3D PRINTING

Sumit
2311228
ECE Department
Ambala College of Engineering and Applied Research
Ambala
sumitharish95@gmail.com
Abstract3-D printing is a unique technology in the
realm of CNC. Often this technology is referred to as
Rapid Prototyping as its functional use is often one of
(relatively) quickly producing a physical object from
a CAD design model. This object can be used to test
form, fit, and function prior to building the object
in its real material, which likely costs more in time
and material stock to produce. As a prototype, this
object is fully (exceptions below) workable and
functions to test both visual and engineering
specifications, as well as completeness, correctness,
and overall design integrity. The production
approach is so simple that it is almost not even worth
consideration. Take your 3D model, run it through
some software, and hit Go. A few hours later, its
done.FDM is one of many so-called Rapid
Prototyping techniques, but they all fall under one
larger conceptual umbrella. They all operate by
deconstructing geometry into distinct layers, then
building up those layers one-by-one, depositing
material on top of material discreetly to slowly build
a 3D form. The process is distinctively additive,
especially as compared with the subtractive processes
we have and will explore with the laser and 3-axis
milling and routing.
I.

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.
II.

GENERAL PRINCIPLES

A. Modeling
3D printable models may be created with a computer aided
design (CAD) package or via a 3D scanner or via a plain
digital camera and photogrammetry software. The manual
modeling process of preparing geometric data for 3D
computer graphics is similar to plastic arts such as sculpting.
3D scanning is a process of analysing and collecting digital
data on the shape and appearance of a real object. Based on
this data, three-dimensional models of the scanned object can
then be produced. Regardless of the 3D modelling software
used, the 3D model (often in .skp, .dae, .3ds or some other
format) then needs to be converted to either a.STL or a .OBJ
format, to allow the printing (a.k.a. "CAM") software to be
able to read it.

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
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

Figure 2.1: 3D model slicing

B. Printing
Before printing a 3D model from an STL file, it must first
be examined for "manifold errors", this step being called the
"fixup". Especially STL's that have been produced from a
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

models. Examples of software that can be used to fix these
errors are netfabb and Meshmixer, or even Cura, or Slic3r.
Once that's done, the .STL file needs to be processed by a
piece of software called a "slicer" which converts the model
into a series of thin layers and produces a G-code
file containing instructions tailored to a specific type of 3D
printer (FDM printers). This G-code file can then be printed
with 3D printing client software (which loads the G-code, and
uses it to instruct the 3D printer during the 3D printing
process). It should be noted here that often, the client software
and the slicer are combined into one software program in
practice. Several open source slicer programs exist, including
Skeinforge, Slic3r, and Cura as well as closed source programs
including Simplify3D and KISSlicer.
C. Finishing
Though the printer-produced resolution is sufficient for
many applications, printing a slightly oversized version of the
desired object in standard resolution and then removing
material with a higher-resolution subtractive process can
achieve greater precision. Some printable polymers allow the
surface finish to be smoothed and improved using chemical
vapour processes.
Some additive manufacturing techniques are capable of
using multiple materials in the course of constructing parts.
These techniques are able to print in multiple colors and color
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.

business paper as the build material to produce a durable

prototype. The main considerations in choosing a machine are
generally speed, cost of the 3D printer, cost of the printed
prototype, cost and choice of materials, and color capabilities.
Printers that work directly with metals are expensive. In some
cases, however, less expensive printers can be used to make a
mould, which is then used to make metal parts.
A. Fused deposition modelling
Fused deposition modeling (FDM) was developed by S.
Scott Crump in the late 1980s and was commercialized in
1990 byStratasys. After the patent on this technology expired,
a large open-source development community developed and
both commercial and DIY variants utilizing this type of 3D
printer appeared. As a result, the price of this technology has
dropped by two orders of magnitude since its creation. In
fused deposition modeling the model or part is produced by
extruding small beads of material which harden immediately
to form layers. A thermoplastic filament or metal wire that is
wound on a coil is unreeled to supply material to
an extrusion nozzle head. The nozzle head heats the material
and turns the flow on and off. Typically stepper
motors or servo motors are employed to move the extrusion
head and adjust the flow. The head can be moved in both
horizontal and vertical directions, and control of the
mechanism is typically done by a computer-aided
manufacturing (CAM) software package running on a
microcontroller.

3D PRINTING PROCESSES

Several different 3D printing processes have been invented

since the late 1970s. The printers were originally large,
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
deposited to create parts and in the materials that are 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 modeling (FDM), or fused filament fabrication
(FFF), while others cure liquid materials using different
sophisticated technologies, e.g. stereolithography (SLA).
With laminated 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,
which is why some companies consequently offer a choice
between powder and polymer for the material used to build the
object. Other companies sometimes use standard, off-the-shelf

Figure 3.1: Fused deposition modeling: 1 nozzle ejecting molten plastic,

2 deposited material (modeled part), 3 controlled movable table

B. Selective Laser Sintering (SLS)

Selective
Laser
Sintering (SLS)
is
an additive
manufacturing (AM) technique that uses a laser as the power
source tosinter powdered material (typically metal), aiming
the laser automatically at points in space defined by a 3D
model, binding the material together to create a solid structure.
It is similar to direct metal laser sintering (DMLS); the two are
instantiations of the same concept but differ in technical
details. Selective laser melting (SLM) uses a comparable
concept, but in SLM the material is fully melted rather than
sintered, allowing
different
properties
(crystal
structure,porosity, and so on). SLS (as well as the other
mentioned AM techniques) is a relatively new technology that

so far has mainly been used for rapid prototyping and for lowvolume production of component parts. Production roles are
expanding as the commercialization of AM technology
improves.
An additive manufacturing layer technology, SLS
involves the use of a high power laser (for example, a carbon
dioxide laser) to fuse small particles of plastic, metal,ceramic,
or glass powders into a mass that has a desired threedimensional shape. The laser selectively fuses powdered
material by scanning cross-sections generated from a 3-D
digital description of the part (for example from a CAD file or
scan data) on the surface of a powder bed. After each crosssection is scanned, the powder bed is lowered by one layer
thickness, a new layer of material is applied on top, and the
process is repeated until the part is completed. Because
finished part density depends on peak laser power, rather than
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).

ultraviolet curable photopolymer "resin"

and
an
ultraviolet laser to build parts' layers one at a time. For each
layer, the laser beam traces a cross-section of the part pattern
on the surface of the liquid resin. Exposure to the ultraviolet
laser light cures and solidifies the pattern traced on the resin
and joins it to the layer below.
After the pattern has been traced, the SLA's elevator
platform descends by a distance equal to the thickness of a
single layer, typically 0.05 mm to 0.15 mm (0.002 in to
0.006 in). Then, a resin-filled blade sweeps across the cross
section of the part, re-coating it with fresh material. On this
new liquid surface, the subsequent layer pattern is traced,
joining the previous layer. A complete 3-D part is formed by
this process. After being built, parts are immersed in a
chemical bath in order to be cleaned of excess resin and are
subsequently cured in an ultraviolet oven.

Figure 3.3: Stereolithography apparatus

IV.
Figure 3.2: Selective laser sintering process

C. Stereolithography
Stereolithography (SLA or SL; also known as optical
fabrication, photo-solidification, solid free-form fabrication,
solid
imaging and Resin
printing)
is
an additive
manufacturing or 3D
printing technology
used
for
producing models,prototypes, patterns, and production parts
up one layer at a time by curing a photo-reactive resin with a
UV laser or another similar power source.
The term stereolithography was coined in 1986
by Charles (Chuck) W. Hull,[2] who patented it as a method
and apparatus for making solid objects by successively
"printing" thin layers of an ultraviolet curable material one on
top of the other. Hull's patent described a concentrated beam
of ultraviolet light focused onto the surface of a vat filled with
liquid photopolymer. The light beam draws the object onto the
surface of the liquid layer by layer, and using polymerization
or cross-linking to create a solid, a complex process which
requires automation. Stereolithography is an additive
manufacturing process which employs a vat of liquid

APPLICATIONS

1) Automobiles
In
early
2014,
the
Swedish supercar manufacturer, Koenigsegg, announced the
One, 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.
2) Construction
An additional use being developed is building printing, or
using 3D printing to build buildings.This could allow faster
construction for lower costs, and has been investigated for
construction of off-Earth habitats. For example, the Sinterhab
project is researching a lunar base constructed by 3D printing
using lunar regolith as a base material. Instead of adding a
binding agent to the regolith, researchers are experimenting
with microwave sintering to create solid blocks from the raw
material.

3) Firearms
In
2012,
the
US-based
group Defense
Distributed disclosed plans to "[design] a working
plastic gun that could be downloaded and reproduced by
anybody with a 3D printer." Defense Distributed has also
designed a 3D printable AR-15 type rifle lower
receiver (capable of lasting more than 650 rounds) and a 30
round M16 magazine The AR-15 has multiple receivers (both
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
after Defense Distributed succeeded in designing the first
working blueprint to produce a plastic gun with a 3D printer in
May 2013, the United States Department of State demanded
that they remove the instructions from their website.After
Defense Distributed released their plans, questions were raised
regarding the effects that 3D printing and widespread
consumer-level CNC machining may
have
on gun
control effectiveness.
4) Medical
3D printing has been used to print patient specific implant
and device for medical use. Successful operations include a
titanium pelvis implanted into a British patient, titanium
lower jaw transplanted to a Belgian patient, and a
plastic tracheal splint for an American infant.The hearing aid
and dental industries are expected to be the biggest area of
future development using the custom 3D printing
technology. In March 2014, surgeons in Swansea used 3D
printed parts to rebuild the face of a motorcyclist who had
been seriously injured in a road accident. Research is also
being conducted on methods to bio-print replacements for lost
tissue due to arthritis and cancer.

6) Education and research

3D printing and open source RepRap 3D printers in
particular, are the latest technology making inroads into the
classroom. 3D printing allows students to create prototypes of
items without the use of expensive tooling required in
subtractive methods. Students design and produce actual
models they can hold.s
V.

3d printing is a relatively new technology. There are no

restrictions on the industry. By using this technology, we can
significantly decrease the product development cycle and
overall costs in making a product. Additive manufacturing,
starting with today's infancy period, requires manufacturing
firms to be flexible, ever-improving users of all available
technologies to remain competitive. Advocates of additive
manufacturing also predict that this arc of technological
development will counter globalisation, as end users will do
much of their own manufacturing rather than engage in trade
to buy products from other people and corporations. The real
integration of the newer additive technologies into commercial
production, however, is more a matter of complementing
traditional subtractive methods rather than displacing them
entirely.
Acknowledgement
The author would like to express his thanks to Prof. Ashok
Kumar, Dean Academics and Head, ECE Department and
Management of Ambala College of Engineering and Applied
Research, Ambala for their encouragement and support during
this work.

5) Space
In September 2014, SpaceX delivered the first zero-gravity
3-D printer to the International Space Station (ISS). On
December 19, 2014, NASA emailed CAD drawings for a
socket wrench to astronauts aboard the ISS, who then printed
the tool using its 3-D printer. Applications for space offer the
ability to print broken parts or tools on-site, as opposed to
using rockets to bring along pre-manufactured items for space
missions to human colonies on the moon, Mars, or
elsewhere. The European Space Agency plans to deliver its
new Portable On-Board 3D Printer (POP3D for short) to the
International Space Station by June 2015, making it the
second 3D printer in space.

CONCLUSION

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