3d printing
R.lohitha
Abstract—
3-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,
it’s 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. 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.
.
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.
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 "fix up".
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.
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
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R.lohitha
III. 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.
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.
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 cross section 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.
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
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R.lohitha
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. 1. industrial design:-
Stereolithography is an additive
Designers use 3D printers to quickly create
manufacturing process which employs a vat
product models and prototypes.
of liquid

2.Automotive and aviation

Figure 3.3: Stereolithography apparatus
IV. APPLICATIONS:-
industries:-
Auto giants and some aviation companies
have found that nothing accelerates
automotive design and manufacturing like
3D printing and adopted in their
manufacturing line.
 different body parts to be printed and can be
used directly for human body. Many human
body parts such as liver, heart, and ear have
been printed but they are of no use till now.

.
.3. Architecture:-
Artists can create models of their projects
Also Quick, automated production of
beautifully complex architectural models is
reality with 3D printing.

6. Jewelry and footwear:-

4. Food Industry:- 3D printing being so versatile in making
Different food items have been printed different shapes that it is
and in the near future many other food being used in producing different designs
items will be tested for 3D printing for jewelry and footwear.

5. Medical industry:-
This sector is a booming sector in 3D
printing. Research is being done for
 3d printing
R.lohitha
7.Engineering and construction:-
3D printing is being used for different
fields NASA is sending a 3D printer to
space station which will help in
constructing the required parts for the
space station. Similarly on earth different
engineering projects and construction
material are being manufactured.
Advantages:-
 Rapid prototyping :- 3d printing
gives designers the ability to quickly
turn concepts into 3d models or
prototypes.
 Clean process :-wastage of
materials is negligible.
 Complex shape:- can be produced.
 Easy to use:- no skilled person
needed.
 Cheap:- cheaper process no process.
disadvantages:-
 process is slow.
 components do not have enough
strength .
 cost of raw materials .
 3-d printers are still expensive.
 misuse of technology .
 although 3-d printers have the
potential of creating many jobs and
opportunities ,they might also put
certain jobs at risk.
Challenges:-
 intellectual property rights of the 3d
printer users
 nearly anything can be printed by 3d
printers and this is troubling prospect
if criminals use 3d printers to create
illegal products
 high cost of 3d printers.
Future scope:-
3d printing has a vast future scope. It is
still a developing field. Be it a basic 3d
printer or a versatile bio printer, there is a
long journey ahead. We have come from
time where 3D printers were a dream to time
where the printers are available for all but at
a high cost.
manufacturing industry. Following are some
of the hot topics for future:-
 resistance to change .
References:-
 http://en.wikipedia.org/wiki/3Dprinti
ng
 www.3dprinting.net/reference/what-
is-3d-printing
 3dprintingindustry .com/

1.COST:-
Cost of 3D printers will
decrease to such an extent that every
household will be
able to buy a 3D printer.

2.SOFTWARE UPDATE:-
Windows has announced to bring 3D printer
support in its next version of windows.

3.BIOPRINTERS:-
Human organs will be made through 3D
printers and will finish the storage of organ

4.FOOD:-
In few years our dinner will be printed

5.INDUSTRY:-
Large 3D printers will be available for
printing large parts and machinery.

6.ARMS:-
With advantages ,disadvantages also come
such as it will be possible for people
to print guns bullets at their home place
leading to insecurity.

Conclusion:-

 relatively new technology.

 no restrictions on industry.
 significant decrease in product
development cycle and cost.
 full effect on business and society
still not known .