from the subject) and then projecting each
photograph onto a screen, whence a pantograph was used to trace the outline onto
modelling clay) through the photopolymerisation of Mitsubishi's Matsubara in 1974.

In photopolymerisation, a vat of liquid polymer is exposed to control lighting under

safelight conditions. The exposed liquid polymer hardens. The build plate then moves
down in small increments and the liquid polymer is again exposed to light. The process
repeats until the model has been built. The liquid polymer is then drained from the vat,
leaving the solid model.
 15

4.4 LAMINATION
Laminated Object Manufacturing works by layering sheets of material on top of
oneanother, binding them together using glue. The printer then slices an outline of the
object into that cross section to be removed from the surrounding excess material later.
Repeating this process builds up the object one layer at a time. Objects printed using LOM
are accurate, strong, and durable and generally show no distortion over time which
makes them suitable for all stages of the design cycle. They can even be additionally
modified by machining or drilling after printing. Typical layer resolution for this process
is defined by the material feedstock and usually ranges in thickness from one to a few
sheets of copy paper. Mcor’s version of the technology makes LOM one of the few 3D
printing processes that can produce prints in full colour.

• Low cost due to readily available raw material

• Paper models have wood like characteristics, and may be worked and finished accordingly
 16

PROCEDURES FOR 3D PRINTING\

There are some procedures for printing. First you must create a computer model for
printing the object. For creating that, you 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 have to be converted to STL (Stereo lithography) file format. 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.

5.1 DESIGNING USING CAD

Computer-aided design (CAD) is the use of computer systems to assist in the creation,
modification, analysis, or optimization of a design. CAD software is used to increase
the productivity of the designer, improve the quality of design, improve communications
 17

through documentation, and to create a database for manufacturing. CAD output is often in
the form of electronic files for print, machining, or other manufacturing operations.

5.2 CONVERSION TO STL FILE FORMAT

An STL file is a triangular representation of a 3D surface geometry. The surface is tessellated
logically into a set of oriented triangles (facets). Each facet is described by the unit outward
normal and three points listed in counter clockwise order representing the vertices of the triangle.
While the aspect ratio and orientation of individual facets is governed by the surface
curvature, the size of the facets is driven by the tolerance controlling the quality of the surface
representation in terms of the distance of the facets from the surface. The choice of the tolerance is
strongly dependent on the target application of the produced STL file. In industrial processing,
where stereolithography machines perform a computer controlled layer by layer laser curing of
a photo-sensitive resin, the tolerance may be in order of 0.1 mm to make the produced 3D part
precise with highly worked out details. However much larger values are typically used in pre-
production STL prototypes, for example for visualization purposes.

5.3 CHOOSING PRINTING INKS

COLLOIDAL INKS: Three-dimensional periodic structures fabricated from

colloidal “building blocks” may find widespread technological application

as advanced ceramics, sensors, composites and tissue engineering scaffolds.

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.

 18

APPLICATIONS

Three-dimensional printing makes it as cheap to create single items as it is to produce

thousands and thus undermines economies of scale. It may have as profound an impact
on the world as the coming of the factory did....Just as nobody could have predicted the
impact of the steam engine in 1750 or the printing press in 1450, or the transistor in 1950 .
It is impossible to foresee the long-term impact of 3D printing. But the technology is
coming, and it is likely to disrupt every field it touches.

6.1 RAPID PROTOTYPING

Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a
physical part or assembly using three-dimensional computer aided design (CAD)
data. Construction of the part or assembly is usually done using 3D printing or
"additive layer manufacturing" technology.

6.2 MASS CUSTOMIZATION

Mass customization is the method of "effectively postponing the task of
differentiating a product for a specific customer until the latest possible point in the
supply network." (Chase, Jacobs & Aquilano 2006, p. 419). Kamis, Koufaris and Stern
(2008) conducted experiments to test the impacts of mass customization when postponed to
the stage of retail, online shopping. They found that users perceive greater usefulness
and enjoyment with a mass customization interface vs. a more typical shopping interface,
particularly in a task of moderate complexity. From collaborative engineering perspective,
mass customization can be viewed as collaborative efforts between customers and
manufacturers, who have different sets of priorities and need to jointly search for
 19

solutions that best match customers’ individual specific needs with manufacturers’
customization capabilities (Chen, Wang & Tseng (2009)).

6.3 AUTOMOBILES
In early 2014, the Swedish supercar manufacturer, Koenigsegg, announced the ‘One:1’, a
supercar that utilises many components that were 3D printed. In the limited run of vehicles
Koenigsegg produces, the ‘One:1’ has side-mirror internals, air ducts, titanium
exhaust components, and even complete turbocharger assembles that have been 3D printed
as part of the manufacturing process. An American company, Local Motors is working
with Oak Ridge National Laboratory and Cincinnati Incorporated to develop large scale
additive manufacturing processes suitable for printing an entire car body.
 20

6.4 WEARABLES
San Francisco-based clothing company, Continuum is among the first to
create wearable, 3D printed pieces. Customers design bikinis on Continuum’s website,
specifying their body shapes and measurements. The company then uses nylon to print
out each unique order. Founder Mary Huang believes that this intersection of fashion and
technology will be the future because it “gives everyone access to creativity.”

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

 21

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.

FUTUTRE SCOPE
 NASA engineers are 3-D printing parts, which are structurally stronger and more
reliable than conventionally crafted parts, for its space launch system. The Mars
Rover comprises some 70 3-D-printed custom parts. Scientists are also exploring
the use of 3-D printers at the International Space Station to make spare parts on the
spot. What once was the province of science fiction has now become a reality.

 Medicine is perhaps one of the most exciting areas of application. Beyond the use of 3-
D printing in producing prosthetics and hearing aids, it is being deployed to treat
challenging medical conditions, and to advance medical research, including in the
area of regenerative medicine. The breakthroughs in this area are rapid and awe-
inspiring.

 3D bio printing for fabricating biological constructs typically involves dispensing

cells onto a biocompatible scaffold using a successive layer-by-layer approach to
generate tissue-like three-dimensional structures. Given that every tissue in
the body.

 Space experts say that the promise of 3D printing is real, but a long way from the hype
that surrounds it. The printer selected by NASA was built by the company Made in
Space, which is based at a technology park next to NASA’s Ames Research Centre in
Moffett Field, California. During the printer’s sojourn on the space station, it will
 22

create objects from a heat sensitive plastic that can be shaped when it reaches
temperatures of about 225–250 °C.

CONCLUSIONS

As the 3D printer is a device, it should be analysed with the advantages and

disadvantages, how the device can change the society and engineering etc in mind. The
very nature of 3D printing, creating a part layer by layer, instead of subtractive methods
of manufacturing lend themselves to lower costs in raw material. Instead of starting with
a big chunk of plastic and carving away (milling or turning) the surface in order to
produce your product. Additive manufacturing only "prints" what you want, where
you want it. Other manufacturing techniques can be just as wasteful. 3D printing
is the ultimate just-in-time method of manufacturing. No longer do you need a
warehouse full of inventory waiting for customers. Just have a 3D printer waiting to print
your next order. On top of that, you can also offer almost infinite design options and
custom products. It doesn't cost more to add a company logo to every product you have or
let your customers pick every feature on their next order, the sky is the limit with additive
manufacturing.

Whether you are designing tennis shoes or space shuttles, you can't just design whatever
you feel like, a good designer always takes into account whether or not his design
can be manufactured cost effectively. Additive manufacturing opens up your designs to a
whole new level. Because undercuts, complex geometry and thin walled parts are difficult
to manufacture using traditional methods, but are sometimes a piece of cake with 3D
printing. In addition, the mathematics behind 3D printing are simpler than subtractive
methods. For instance, the blades on a centrifugal supercharger would require very
difficult path planning using a 5-axis CNC machine. The same geometry using
additive manufacturing techniques is very simple to calculate, since each layer is
analysed separately and 2D information is always simpler than
 23

REFRENCES
(1) Siddharth Bhandari, B Regina, “3D Printing and Its Applications”, International Journal of Computer
Science and Information Technology Research ISSN 2348-120X.

(2) 3D printed poly(lactic acid) scaffolds modified with chitosan and hydroxyapatite for bone repair applications-
Muhammad Anwaar Nazeera,b , Ozgun Can Ondera,1 , Ilkem Sevgilib,2 , Emel Yilgora , Ibrahim Halil
Kavaklic , Iskender Yilgora, *.

(3) Jie Sun, Zhuo Peng, Weibiao Zhou, Jerry Y.H. Fuh, Geok Soon Hong and Annette Chiu, "A Review on 3D
Printing for Customized Food Fabrication", Procedia Manufacturing, vol. 1, 2015.

(4) www.zdnet.com/how-3d-printing-is-building-a-new-future-7000032248

(5) www.stratasys.com/applications