3D PRINTING

Sumit
2311228
ECE Department
Ambala College of Engineering and Applied Research
Ambala
[email protected]

Abstract—3-D printing is a unique technology in the revolutionary method for creating 3D models with the use of
realm of CNC. Often this technology is referred to as inkjet technology saves time and cost by eliminating the need
Rapid Prototyping as its functional use is often one of to design; print and glue together separate model parts. Now,
(relatively) quickly producing a physical object from we can create a complete model in a single process using 3D
a CAD design model. This object can be used to test printing. The basic principles include materials cartridges,
flexibility of output, and translation of code into a visible
“form, fit, and function” prior to building the object pattern.
in its real material, which likely costs more in time
and material stock to produce. As a prototype, this
II. GENERAL PRINCIPLES
object is fully (exceptions below) workable and
functions to test both visual and engineering A. Modeling
specifications, as well as completeness, correctness, 3D printable models may be created with a computer aided
and overall design integrity. The production design (CAD) package or via a 3D scanner or via a plain
approach is so simple that it is almost not even worth digital camera and photogrammetry software. The manual
consideration. Take your 3D model, run it through modeling process of preparing geometric data for 3D
some software, and hit “Go”. A few hours later, it’s computer graphics is similar to plastic arts such as sculpting.
done.FDM is one of many so-called Rapid 3D scanning is a process of analysing and collecting digital
Prototyping techniques, but they all fall under one data on the shape and appearance of a real object. Based on
this data, three-dimensional models of the scanned object can
larger conceptual umbrella. They all operate by then be produced. Regardless of the 3D modelling software
deconstructing geometry into distinct layers, then used, the 3D model (often in .skp, .dae, .3ds or some other
building up those layers one-by-one, depositing format) then needs to be converted to either a.STL or a .OBJ
material on top of material discreetly to slowly build format, to allow the printing (a.k.a. "CAM") software to be
a 3D form. The process is distinctively additive, able to read it.
especially as compared with the subtractive processes
we have and will explore with the laser and 3-axis
milling and routing.
I. INTRODUCTION
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, we 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 printing is a form Figure 2.1: 3D model slicing
of additive manufacturing technology where a three
dimensional object is created by laying down successive B. Printing
layers of material. It is also known as rapid prototyping, is a Before printing a 3D model from an STL file, it must first
mechanized method whereby 3D objects are quickly made on
be examined for "manifold errors", this step being called the
a reasonably sized machine connected to a computer
containing blueprints for the object. The 3D printing concept "fixup". Especially STL's that have been produced from a
of custom manufacturing is exciting to nearly everyone. This model obtained through 3D scanning often have many
manifold errors in them that need to be fixed. Examples of
manifold errors are surfaces that do not connect, gaps in the business paper as the build material to produce a durable
models. Examples of software that can be used to fix these prototype. The main considerations in choosing a machine are
errors are netfabb and Meshmixer, or even Cura, or Slic3r. generally speed, cost of the 3D printer, cost of the printed
Once that's done, the .STL file needs to be processed by a prototype, cost and choice of materials, and color capabilities.
piece of software called a "slicer" which converts the model Printers that work directly with metals are expensive. In some
cases, however, less expensive printers can be used to make a
into a series of thin layers and produces a G-code mould, which is then used to make metal parts.
file containing instructions tailored to a specific type of 3D
printer (FDM printers). This G-code file can then be printed A. Fused deposition modelling
with 3D printing client software (which loads the G-code, and Fused deposition modeling (FDM) was developed by S.
uses it to instruct the 3D printer during the 3D printing Scott Crump in the late 1980s and was commercialized in
process). It should be noted here that often, the client software 1990 byStratasys. After the patent on this technology expired,
and the slicer are combined into one software program in a large open-source development community developed and
practice. Several open source slicer programs exist, including both commercial and DIY variants utilizing this type of 3D
Skeinforge, Slic3r, and Cura as well as closed source programs printer appeared. As a result, the price of this technology has
including Simplify3D and KISSlicer. dropped by two orders of magnitude since its creation. In
fused deposition modeling the model or part is produced by
C. Finishing extruding small beads of material which harden immediately
Though the printer-produced resolution is sufficient for to form layers. A thermoplastic filament or metal wire that is
many applications, printing a slightly oversized version of the wound on a coil is unreeled to supply material to
desired object in standard resolution and then removing an extrusion nozzle head. The nozzle head heats the material
material with a higher-resolution subtractive process can and turns the flow on and off. Typically stepper
achieve greater precision. Some printable polymers allow the motors or servo motors are employed to move the extrusion
surface finish to be smoothed and improved using chemical head and adjust the flow. The head can be moved in both
vapour processes. horizontal and vertical directions, and control of the
Some additive manufacturing techniques are capable of mechanism is typically done by a computer-aided
using multiple materials in the course of constructing parts. manufacturing (CAM) software package running on a
These techniques are able to print in multiple colors and color microcontroller.
combinations simultaneously, and would not necessarily
require painting. Some printing techniques require internal
supports to be built for overhanging features during
construction. These supports must be mechanically removed
or dissolved upon completion of the print. All of the
commercialized metal 3-D printers involve cutting the metal
component off of the metal substrate after deposition. A new
process for the GMAW 3-D printing allows for substrate
surface modifications to remove aluminum components
manually with a hammer.

III. 3D PRINTING PROCESSES

Several different 3D printing processes have been invented Figure 3.1: Fused deposition modeling: 1 – nozzle ejecting molten plastic,
since the late 1970s. The printers were originally large, 2 – deposited material (modeled part), 3 – controlled movable table
expensive, and highly limited in what they could produce. A
large number of additive processes are now available. The
main differences between processes are in the way layers are B. Selective Laser Sintering (SLS)
deposited to create parts and in the materials that are used. Selective Laser Sintering (SLS) is an additive
Some methods melt or soften material to produce the layers, manufacturing (AM) technique that uses a laser as the power
e.g. selective laser melting (SLM) or direct metal laser source tosinter powdered material (typically metal), aiming
sintering (DMLS), selective laser sintering (SLS), fused
deposition modeling (FDM), or fused filament fabrication the laser automatically at points in space defined by a 3D
(FFF), while others cure liquid materials using different model, binding the material together to create a solid structure.
sophisticated technologies, e.g. stereolithography (SLA). It is similar to direct metal laser sintering (DMLS); the two are
With laminated object manufacturing (LOM), thin layers are instantiations of the same concept but differ in technical
cut to shape and joined together (e.g. paper, polymer, and details. Selective laser melting (SLM) uses a comparable
metal). Each method has its own advantages and drawbacks, concept, but in SLM the material is fully melted rather than
which is why some companies consequently offer a choice sintered, allowing different properties (crystal
between powder and polymer for the material used to build the structure,porosity, and so on). SLS (as well as the other
object. Other companies sometimes use standard, off-the-shelf mentioned AM techniques) is a relatively new technology that
so far has mainly been used for rapid prototyping and for low- ultraviolet curable photopolymer "resin" and an
volume production of component parts. Production roles are ultraviolet laser to build parts' layers one at a time. For each
expanding as the commercialization of AM technology layer, the laser beam traces a cross-section of the part pattern
improves. on the surface of the liquid resin. Exposure to the ultraviolet
An additive manufacturing layer technology, SLS laser light cures and solidifies the pattern traced on the resin
involves the use of a high power laser (for example, a carbon and joins it to the layer below.
dioxide laser) to fuse small particles of plastic, metal,ceramic, After the pattern has been traced, the SLA's elevator
or glass powders into a mass that has a desired three- platform descends by a distance equal to the thickness of a
dimensional shape. The laser selectively fuses powdered single layer, typically 0.05 mm to 0.15 mm (0.002 in to
material by scanning cross-sections generated from a 3-D 0.006 in). Then, a resin-filled blade sweeps across the cross
digital description of the part (for example from a CAD file or section of the part, re-coating it with fresh material. On this
scan data) on the surface of a powder bed. After each cross- new liquid surface, the subsequent layer pattern is traced,
section is scanned, the powder bed is lowered by one layer joining the previous layer. A complete 3-D part is formed by
thickness, a new layer of material is applied on top, and the this process. After being built, parts are immersed in a
process is repeated until the part is completed. Because chemical bath in order to be cleaned of excess resin and are
finished part density depends on peak laser power, rather than subsequently cured in an ultraviolet oven.
laser duration, a SLS machine typically uses a pulsed laser.
The SLS machine preheats the bulk powder material in the
powder bed somewhat below its melting point, to make it
easier for the laser to raise the temperature of the selected
regions the rest of the way to the melting point. Unlike some
other additive manufacturing processes, such
as stereolithography (SLA) and fused deposition
modeling (FDM).

Figure 3.3: Stereolithography apparatus

IV. APPLICATIONS

Figure 3.2: Selective laser sintering process 1) Automobiles

C. Stereolithography In early 2014, the
Swedish supercar manufacturer, Koenigsegg, announced the
Stereolithography (SLA or SL; also known as optical
One, a supercar that utilises many components that were 3D
fabrication, photo-solidification, solid free-form fabrication,
printed. In the limited run of vehicles Koenigsegg produces,
solid imaging and Resin printing) is an additive
the One:1 has side-mirror internals, air ducts, titanium exhaust
manufacturing or 3D printing technology used for
components, and even complete turbocharger assembles that
producing models,prototypes, patterns, and production parts
have been 3D printed as part of the manufacturing process.
up one layer at a time by curing a photo-reactive resin with a
UV laser or another similar power source. 2) Construction
The term “stereolithography” was coined in 1986
by Charles (Chuck) W. Hull,[2] who patented it as a method An additional use being developed is building printing, or
and apparatus for making solid objects by successively using 3D printing to build buildings.This could allow faster
"printing" thin layers of an ultraviolet curable material one on construction for lower costs, and has been investigated for
top of the other. Hull's patent described a concentrated beam construction of off-Earth habitats. For example, the Sinterhab
of ultraviolet light focused onto the surface of a vat filled with project is researching a lunar base constructed by 3D printing
liquid photopolymer. The light beam draws the object onto the using lunar regolith as a base material. Instead of adding a
surface of the liquid layer by layer, and using polymerization binding agent to the regolith, researchers are experimenting
or cross-linking to create a solid, a complex process which with microwave sintering to create solid blocks from the raw
requires automation. Stereolithography is an additive material.
manufacturing process which employs a vat of liquid
 3) Firearms 6) Education and research
In 2012, the US-based group Defense 3D printing and open source RepRap 3D printers in
Distributed disclosed plans to "[design] a working particular, are the latest technology making inroads into the
plastic gun that could be downloaded and reproduced by classroom. 3D printing allows students to create prototypes of
anybody with a 3D printer." Defense Distributed has also items without the use of expensive tooling required in
designed a 3D printable AR-15 type rifle lower subtractive methods. Students design and produce actual
receiver (capable of lasting more than 650 rounds) and a 30 models they can hold.s
round M16 magazine The AR-15 has multiple receivers (both
V. CONCLUSION
an upper and lower receiver), but the legally controlled part is
the one that is serialised (the lower, in the AR-15's case). Soon 3d printing is a relatively new technology. There are no
after Defense Distributed succeeded in designing the first restrictions on the industry. By using this technology, we can
working blueprint to produce a plastic gun with a 3D printer in significantly decrease the product development cycle and
May 2013, the United States Department of State demanded overall costs in making a product. Additive manufacturing,
that they remove the instructions from their website.After starting with today's infancy period, requires manufacturing
Defense Distributed released their plans, questions were raised firms to be flexible, ever-improving users of all available
regarding the effects that 3D printing and widespread technologies to remain competitive. Advocates of additive
consumer-level CNC machining may have on gun manufacturing also predict that this arc of technological
control effectiveness. development will counter globalisation, as end users will do
much of their own manufacturing rather than engage in trade
4) Medical to buy products from other people and corporations. The real
3D printing has been used to print patient specific implant integration of the newer additive technologies into commercial
and device for medical use. Successful operations include a production, however, is more a matter of complementing
titanium pelvis implanted into a British patient, titanium traditional subtractive methods rather than displacing them
lower jaw transplanted to a Belgian patient, and a entirely.
plastic tracheal splint for an American infant.The hearing aid
and dental industries are expected to be the biggest area of
Acknowledgement
future development using the custom 3D printing
technology. In March 2014, surgeons in Swansea used 3D The author would like to express his thanks to Prof. Ashok
printed parts to rebuild the face of a motorcyclist who had Kumar, Dean Academics and Head, ECE Department and
been seriously injured in a road accident. Research is also Management of Ambala College of Engineering and Applied
being conducted on methods to bio-print replacements for lost Research, Ambala for their encouragement and support during
tissue due to arthritis and cancer. this work.
5) Space
References
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