BERHAMPUR, GANJAM

3D-PRINTING
DIPLOMA IN
ELECTRONIC & TELECOMMUNICATION
2021-2023

SUBMITTED BY
SHIBAM SAHU
ROLL NO: 54
REGD NO-F20012003054
SEC: C

UNDER THE GUIDANCE OF

ER.PARAMANANDA GOUDA & MRS POONAM
PANDA
i
 ACKNOWLEDGEMENT

Completing a task is never one man's effort; it is often the result of valuable
contribution of individuals in a direct or indirect manner.

I am deeply grateful to my project advisors, Er. PARAMANANDA GOUDA &

MRS. POONAM PANDA (Lecturer, E & TC) for being a constant source of
encouragement for my seminar on ‘3D PRINTING also express my sincere
thanks to Other Staff Members of our Department and our institution who
became the source of inspiration for nu in completion of the serrinar and
their supports in achieving the objective of my seminar. Finally, I thank to
Er.
S. N. DHAR (Principal, U.C.P. Engineering School, for his continuous strive
for the betterment of qualitative environment in U.C.P. Ergg. School.

BERHAMPUR : Mr.Shibam Sahu

Date-18/09/2021 Regd No-F20012003054

ii
 DECLARATION

I AM Mr.Shibam Sahu Bearing Regd No-F20012003037 here by

informed that the seminar entitled ‘3D PRINTING’ being submitted to UCP
ENGG. SCHOOL, BERHAMPUR for the partial fulfillment of the requirements
for the Diploma in Electronic & Telecommunication Engineering is a work
of my own and it has not been submitted earlier to any other institution.
This piece of work has not been submitted by me or not anybody else for
award of any other Diploma. This is the fruit of my own hard work.

BERHAMPUR : Mr. Shibam Sahu

Date-18/09/2021 Regd No-F20012003054

iii
 CONTENTS

Title Page No.

COVER PAGE i

CERTIFICATE ii

ACKNOWLEDGEMENT iii

ABSTRACT iv

CONTENTS v

LIST OF FIGURES vii

1 INTRODUCTION
2
2 3D-PRINTER

3 ARCHITECTURE 3

4 ADDITIVE MANUFACTURING 5

4.1 EXTRUSION DEPOSITION 7

4.2 GRANULAR MATERIAL BINDING 8

4.3 PHOTOPOLYMERISZATION 9

4.4 LAMINATION 10

5 PROCEDURES FOR PRINTING 11

5.1 DESIGNING USING CAD 12

5.2 CONVERSION TO STL FILE FORMAT 13

5.3 CHOOSING PRINTING INKS 14

iv
6 APPLICATIONS 16

6.1 RAPID PROTOTYPING 17

6.2 MASS CUSTOMIZATION 18

6.3 AUTOMOBILE 19

6.4 WEARABLES 20

7 ADVANTAGES 21

8 DISADVANTAGES 22

9 FUTURE SCOPE 23

9.1 ROCKET ENGINE 24

9.2 3D BIO-PRINTING 25

9.3 PRINTING IN SPACE 26

10 CONCLUSION 27

11 BIBLIOGRAPHY 28

v
 CHAPTER 1
INTRODUCTION

3D printing or additive manufacturing (AM) is any of various processes for making

athree-dimensionalobject of almost any shape from a3D modelor 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 ofindustrial robot.

Early AM equipment and materials were developed in the 1980s. In 1984,Chuck

Hullof 3D Systems Corp, invented a process known as stereo
lithographyemployingUVlasersto curephotopolymers. Hull also developed theSTL file
formatwidely 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 asselective laser sinteringanddirect 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 Stratasysunder the name fused deposition modelling(FDM). In 1995, Z
Corporationcommercialized an MIT-developed additive process under the trademark3D
printing (3DP), referring at that time to a proprietary processinkjet deposition of liquid
binder on powder.

AM technologies found applications starting in the 1980s inproduct

development,data visualization,rapid prototyping, and specialized manufacturing. Their
expansion into production (job production,mass production, anddistributed manufacturing)
has been under development in the decades since. Industrial production roles within
themetalworkingindustries achieved significant scale for the first time in the early 2010s.
Since the start of the 21st century there has been a large growth in the sales of AM machines,
and their price has dropped substantially. According to Wohlers Associates, a consultancy,
the market for 3D printers and services was worth $2.2 billion worldwide in 2012, up 29%
from 2011. Applications are many, including architecture, construction (AEC),industrial
design, automotive,aerospace, military,engineering, dental and medical industries, biotech
(human tissue replacement), fashion, footwear, jewellery, eyewear, education, geographic
information systems, food, and many other fields.
 CHAPTER 2
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
partsand even human organs using a person’s own cells.

We live in an age that is witness to what many are calling the Third Industrial
Revolution. 3D printing, more professionally called additive manufacturing, moves us away
from the Henry Ford era mass production line, and will bring us to a new reality of
customizable, one-off production.

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 2D world, a sheet of printed paper output from a printer was “designed” on the
computer in a program such as Microsoft Word. The file - the Word document which
contains the instructions that tell the printer what to do.

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.
 CHAPTER 3
ARCHITECTURE & STRUCTURE

Extruder

X Motor X-axis
Motor
uController Driver
Y Motor Y-axis

Level
Table Z-axis
Shifter

Fig.1
 Fig.2

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.

In the case of desktop printers, the printing ink is usually plastic wire that has been melted
by the extruder at the time of printing. While printing, the plastic wire will melt and when it
fall down to the printing 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.

Generalizing the facts, the extruder need to access all the 3 coordinates in space to print and
object. The method used for that doesn’t matters much.
 CHAPTER 4
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. Since it works in a similar fashion to an office printer laying ink on paper,
this process is often referred to as 3D printing. The 3D printers can create a vast range of
products, including parts for use in airplanes and automobiles, to replacing aging or broken
industrial equipment, or for precise components for medical needs.
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.

Additive manufacturing swiftly creates product prototypes – an increasingly critical

function that significantly reduces the traditional trial-and-error process – so new products
can enter the market more quickly. Likewise, it can promptly create unique or specialized
metal products that can replace worn or broken industrial parts. That means companies can
avoid costly shut downs and drastically compress the time it takes to machine a replacement
part.

With additive manufacturing, once a CAD drawing is created the replacement part can be
printed. Storage of bulky patterns and tooling is virtually eliminated.

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, presses and plastic
injection moulding equipment.

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

Fig.3 and the materialization of objects

by eliminating traditional
manufacturing constraints.

A large number of additive processes are now available. They differ in the way layers are
deposited to create parts and in the materials that can be used. Some methods melt or soften
material to produce the layers, e.g. selective laser melting(SLM) or direct metal laser
sintering(DMLS),selective laser sintering(SLS),fused deposition modelling(FDM), while
others cure liquid materials using different sophisticated technologies,
e.g.stereolithography(SLA). Withlaminated object manufacturing(LOM), thin layers are cut
to shape and joined together (e.g. paper, polymer and metal). Each method has its own
advantages and drawbacks, and some companies consequently offer a choice between
powder and polymer for the material from which the object is built. Some companies use
standard, offthe-shelf business paper as the build material to produce a durable prototype.

4.1 EXTRUSION DEPOSITION

Fig.4

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 sectional
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 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 includeselective laser sintering(SLS), with
both metals and polymers (e.g. PA, PA-GF, Rigid GF, PEEK, PS, Alumide, Carbonmide,
elastomers), anddirect 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). EBM
manufactures parts by melting metal powder layer by layer with an electron beam in a high
vacuum. Unlike metal sintering techniques that operate below melting point, EBM parts are
fully dense, void-free, and very strong. Another method consists of aninkjet 3D
printingsystem. The printer creates the model one layer at a time by spreading a layer of
powder (plaster, orresins) and printing a binder in the cross-section of the part using an
inkjet-like process. The strength of bonded powder prints can be enhanced with wax
orthermoset polymerimpregnation.

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 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
undersafelightconditions. 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. TheEnvisionTECPerfactoryis an example of a DLP rapid
prototyping system.
Inkjet printer
systems like the Objet
PolyJet system spray
photopolymer
materials onto a build
tray in ultrathin layers
(between 16 and 30
µm) until the part is
completed. Each
photopolymer layer is
curedwith UV light
after it is jetted,
producing fully cured
models that can be
handled and used
immediately, without
post-curing. The gel-
like support material,
which is designed to
support complicated
geometries,
is removed by hand and water jetting. It is also suitable for elastomers.
Ultra-small features can be made with the 3D micro fabrication technique used
inmultiphotonphotopolymerisation. This approach traces the desired 3D object in a block of
gel using a focused laser. Due to the nonlinear nature of photo excitation, the gel is cured to
a solid only in the places where the laser was focused and the remaining gel is then washed
away. Feature sizes of under 100 nm are easily produced, as well as complex structures with
moving and interlocked parts.

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
• Dimensional accuracy is slightly less than that ofstereolithographyandselective laser
sinteringbut no milling step is necessary.

CHAPTER 5
PROCEDURES FOR 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. 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. 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.

5.1 DESIGNING USING CAD

Computer-aided design (CAD) is the use ofcomputersystems to assist in the creation,
modification, analysis, or optimization of adesign. CAD software is used to increase the
productivity of the designer, improve the quality of design, improve communications
through documentation, and to create a database for manufacturing. CAD output is often in
theform of electronic filesfor print, machining, or other manufacturing operations.

CAD software for mechanical design uses either vector-based graphics to depict the
objects of traditional drafting, or may also produce raster graphicsshowing the overall
appearance of designed objects. However, it involves more than just shapes. As in the
manual draftingof technicaland engineering drawings, the output of CAD must convey
information, such as materials, processes,dimensions, andtolerances, according to
applicationspecific conventions.

CAD may be used to design curves and figures intwo-dimensional(2D) space; or

curves, surfaces, and solids inthree-dimensional(3D) space. CAD is an importantindustrial
artextensively used in many applications, including automotive, shipbuilding, and aerospace
industries, industrial and architectural design,prosthetics, and many more. CAD is also
widely used to producecomputer animationforspecial effectsin movies,advertisingand
technical manuals, often called DCC digital content creation. The modern ubiquity and
power of computers means that even perfume bottles and shampoo dispensers are designed
using techniques unheard of by engineers of the 1960s. Because of its enormous economic
importance, CAD has been a major driving force for research in computational
geometry,computer graphics (both hardware and software), and discrete differential
geometry.
 The design of geometric modelsfor object shapes, in particular, is occasionally called
computer-aided geometric design (CAGD).Unexpected capabilities of these associative
relationships have led to a new form ofprototypingcalleddigital prototyping. In contrast to
physical prototypes, which entail manufacturing time in the design. That said, CAD models
can be generated by a computer after the physical prototype has been scanned using
anindustrial CT scanningmachine. Depending on the nature of the business, digital or
physical prototypes can be initially chosen according to specific needs.

Today, CAD systems exist for all the major platforms

(Windows,Linux,UNIXandMac OS X); some packages even support multiple platforms
which enhances the capabilities of 3D printing into a new level.

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 counterclockwise 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.

The native STL format has to fulfil the following specifications:

(i) The normal and each vertex of every facet are specified by three coordinates
each, so there is a total of 12 numbers stored for each facet.
(ii) Each facet is part of the boundary between the interior and the exterior of the
object. The orientation of the facets (which way is ``out'' and which way is
``in'') is specified redundantly in two ways which must be consistent. First,
the direction of the normal is outward. Second, the vertices are listed in
 counterclockwise order when looking at the object from the outside (right-
hand rule).
(iii) Each triangle must share two vertices with each of its adjacent triangles. This
is known as vertex-to-vertex rule.
(iv) The object represented must be located in the all-positive
octant (all vertex coordinates must be positive).

However, for non-native STL applications, the STL format can

be generalized. The normal, if not specified (three zeroes might be used
instead), can be easily computed from the coordinates of the vertices
using the right-hand rule. Moreover, the vertices can be located in any
octant. And finally, the facet can even be on the interface between two
objects (or two parts of the same object). This makes the generalized
STL format suitable for modelling of 3D nonmanifolds objects.

5.3 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 INKS: 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 millimetres) 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.
POLYELECTROLYTE INK: Polyelectrolyte complexes exhibit a rich phase behaviour
that depends on several factors, including the polyelectrolyte type and architecture, their
individual molecular weight and molecular weight ratio, the polymer concentration and
mixing ratio, the ionic strength and pH of the solution, and the mixing conditions. So such
inks are used for creating sensors, transducers etc.
SOL-GEL INK:In this chemical procedure, the 'sol' (or solution) gradually evolves towards
the formation of a gel-like diphasic system containing both aliquidphase andsolidphase
whose morphologies range from discrete particles to continuous polymer networks. In the
case of thecolloid, the volume fraction of particles (or particle density) may be so low that a
significant amount of fluid may need to be removed initially for the gel-like properties to be
recognized. These inks are very useful in creating power supply modules in the printed
object.

CHAPTER 6
APPLICATIONS
Three-dimensional printing makes it as cheap to create single items as it is to
producethousands and thus undermineseconomies of scale. It may have as profound an
impact on theworld as the coming of the factory did....Just as nobody could have predicted
the impact ofthesteam engine in 1750or theprinting press in 1450, or thetransistor in 1950. It
is impossibleto foresee the long-term impact of 3D printing. But the technology is coming,
and it is likelyto disrupt every field it touches.

Additive manufacturing's earliest applications have been on thetool roomend of the

manufacturing spectrum. For example, rapid prototypingwas one of the earliest additive
variants, and its mission was to reduce thelead timeand cost of developing prototypes of new
parts and devices, which was earlier only done with subtractive tool room methods (typically
slowly and expensively). With technological advances in additive manufacturing, however,
and the dissemination of those advances into the business world, additive methods are
moving ever further into the production end of manufacturing in creative and sometimes
unexpected ways. Parts that were formerly the sole province of subtractive methods can now
in some cases be made more profitably via additive ones.
 Standard applications include design visualization, prototyping/CAD, metal casting,
architecture, education, geospatial, healthcare, and entertainment/retail.

3D printer came with immense number of applications. All the traditional methods of
printing causes wastage of resources. But 3D printer only uses the exact amount of material
for printing. This enhances the efficiency. If the material is very costly, 3d printing
techniques can be used to reduce the wastage of material.

Consider printing of a complex geometry like combustion chamber of a rocket engine. The
3D printing will enhance the strength and accuracy of the object. Conventional methods use
parts by parts alignment. This will cause weak points in structures. But in the case of 3D
printed object, the whole structure is a single piece.

3D printer has numerous application in every field it touches. Since it is a product

development device, rate of production, customization and prototyping capabilities need to
be considered.

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 using3D printingor "additive layer
manufacturing" technology.

The first methods for rapid prototyping became available in the late 1980s and were
used to produce modelsand
prototypeparts. Today, they are used
for a wide range of applications and
are used tomanufactureproduction-
quality parts in relatively small
numbers if desired without the typical
unfavourable short-run
technology economics. This economy has
encouraged online service bureaus.
modern Historical surveys of RP start
with discussions of

simulacra

production techniques used by 19th-century sculptors. Some use

the progeny
 technology to
produceexhibitions. The ability to reproduce designs from a
dataset has given rise to issues of rights, as it is now possible to interpolate volumetric data
from one-dimensional images. As withCNCsubtractive methods, the computer-aided-design
- computer-aided manufacturingCAD-CAMworkflow in the traditional Rapid Prototyping
process starts with the creation of geometric data, either as a 3D solid using
aCADworkstation, or 2D slices using a scanning device. For RP this data must represent a
valid geometric model; namely, one whose boundary surfaces enclose a finite volume,
contain no holes exposing the interior, and do not fold back on themselves. In other words,
the object must have an “inside.” The model is valid if for each point in 3D space the
computer can determine uniquely whether that point lies inside, on, or outside the boundary
surface of the model.CADpost-processors will approximate the application vendors’
internalCADgeometric forms (e.g., B-splines) with a simplified mathematical form, which
in turn is expressed in a specified data format which is a common feature inAdditive
Manufacturing: STL (stereolithography) a de facto standard for transferring solid geometric
models to SFF machines. To obtain the necessary motion control trajectories to drive the
actual SFF, Rapid Prototyping,3D Printingor Additive Manufacturing mechanism.

6.2 MASS CUSTOMIZATION

Mass customization, inmarketing,manufacturing,call centersandmanagement, is the
use of flexible computer-aided manufacturing systems to produce custom output. Those
systems combine the low unit costs of mass productionprocesses with the flexibility of
individual 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 solutions that best match customers’
individual specific needs with manufacturers’ customization capabilities (Chen, Wang &
Tseng (2009)).

With the arrival of 3D printer, we are able to customize any products we want.
Consider you are in a shop to buy a spectacle. The only choice you have is to select a model
from the shop. If you didn’t like any model, you will probably go to another shop. By the
implementation of 3d printed spectacles, you are provided with power for creating any
spectacle in the world with just the CAD model.Many implementations of mass
customization are operational today, such as software-based product configurators that make
it possible to add and/or change functionalities of a core product or to build fully custom
enclosures from scratch.

6.3 AUTOMOBILES
In early 2014, the Swedishsupercarmanufacturer,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 Motorsis working with Oak Ridge National
Laboratoryand Cincinnati Incorporated to develop large scale additive manufacturing
processes suitable for printing an entire car body. The company plans to print the vehicle live
in front of an audience in September 2014 at the International Manufacturing Technology
Show. Produced from a new fibre-reinforced thermoplastic strong enough for use in an
automotive application, the chassis and body without drivetrain, wheels and brakes weighs a
scant 450 pounds and
the completed car is
comprised of just 40
components, a number
that gets smaller with
every revision.

Fig.12 shows the

3D CAD model of a
bike, actually of a
3D printed scale
replica created
by designer Jacky Wan fromRedicubricks. The 3D printed bike is made of over 40
individual pieces andWandetailshisprintandbuildprocessover on Ultimakers blog. He even
includes alinktohis3Dfilesso you can build one yourself if you think you’re up to it. The
project is certainly not for beginners. When designing the bike replica, Wan imposed
several goals on himself; He wanted to maintain the external looks of the bike, all parts
needed to snap fit together to make gluing easier, keep seams and striation to a minimum
and everything needed to print on hisUltimaker:Original. Of course 3D printing a realistic
motorcycle replica wasn’t going to make it easy for him to meet to those goals.

6.4 WEARABLES
San Francisco-based clothing company, Continuumis 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.”
 This year, architect Francis Bitonti and fashion designer Michael Schmidt
collaborated to make adressfor
burlesque diva Dita Von Teese.
She wore the garment to the Ace
Hotel in March for a convention
hosted by online 3D printing
marketplace, Shapeways. The
dress consists of 2,500
intersecting joint pieces that were
linked together by hand. The
finishing touches a black lacquer coating and 12,000 hand-placed
Swarovski crystals reflect
Schmidt’s iconic glam that attracts a clientele of Madonna, Rihanna, Lady Gaga, and the like.
British designerCatherineWalesis making moves too. She is best known for her Project DNA
collection, which includes avant-garde 3D printed masks, accessories, and apparel, all printed
with white nylon. The eccentric shapes ofhergarmentsreflect that 3D printed clothing is still
in its early stages. Today, the materials and technologies used for 3D printing still dictate
and affect garment design.
Dutch designer Iris Van Herpen has already put this new material to the test in her
Voltage Haute Couture collection, which raised eyebrows at Paris Fashion Week in January
2013. A frontrunner in the realm of futuristic fashion design, Van Herpen has been taking
her 3D printeddressesand shoes to the runways since 2010. Still, she admits that there are
challenges associated with incorporating a new medium into the manufacturing process. “I
always work together with an architect because I am not good with the 3D programs
myself,” she said.
The idea of custom design has mass appeal and marketability. Who doesn’t want to
wear a one-of-a-kind, perfectly tailored piece? Perhaps the teenage girl of the future won’t
have to suffer the social agony of showing up to a school dance wearing the same dress as
her archenemy.
 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.

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.

 FUTURE SCOPE

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

Medicine is perhaps one of the most exciting areas of application. Beyond the use
of3-D printing in producing prosthetics and hearing aids, it is being deployed to treat
challengingmedical conditions, and to advance medical research, including in the area of
regenerativemedicine. The breakthroughs in this area are rapid and awe-inspiring.

Whether or not they arrive en-mass in the home, 3D printers have many promising
areas of potential future application. They may, for example, be used to output spare parts
for all manner of products, and which could not possibly be stocked as part of the inventory
of even the best physical store. Hence, rather than throwing away a broken item (something
unlikely to be justified a decade or two hence due toresource depletionand enforced
recycling), faulty goods will be able to be taken to a local facility that will call up the
appropriate spare parts online and simply print them out. NASA has already tested a 3D
printer on the International Space Station, and recently announced its requirement for a high
resolution 3D printer to produce spacecraft parts during deep space missions. The US Army
has also experimented with a truck-mounted 3D printer capable of outputting spare tank and
other vehicle components in the battlefield.

As noted above, 3D printers may also be used to make future buildings. To this end, a team
at Loughborough University is working on a3D concrete printingproject that could allow
large building components to be 3D printed on-site to any design, and with improved
thermal properties.

Another possible future application is in the use of 3D printers to create replacement organs
for the human body. This is known asbio printing, and is an area of rapid development. You
can learn more on the bio printing page, or see more in my bio printing or the Future Visions
gallery.
 ROCKET ENGINE

NASA's first attempt at using 3D-printed parts for rocket engines has passed its
biggest, and hottest, test yet. The largest 3D-printed rocket part built to date, a rocket engine
injector, survived a major hot-fire test. The injector generated 10 times more thrust than any
injector made by 3D printing before, the space agency announced. ANASA video of the 3D-
printed rocket part testshows the engine blazing to life at the agency's Marshall Space Flight

Center (MSFC) in Huntsville Ala.

Space’s Dragon capsule has been taking

cargo to the International Space Station since
2012.Dragon V2 comes with new
"SuperDraco" 16,000 lb-thrust engines that can
be restarted multiple times if necessary. In
addition, the engines have the ability to deep
throttle, providing astronauts with precise
control and enormous power.

The SuperDraco engine chamber is manufactured using 3D printing technology, the

state-of-the-art direct metal laser sintering (DMLS) which uses lasers to quickly
manufacture high-quality parts from metal powder layer by layer. The chamber is
regeneratively cooled and printed in Inconel, a high-performance superalloy that offers both
high strength and toughness for increased reliability. Fig.14 shows the image of the
SuperDraco engine.

Totally eight SuperDraco engines built into the side walls of the Dragon spacecraft
will produce up to 120,000 pounds of axial thrust to carry astronauts to safety should an
emergency occur during launch.

As a result, Dragon will be able to provide astronauts with the unprecedented ability
to escape from danger at any point during the ascent trajectory, not just in the first few
minutes. In addition, the eight SuperDraco provide redundancy, so that even if one engine
fails an escape can still be carried out successfully.
 3D BIO-PRINTING
3D bio printing is the process of generating spatially-controlled cell patterns using 3D
printing technologies, where cell function and viability are preserved within the printed
construct.Using 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 is
naturally compartmentalized of different cell types, many technologies for printing these
cells vary in their ability to ensure stability and viability of the cells during the
manufacturing process. Some of the methods
that are used for 3D bio printing of cells are
photolithography, magnetic bio printing,
stereolithography, and direct cell extrusion.
When a bio printed pre-tissue is transferred to an
incubator then this cell-based pre-tissue matures
into a tissue.

3D-bioprinting attributes to significant

advances in the medical field of tissue
engineering by allowing for research to be done
on innovative materials called biomaterials.
Biomaterials are the materials adapted and used
for printing threedimensional objects. Some of
the most notable bioengineered substances that
are usually stronger than the average bodily
materials, including soft tissue and bone. These
constituents can act as future substitutes, even
improvements, for the original body materials.
Alginate, for example, is an anionic polymer
with many biomedical implications including
feasibility, strong biocompatibility, low toxicity,
and stronger structural ability in comparison to
some of the body's structural material.
 3D PRINTING IN SAPCE
In one small step towards space
manufacturing, NASA is sending a 3D printer to
the International Space Station. Astronauts will be
able to make plastic objects of almost any shape
they like inside a box about the size of a
microwave oven enabling them to print new parts
to replace broken ones, and perhaps even to invent
useful tools.

The launch, slated for around September

19, will be the first time that a 3D printer flies in space.
The agency has already embraced ground-based 3D
printing as a fast, cheap way to make spacecraft parts, including rocket engine components
that are being tested for its next generation of heavy-lift launch vehicles. NASA hopes that
the new capability will allow future explorers to make spacecraft parts literally on the fly.

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 create
objects from a heat sensitive plastic that can be shaped when it reaches temperatures of
about 225–250 °C. The team is keeping quiet about what type of object it plans to print first,
but the general idea is to fashion tools for use aboard the station.

The Made in Space printer is also a testbed for performance of the technology in near
zero gravity. The machines work by spraying individual layers of a material that build up to
form a complete, 3D object. But in near-weightless environments, there is no gravitational
pull to hold the material down.
 CONCLUSION

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 3D. This mathematical difference, while hard to explain is the
fundamental reason why 3D printing is superior to other manufacturing techniques. It
almost always better to keep things simple and additive manufacturing is simple by its very
nature.

With so many potential benefits of 3D printing, there’s no surprise that this method
is making its way through a diverse number of industries and quickly becoming a favourite
tool of progressive marketers.

Comparing the numerous advantages, applications and future scope, we can conclude
that the 3D printer and its technology is able to create next industrial revolution.
 BIBLIOGRAPHY

Books

• The Book on 3D Printing Paperback – August 31, 2013

By Isaac Budmen

• 3D Printing: The Next Industrial Revolution Paperback – May 4, 2013

By Christopher Barnatt

• Fabricated: The New World of 3D Printing Paperback – February 11, 2013

By Hod Lipson

Links

• www.3dprinting.com

• www.3dprinter.net/reference

• www.3dprintingindustry.com

• www.stratasys.com/applications

• www.en.wikipedia.org/wiki/3D_printing

• www.3ders.org/3d-print-technology.html

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