Additive manufacturing

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by:
Rahil Salot (16BME125)
Biraj Dhaduk (16BME126)

MECHANICAL ENGINEERING DEPARTMENT

INSTITUTE OF TECHNOLOGY
NIRMA UNIVERSITY
2019

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 Declaration

This is certify to that

 The project work comprises my original work towards the Minor Project (ME 705)
subject of 7th semester in Mechanical Engineering at Nirma University and has not been
submitted elsewhere.
 Due acknowledgement has been made in the text to all other material used

Sign
Name:
Roll No:

Sign
Name:
Roll No:

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 Certificate
TO WHOM IT MAY CONCERN
This is to certify that, Mr./ Ms. ___________________________________student of
Mechanical engineering, 7th Semester of, Institute of Technology, Nirma University
has satisfactorily completed the project report titled ‘Additive manufacturing’.

Date:

Guide and
Co-guide Name(s)
Prof. Prashant Bagga
Guide, Associate Professor,
Department of Mechanical Engineering,
Institute of Technology
Nirma University, Ahmedabad

Dr. V. J. Lakhera
Head and Professor,
Department of Mechanical Engineering,
Institute of Technology
Nirma University, Ahmedabad

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 Approval Sheet

The Project entitled Additive manufacturing by Rahil salot (16bme125) and biraj dhaduk
(16bme126) is approved towards the Minor Project (ME 705) subject of 7th semester of
Bachelor of Technology in Mechanical Engineering of Nirma University, Ahmedabad

Examiners

___________________

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 Acknowledgments

We thank Prof. prashant bagga for sharing his pearls of wisdom with us and constantly helping
and guiding us during this seminar project. We would also like to thank prof. Arvind shankhla
Sir .We also like to thank Head of Department of Mechanical Engineering Dr. Vikas Lakhera
for providing us the exposure to project based learning through this minor project.

Name and signature of student

Rahil salot
Date:
Place:

Biraj dhaduk
Date:
Place:

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 Abstract
3D printing is one of the most emerging technologies in the field of manufacturing
replacing subtractive manufacturing and thus saving the expensive resources of the
earth. In this report we have mentioned about how the 3D printing is emerging at a very
rapid rate however still requires some modifications since the technology is new and
costly. In this report we have done cost and force analysis of the 3D printer for the
purpose of reducing cost of manufacturing a 3D printer. We have designed a 3d printer
equipped with a gyroscope with the purpose of manufacturing in a product in a
moving/unsteady environment which has a potential of taking 3d printing to new
heights.

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 List of figures

Figure 1.1 additive manufacturing……………………………………………………………9

Figure 1.2 subtractive manufacturing ………………………………………………………..9
Figure 2.1 SLA printing (1)…………………………………………………………………..11
Figure 2.2 SLA printing (2)…………………………………………………………………..11
Figure 2.3 Top dowm/bottom up approach…………………………………………………..12
Figure 2.4 DLP printing……………………………………………………………………...13
Figure 2.5 FDM printing……………………………………………………………………..13
Figure 2.6 FDM printing (2)…………………………………………………………………14
Figure 3.1 Classification of materials………………………………………………………..15
Figure 4.1 Aluminum profile………………………………………………………………...16
Figure 4.2 end support……………………………………………………………………….17
Figure 4.3 Bracket…………………………………………………………………………...17
Figure 4.4 LCD screen display………………………………………………………………18
Figure 4.5 LCD components………………………………………………………………...18
Figure 4.6 Nema 17 stepper motor………………………………………………………….19
Figure 4.7 Raspberry pi 3b………………………………………………………………….19
Figure 4.8 Nano dlp shield v1.1…………………………………………………………….20
Figure 4.9 Polymer resin……………………………………………………………………20
Figure 5.1 Costing (1)………………………………………………………………………21
Figure 5.2 Costing (2)……………………………………………………………………....21
Figure 6.1 Table…………………………………………………………………………….22
Figure 6.2 Table holder……………………………………………………………………..23
Figure 6.3 Guide rod………………………………………………………………………..23
Figure 6.4 Motor bracket…………………………………………………………………...24
Figure 6.5 Working of a 3-axis gimbal…………………………………………………….25
Figure 6.6 Stabilizer system (1)…………………………………………………………....26
Figure 6.7 Stabilizer system (2)…………………………………………………………....26
Figure 6.8 Stabilizer system. ………………………………………………………………26

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.

Table of contents
Contents
Chapter 1 Introduction ............................................................................................................... 9
1.1 What is 3D printing ? ....................................................................................................... 9
1.2 How does 3D printing work? ......................................................................................... 10
Chapter 2 Different 3D printing technologies. ........................................................................ 11
2.1 SLA printing .................................................................................................................. 11
2.2 DLP Printing .................................................................................................................. 12
2.3 Fused deposition molding .............................................................................................. 13
Chapter 3 Additive manufacturing materials ........................................................................... 15
3.1 Materials for additive manufacturing............................................................................. 15
Chapter 4 Components required for manufacturing 3D printer ............................................... 16
Chapter 5 Costing of 3D printer............................................................................................... 21
Chapter 6 Analysis of 3D printer ............................................................................................. 22
6.1 Table .............................................................................................................................. 22
6.2 Table holder ................................................................................................................... 23
6.3 Guide rod ....................................................................................................................... 23
6.4 Motor bracket ................................................................................................................. 24
6.5 Parameters of 3D printer ................................................................................................ 24
6.6 3D printer on water vehicles .......................................................................................... 25
Chapter 7 Recent trends and applications ................................................................................ 27
Chapter 8 Conclusion ............................................................................................................... 28

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Chapter 1 Introduction
1.1 What is 3D printing ?

Additive manufacturing, also known as 3D printing, is a transformative approach to industrial

production that enables the creation of lighter, stronger parts and systems. Additive
manufacturing uses data computer-aided-design (CAD) software or 3D object scanners to
direct hardware to deposit material, layer upon layer, in precise geometric shapes. As its name
implies, additive manufacturing adds material to create an object. By contrast, when you create
an object by traditional means, it is often necessary to remove material through milling,
machining, carving, shaping or other means. Although the terms "3D printing" and "rapid
prototyping" are casually used to discuss additive manufacturing, each process is actually a
subset of additive manufacturing.

Nowadays, additive manufacturing plays an important role in the growth of product

development. It does not only build products fast, but also makes the manufacturing process
more innovative and cost-effective. Additive Manufacturing or AM is a suitable name to
describe the technology that is used in building 3D objects by adding materials layer by layer.
The term “additive” refers to the method of adding and building the product repeatedly.
Additive manufacturing is an opposite method of subtractive manufacturing. Subtractive
manufacturing is a process in which 3D objects are constructed by cutting materials through a
standard machining process such as drilling or milling. It is also called the traditional
manufacturing and used in CNC machining.

Figure 1.1 Additive manufacturing Figure 1.2 subtractive manufacturing

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1.2 How does 3D printing work?

The term “additive manufacturing” references technologies that grow three-dimensional

objects one superfine layer at a time. Each successive layer bonds to the preceding layer of
melted or partially melted material. It is possible to use different substances for layering
material, including metal powder, thermoplastics, ceramics, composites, glass and even edibles
like chocolate.
Objects are digitally defined by computer-aided-design (CAD) software that is used to create
.stl files that essentially "slice" the object into ultra-thin layers. This information guides the
path of a nozzle or print head as it precisely deposits material upon the preceding layer. Or, a
laser or electron beam selectively melts or partially melts in a bed of powdered material. As
materials cool or are cured, they fuse together to form a three-dimensional object.
The journey from .stl file to 3D object is revolutionizing manufacturing. Gone are the
intermediary steps, like the creation of molds or dies, that cost time and money.

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Chapter 2 Different 3D printing technologies.
2.1 SLA printing

Stereolithography (SLA) is an additive manufacturing process that belongs to the Vat Photo
polymerization family. Here is how it works:
Here is how the SLA fabrication process works:
 The build platform is first positioned in the tank of liquid photopolymer, at a distance
of one layer height for the surface of the liquid.
 Then a UV laser creates the next layer by selectively curing and solidifying the
photopolymer resin. The laser beam is focused in the predetermined path using a set of
mirrors, called galvos. The whole cross sectional area of the model is scanned, so the
produced part is fully solid.
 When a layer is finished, the platform moves at a safe distance and the sweeper blade
re-coats the surface. The process then repeats until the part is complete.
 After printing, the part is in a green, no-fully-cured state and requires further post
processing under UV light if very high mechanical and thermal properties are required.

Figure 2.1 SLA printing

Figure 2.2 SLA printing (2)

Two types of SLA printers :

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1) Top-Down- The top-down SLA printers place the laser source above the tank and the part
is built facing up. The build platform begins at the very top of the resin vat and moves
downwards after every layer.

2) Bottom up: The bottom-up SLA printers place the light source under the resin tank (see
figure above) and the part is built facing upside down.

Figure 2.3 Top down/Bottom up approach

2.2 DLP Printing

DLP stands for digital light processing, and is a type of vat polymerization. Vat
polymerization 3D printing technologies make use of a (liquid) photopolymer resin which is
able to cure (solidify) under a light source. Now that we know how SLA works, it’s time to
take a closer look at DLP. DLP is a “sister technology” to SLA as the only big difference is the
light source used to cure the resin. As we just mentioned, SLA printers use lasers combined
with galvanometers to cure resin With a DLP 3D printer, the light source is a specially
developed digital light projector screen. Thanks to this screen, DLP is generally considered to
be faster than SLA, and here’s why:
With SLA, the laser has to individually cure the resin in a “point to point” technique. On the
other hand, a DLP projector screen flashes an image of a layer all at once!

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DLP stands for digital light processing, and is a type of vat polymerization. Vat
polymerization 3D printing technologies make use of a (liquid) photopolymer resin which is
able to cure (solidify) under a light source.
Now that we know how SLA works, it’s time to take a closer look at DLP. DLP is a “sister
technology” to SLA as the only big difference is the light source used to cure the resin. As we
just mentioned, SLA printers use lasers combined with galvanometers to cure resin.
With a DLP 3D printer, the light source is a specially developed digital light projector screen.
Thanks to this screen, DLP is generally considered to be faster than SLA, and here’s why:
With SLA, the laser has to individually cure the resin in a “point to point” technique. On the
other hand, a DLP projector screen flashes an image of a layer all at once! Thus all points of a
layer can be cured simultaneously. In this way, the print speed is increased in comparison to
SLA since it takes less time to cure a single layer.

Figure 2.4 DLP printing

2.3 Fused deposition molding

Fused Deposition Modeling (FDM), or Fused Filament Fabrication (FFF), is an additive
manufacturing process that belongs to the material extrusion family. In FDM, an object is built
by selectively depositing melted material in a pre-determined path layer-by-layer. The
materials used are thermoplastic polymers and come in a filament form
Steps of FDM 3d printing.
• A spool of thermoplastic filament is first loaded into the printer. Once the nozzle has
reached the desired temperature, the filament is fed to the extrusion head and in the
nozzle where it melts.

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• The extrusion head is attached to a 3-axis system that allows it to move in the X, Y and
Z directions. The melted material is extruded in thin strands and is deposited layer-by-
layer in predetermined locations, where it cools and solidifies. Sometimes the cooling
of the material is accelerated through the use of cooling fans attached on the extrusion
head.
• To fill an area, multiple passes are required (similar to coloring a rectangle with a
marker). When a layer is finished, the build platform moves down (or in other machine
setups, the extrusion head moves up) and a new layer is deposited. This process is
repeated until the part is complete.

Figure 2.5 FDM printing.

Figure 2.6 FDM printing (2)

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Chapter 3 Additive manufacturing materials
3.1 Materials for additive manufacturing

It is possible to use many different materials to create 3D-printed objects. AM technology

fabricates jet engine parts from advanced metal alloys, and it also creates chocolate treats and
other food items.
• Thermoplastics:
Thermoplastic polymers remain the most popular class of additive manufacturing
materials. Acrylonitrile butadiene styrene (ABS), polylactic acid (PLA) and
polycarbonate (PC) each offer distinct advantages in different applications. Water-
soluble polyvinyl alcohol (PVA) is typically used to create temporary support
structures, which are later dissolved away.
• Metals:
Many different metals and metal alloys are used in additive manufacturing, from
precious metals like gold and silver to strategic metals like stainless steel and titanium.
• Ceramics:
A variety of ceramics have also been used in additive manufacturing, including
zirconia, alumina and tricalcium phosphate. Also, alternate layers of powdered glass
and adhesive are baked together to create entirely new classes of glass products.

Figure 3.1 classification of materials

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Chapter 4 Components required for
manufacturing 3D printer
1. Aluminium profile (20X20)

Why Aluminium profile?

• Easily available.
• High precision.
• More modular.
• High reliability.
• Can be upgraded with accessories.

Figure 4.1 Aluminium profile

2. Components for table

• Guide rod for guiding the table.

• End support for supporting the guide rod.(SK8)
• Lead screw and nut for linear movement of table.
• Linear bearing for smooth movement of table.(LMk8LUU)
• Roller Bearing for supporting lead screw.

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 Figure 4.2 end support.

3. Other Components.
• Nema 17 Bracket
• FEP film for easy penetration of U.V light and to prevent resin from getting solidified
on film.
• Custom made aluminium plate for supporting screen.
• 8mm to 5mm coupling.

Figure 4.3 Bracket

4. Electronic components

a. 10.1 inch LCD screen:

• Resolution:1600X2560 (2K)
• Without polarized film and backlight.
• Input voltage: 3.3 Volt.
• HDMI Driver: 40 pins

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 Figure 4.4 LCD screen display

Figure 4.5 LCD components

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5. Nema 17 stepper motor:
• NEMA17 4.2 Kgcm Stepper Motor for high torque applications.
• Features:
Step Angle: 1.8°
Rated Voltage: 2.5-3.0V
Rated Current: 1.6A
Holding Torque: 4.2 kg cm
A4998 Stepper motor drive

Figure 4.6 nema 17 stepper motor

6. Raspberry pi 3b:
For installation of nano DLP software.
To run LCD screen though HDMI cable.
For mounting of nano DLP shield.
For user interface (If required) through LED touch screen.

Figure 4.7 Raspberry pi 3b

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7. Nano DLP Shield v1.1
Features:
2X Endstops
Controled MOS for ext LED driver
I2C Connector for LCD1602
Uart Connector for Touch Screen
Shutter support
5V OUT Connector for ext Board

Figure 4.8 Nano DLP Shield v1.1

8. U.V LED :
Specification:
Power: 50 W
Wavelength: 395 nm
With heat sink

9. Polymer resin
Name: Dropshape
Works in wide range of UV wavelength between 365nm to 405nm
Shrinkage less than 5%.
Curing times of as low as 0.25 seconds for 0.05mm layers

Figure 4.9 Polymer resin

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Chapter 5 Costing of 3D printer

Figure 5.1 costing (1)

Figure 5.2 Costing (2)

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Chapter 6 Analysis of 3D printer

Accuracy in a 3D printer is a big thing and is very difficult to analyze. The higher the accuracy
more will be the robustness of the build model. Variation in cooling time and intensity of light
can lead to uneven solidification. Here, support plays an important role in defining the accuracy
of any printer. Also, if the size of the object increases the accuracy drops due to addition of
mass.
Different components have different materials and hence, different deformation. Also, the table
is not hung in single position. This results in the addition of deformations of several
components at the end of the table. Here, we have first calculated the deformation of individual
components and tried to find the sum of the deformation. Final deformation will define the
accuracy of the printer.
The critical components which play role in accuracy are:
Table, table holder, guide rods, lead screw, stepper motor bracket.
Here, we are using the standard aluminum section which are highly rigid and hence, the
deformations of that is neglected. Also, the deformation of standard components like linear
bearing, end supports, nuts and bolts are also neglected. Analysis of different components with
their maximum deformation is shown ahead.

6.1 Table

Here the material of the table is taken as Aluminium alloy having yield strength 280 MPa. The
density of the photopolymer resin is taken as 1200 kg/m3. Calculating the volume and then
finding the maximum weight of resin in the pool we get around 0.8 kg. So, applying a load of
10N on the surface of the table we get the maximum deflection at the end of around 1 micron.
Here, the deformation on Y-axis is calculated as it center of analysis.

Figure 6.1 table

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6.2 Table holder

Here, the material of the table is taken same as that of the table i.e. Aluminium alloy. And a
after analyzing in the same as former way we found maximum deformation of around 5
micron.

Figure 6.2 table holder

6.3 Guide rod

The diameter of guide rod is 8 mm and the material chrome plated hardened steel. The
maximum moment is acting when the object is about to complete or when the table is
completely submerged in the pool. The moment is calculated at critical point came out to be
24Nm. Then the force was applied on the critical point of the guide rod. The maximum
deformation along z direction comes out to be around 8 micron. This shows that at the end of
the completion of object the final layer will shift around 10 micron form first layer considering
the deflection of the guide rod.

Figure 6.3 Guide rod

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6.4 Motor bracket

The entire load of the resin, table and table holder is transferred to the motor bracket through
the lead screw. The entire load of 2 kg comes on lead screw. As the bracket deflects the required
thickness of the layer is not obtained i.e. thinner layer is formed. The material selected is
structural steel. Through analysis we get maximum deflection of around 15 micron. This shows
that the deflection of the bracket is much critical compared to other components.
From the given above analysis we found out maximum deflection to be 30 micron due to
deflection. Here, we have no considered deflection due to torque of motor. This will result into
the angular deflection and so, there may remain some kind of twist in the final object.

Figure 6.4 motor bracket

6.5 Parameters of 3D printer

Successful printing of objects by these methods requires some predetermined knowledge of the
photo curing properties of the starting material (viscosity, critical energy for polymerization,
photon penetration depth) and processing capabilities of the printer (photon wavelength, power
density). Unfortunately, this kind of information is often not provided or, if provided, few
details are given as to how the values were determined or to what degree they are under control.
The lack of this basic information or the unknown quality of the data could very likely impact
the manufacturability and properties of the final product.
There are mainly two parameters that govern the polymerization of the resin namely:
penetration depth of the curing light
the energy required for polymerization
The penetration of light follows a Beer-Lambert relationship:

Where Pz is the power of light (usually in mW/cm2) at some depth z. P0 is the power at the
surface. Dp is the depth at which the penetrating light intensity falls to 1/e of the surface
intensity. z becomes the cure depth when the appropriate amount on light is present.

Jacobs’ basic working curve equation:

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where Cd is the thickness of cured resin, E0 is the energy of light at the surface, and Ec is the
critical energy required to initiate polymerization of the resin. With the help of Dp and Ec,
exposure parameters can be chosen that optimize the printing process to achieve the desired
part properties.
Knowing Dp and Ec allows the user or printer manufacturer to choose the appropriate settings
of light exposure (power, resolution, wavelength, scan speed) and z-axis increments to
optimize the curing conditions to achieve desired results.

6.6 3D printer on water vehicles

3D printing on water vehicle is almost next to impossible as the system always remains
unstable. But, there are certain over and under water applications which can open rooms for
3D printer. Photopolymer printed material is particularly suited for underwater applications
requiring sealed housings, since SLA printers are capable of producing high-resolution models
that are fully solid and impervious to water. The unstable environment onboard a moving
vehicle could impact the ability of a resin printer to selectively cure polymer in a liquid resin
bath as it undergoes constant motion, and can cause spilling over the walls of the resin tank.
However, this can be achievable using a system of stabilizers. A system of a gyroscope and
few dampers can help to achieve stability. The below figure shows a spatial representation of
a gyroscopic stabilizer with the printer loaded on it. Actually, there are many commercially
available GIMBAL used for stabilization of camera. The basic principle can be used to design
our stabilizer.

Figure 6.5 Working of a 3-axis gimbal

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 Figure 6.6 stabilizer system(1) Figure 6.7 Stabilizer system(2)

Figure 6.8 Stabilizer system

Here the angular momentum of the roatating disc must be greater than that of the printer. If the
angular momentum of the disc is less than that of printer then it will not be able to withstand
the shock. The angular velocity of the printer must be taken when the unbalance had just started.

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Chapter 7 Recent trends and applications

• 3D printed cookies.
• Scientists have used 3D-printing to make automobile parts and prosthetics
before but now 3D-printing food is becoming a reality. Researchers from the
Indian Institute of Food Processing Technology (IIFPT), Thanjavur, have
printed a nutritious snack using millets, green gram, fried gram and ajwain
seeds. Taking just five to seven minutes to print, followed by a microwave
drying process, this technology may help in customising food according to the
individuals’ nutritional requirements.
• World’s fastest 3D printer:
• A new 3D printer is using innovative technology to be the fastest device ever
when it comes to printing speeds for larger objects known as the HARP printer,
an acronym for ‘high-area rapid printing’, the device has a print bed with a
footprint of 2.5 square-foot and is 13-feet tall, and it can print an object the size
of an adult human in a couple of hours (Madame Tussauds has probably got its
order in already).Specifically, it’s capable of printing objects vertically at a
speed of half a yard (just under half a meter) per hour, which represents a record
level of throughput in 3D printing.
• Aerospace
• AM excels at producing parts with weight-saving, complex geometric designs.
Therefore, it is often the perfect solution for creating, strong aerospace parts.
• In August 2013, NASA successfully tested an SLM-printed rocket injector
during a hot fire test that generated 20,000 pounds of thrust. In 2015, the FAA
cleared the first 3D-printed part for use in a commercial jet engine.
CFM's LEAP engine features 19 3D-printed fuel nozzles. At the 2017 Paris Air
Show, FAA-certified, Boeing 787 structural parts fabricated from titanium wire
were displayed, according to Aviation Week.
• Automotive
• CNN reported that the McLaren racing team is using 3D-printed parts in its
Formula 1 race cars. A rear wing replacement took about 10 days to produce
instead of five weeks. The team has already produced more than 50 different
parts using additive manufacturing. In the auto industry, AM's rapid prototyping
potential garners serious interest as production parts are appearing. For
example, aluminum alloys are used to produce exhaust pipes and pump parts,
and polymers are used to produce bumpers.

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Healthcare
• At the New York University School of Medicine, a clinical study of 300 patients will
evaluate the efficacy of patient-specific, multi-colored kidney cancer models using
additive manufacturing. The study will examine whether such models effectively assist
surgeons with pre-operative assessments and guidance during operations.
• Global medical device manufacturing company Stryker are funding a research project
in Australia that will use additive manufacturing technology to create custom, on-
demand 3D printed surgical implants for patients suffering from bone cancer.
In general, healthcare applications for additive manufacturing are expanding,
particularly as the safety and efficacy of AM-built medical devices is established. The
fabrication of one-of-a-kind synthetic organs also shows promise.
Product Development
As the potential for AM's design flexibility is realized, once impossible design concepts
are now being successfully re-imagined. Additive manufacturing unleashes the creative
potential of designers who can now operate free of the constraints under which they

once labored .

Chapter 8 Conclusion

LCD printing being one of the most recent technology in the market suffers from the high cost.
Companies manufacturing open source printers take undue advantage of this by selling it at
high prices. These printer can actually be build at a very low price as compared to actual printer
available in the market. We found From the literature study that The penetration of light follows
a Beer-Lambert relationship which helps us in deciding the specifications of the printer
From the force analysis we can conclude that minimum error of 30 micron in layer thickness
and 10 micron in 2D plane. Novel approach was taken to stabilize the structure in all terrains.
A common gyroscope called gimbal was modified for the stabilization of 3D printer.
.

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References.

1 Additive manufacturing aboard a moving vessel at sea using passively stabilized

stereolithography (SLA) 3D printing
2 Author links open overlay panelBrennan T.PhillipsabJoshAllderaGradyBolanaR.
3 SeanNagleaAllisonRedingtonaTessHellebrekerscJohnBordendNikolaiPawlenkoeStephen
Lichta
4 Measuring UV curing parameters of commercial photopolymers used in additive
manufacturing
5 Author links open overlay panelJoeBennett
6 3D printing of ceramics: A review Additive Manufacturing Institute, College of
Mechatronics and Control Engineering, Shenzhen University, Shenzhen, 518060, China
7 3D printing a mechanically-tunable acrylate resin on a commercial DLP-SLA printer
Cardiovascular Research Center at the Icahn School of Medicine at Mount Sinai Center,
United States.
8 https://collingwood.me.uk/blog/index.php/raspberry-pi-and-the-nanodlp-shield-v1-1/
9 https://www.3ders.org/articles/20160727-lcd-led-based-utopiaprinter-widens-the-door-to-
low-cost-diy-sla-3d-printing.html.

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