1 Abstract

By using Additive Manufacturing (AM) instead of traditional subtractive processes, component

manufacture may be approached in a transformational way. This method allows for the production
of exact components by gradually adding material from an initial state to a final configuration.
With its versatility in working with materials including plastic, metal, and composites, additive
manufacturing (AM) finds useful use in the production of models, prototypes, and parts. The goal
of this project is to create a model of a diesel engine model using SolidWorks software and then
utilize 3D printing to create the engine using PLA (polylactic acid). Because PLA is easily reusable
and biodegradable, it is a great option for building sturdy yet lightweight engine model
components. Because of the versatility that 3D printing offers, complex designs can be created that
not only accurately depict the engine but also allow for future design adjustments to minimize
extra material and improve part fits. The potential for innovation in the development and
manufacture of complicated mechanical systems is demonstrated of additive manufacturing
techniques with sophisticated design software. The overall dimensions of the project are L =
200mm, width = 100mm and height of this prototype is 128mm. Diameter of pinion gear is
21.80mm, no. of teeth on the pinion are 20 and gear width is 6mm similarly diameter of bull gear
is 41.45mm, no. of the teeth on bull gear are 40 and width of gear is 20mm. Length of rocker is
95mm and its width is 5mm, slider is a like a square box with 20mm length and width having
10.10mm hole for pin at the center. Crank diameter is 50mm and shaft connecting to it is of 30mm.
Table of Contents
1 Abstract .................................................................................................................................... 1

1. Introduction ............................................................................................................................. 4

1.1 Features of 3D printing .................................................................................................... 5

1.2 Comparison to other manufacturing processes ................................................................ 6

2 Design Methodology ............................................................................................................... 7

3 Selection of material ................................................................................................................ 7

4 Selection and detail of manufacturing process ........................................................................ 9

5 Software Model Lifting Mechanism: ...................................................................................... 9

5.1 Base drawing .................................................................................................................... 9

5.3 Dimension of the Lifting Mechanism ............................................................................ 14

5.4 Gear ratio of assembly.................................................................................................... 14

6 Conclusion ............................................................................................................................. 14

7 Reference ............................................................................................................................... 15
Table of Figures

Figure 1 Manufacturing process steps [2] ....................................................................................... 4

Figure 2 A 3D printing machine [4] ............................................................................................... 4
Figure 3 Working principle of 3D printing machine [5]................................................................. 5
Figure 4 Application areas of Additive manufacturing [7] ............................................................. 6
Figure 5 Flowchart of diesel engine manufacturing process .......................................................... 7
Figure 6 Manufacturing process of PLA [8] ................................................................................... 8
Figure 7 PLA material .................................................................................................................... 8
Figure 8 Engineering drawing of the base ...................................................................................... 9
Figure 9 Drawing of crank ............................................................................................................ 10
Figure 10 Drawing of crank. ......................................................................................................... 10
Figure 11 drawing of gear motor .................................................................................................. 11
Figure 12 Diagram of Bull gear .................................................................................................... 11
Figure 13 Drawing of the rocker ................................................................................................... 12
Figure 14 Drawing of the Rocker ................................................................................................. 12
Figure 15 Engineering drawing of the Complete Assembly\........................................................ 13
 1. Introduction
Manufacturing is a methodical and intricate process that involves a number of procedures and
actions to transform raw materials into completed goods. Many businesses, including the food,
pharmaceutical, and automobile sectors, depend heavily on this process. The purpose of
manufacturing is to make things that are economical, effectively produced in large quantities, and
satisfy certain quality requirements [1].

Figure 1 Manufacturing process steps [2]

Additive manufacturing, or 3D printing, has become a hot new technology that could revolutionize
a number of different industries. In contrast to conventional manufacturing techniques, which use
material subtraction to create an object, 3D printing uses digital models to build a product layer by
layer. There are significant ramifications for manufacturing, design, healthcare, and other fields
for this innovative approach [3].

Figure 2 A 3D printing machine [4]

The idea of layer-by-layer assembly is the foundation of 3D printing. Using computer-aided design
(CAD) software, a digital model is produced at the start of the process. The main benefits of 3D
printing lie in how technology affects product development and prototyping. Conventional
prototype techniques, which sometimes require the development of molds and equipment, may be
costly and time-consuming. Designers can test and iterate concepts more rapidly with 3D printing,
which speeds up the product development cycle. Businesses are able to launch goods more quickly
and for less money because to this adaptability.

Figure 3 Working principle of 3D printing machine [5]

1.1 Features of 3D printing

 Customization is made possible by 3D printing on a scale never before possible.
Technology enables the creation of one-of-a-kind products, ranging from customized
consumer goods to patient-specific medical implants. In addition to satisfying particular
consumer preferences, this degree of customization caters to niche markets that
conventional production techniques could not have made profitable [6]
 Manufacturing waste might be decreased with the use of 3D printing. When materials are
cut or machined from bigger blocks, traditional subtractive manufacturing techniques can
 produce a huge amount of waste. 3D printing, on the other hand, minimizes material waste
by building items layer by layer. Furthermore, lighter and more resource-efficient items
may be produced by using sophisticated structures with optimal geometry.
 Even though 3D printing has a lot of potential, there are certain difficulties. Researchers
and industry experts are still addressing issues related to material restrictions, construction
size constraints, and the requirement for standardized techniques. Nonetheless, further
developments in software, hardware, and materials point to a promising future for 3D
printing across a variety of industries.

1.2 Comparison to other manufacturing processes

 In contrast to subtractive techniques, which entail molding or cutting materials to the
required shape, 3D printing builds items digitally and builds them layer by layer.
 Rapid prototyping and on-demand production are made possible by the increased design
freedom and customization that 3D printing provides. However, conventional
manufacturing techniques can offer economies of scale and faster production rates, which
makes them more suited for mass producing standardized components.

Figure 4 Application areas of Additive manufacturing [7]

2 Design Methodology

Figure 5 Flowchart of diesel engine manufacturing process

3 Selection of material
Polylactic acid, or PLA, is a thermoplastic that is both biodegradable and bioactive [9]. It is made
from renewable resources, most often fermented plant starch, such as sugarcane or maize starch.
Due to its simplicity of use and environmentally favorable qualities, it has become more and more
popular as a filament material in the field of 3D printing. PLA works well with home 3D printers
because of its low melting point. The substance has a pleasant, non-acrid smell and is well known
for warping very little when printed. PLA creates glossy, detailed prints that are easily attainable
by both pros and enthusiasts because to its vast range of color options.

Figure 6 Manufacturing process of PLA [8]

PLA has drawbacks, such as a poorer heat resistance than certain other filaments, despite its
reputation for being environmentally friendly. Therefore, PLA is widely utilized in prototyping,
teaching, and the creation of visually beautiful but non-functional objects. It is more appealing for
applications where environmental impact is a concern because of its biodegradability.

Figure 7 PLA material

4 Selection and detail of manufacturing process
As in the industrial as daily life usage the lifting process is involved, it is therefore a lifting
mechanism is selected for this project Which consists of major parts such as base, crank, rocker,
connecter, slider, lifter and gears. For the designing purpose SolidWorks is used and then the file
is converted into readable able from SolidWorks. After the design prototype is linked to the
available 3D printer / inject printer. The model is created lay by layer. Model obtained from the
3D printer is similar to the actual model. Lifting mechanism usually may be pneumatic or
hydraulic type, due to the capability of large load lifting, extension of ranges, and environmental
versatility.

5 Software Model Lifting Mechanism:

5.1 Base drawing

Figure 8 Engineering drawing of the base

Figure 9 Drawing of crank

Figure 10 Drawing of crank.

Figure 11 drawing of gear motor

Figure 12 Diagram of Bull gear

5.2
Figure 13 Drawing of the rocker

Figure 14 Drawing of the Rocker

Figure 15 Engineering drawing of the Complete Assembly\
5.3 Dimension of the Lifting Mechanism
As it is already mentioned that major parts of lifting mechanism are base, crank, slider, pinion and
bull gear etc. The overall dimensions of the project are L = 200mm, width = 100mm and height of
this prototype is 128mm. Diameter of pinion gear is 21.80mm, no. of teeth on the pinion are 20
and gear width is 6mm similarly diameter of bull gear is 41.45mm, no. of the teeth on bull gear
are 40 and width of gear is 20mm. Length of rocker is 95mm and its width is 5mm, slider is a like
a square box with 20mm length and width having 10.10mm hole for pin at the center. Crank
diameter is 50mm and shaft connecting to it is of 30mm.

5.4 Gear ratio of assembly

As gear ratio is the ratio of number of teeth on bull gear to number of teeth on pinion gear as
indicated and calculated below,

𝑇𝑒𝑒𝑡ℎ 𝑜𝑛 𝑏𝑢𝑙𝑙 𝑔𝑒𝑎𝑟

𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 =
𝑇𝑒𝑒𝑡ℎ 𝑜𝑓 𝑝𝑖𝑛𝑖𝑜𝑛

40
𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 =
20

𝐺𝑒𝑎𝑟 𝑟𝑎𝑡𝑖𝑜 = 2

6 Conclusion
The goal of this project was to create a model of a lifting mechanism model using
SolidWorks software and then utilize 3D printing to create the engine using PLA (polylactic acid).
PLA is chosen as material of manufacture due to easily reusable and biodegradable, it is a great
option for building sturdy yet lightweight engine model components. Because of the versatility
that 3D printing offers, complex designs can be created that not only accurately depict the
mechanism but also allow for future design adjustments to minimize extra material and improve
part fits. The overall dimension of the diesel engine assembly are 200mm length and 100mm with
and 128mm is height. Gear ratio of the bull gear and pinion gear assembly is 2. The feature of
choosing 3D printing due to its versatility of manufacturing for building porotype projects, also it
tends to reduce the wastage of product and environment friendly.
7 Reference
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[3] What Can 3D Printing Be Used For? Here Are 10 Amazing Examples. (n.d.). Retrieved
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printing-be-used-for-here-are-10-amazing-examples/?sh=52e96e4f4d69

[4] JGAURORA 3D Printer Desktop FDM 3D Printers Metal Pakistan | Ubuy. (n.d.).
Retrieved December 7, 2023, from https://www.ubuy.com.pk/en/product/2NBWT9HK-jgaurora-
3d-printer-desktop-fdm-3d-printers-metal-frame-professional-high-resolution-stable-working-

[5] 3D printing | Definition, Technology, History, & Applications | Britannica. (n.d.).

Retrieved December 7, 2023, from https://www.britannica.com/technology/3D-printing
[6] What are the Advantages and Disadvantages of 3D Printing? - TWI. (n.d.). Retrieved
December 7, 2023, from https://www.twi-global.com/technical-knowledge/faqs/what-is-3d-
printing/pros-and-cons
[7] Which Additive Manufacturing Process Is Right for You? | manufacturing.REPORT.
(n.d.). Retrieved December 7, 2023, from https://manufacturing.report/articles/which-additive-
manufacturing-process-is-right-for-you
[8] Polylactic Acid or Polylactide (PLA). (n.d.). Retrieved December 7, 2023, from
https://bioplasticsnews.com/polylactic-acid-or-polylactide-pla/