3D Printing Specifications and Software

Reporters:
Belocura, Kim
Sawit, Lheanmuel
Valentino, Aila

Introduction

3D printing, or additive manufacturing, is a process of creating three-dimensional

objects from a digital model by building them layer by layer. This technology is widely
used in industries such as aerospace, automotive, healthcare, and consumer
products due to its ability to produce complex geometries and reduce material waste.

Key Technologies in 3D Printing

1. Fused Deposition Modeling (FDM): Uses a thermoplastic filament that is

melted and deposited layer by layer to build objects.
2. Stereolithography (SLA): Utilizes a UV laser to cure liquid resin into solid
layers.
3. Selective Laser Sintering (SLS): Employs a laser to sinter powdered
material, such as plastics or metals, into solid objects​.

History

The 1980s: When Was 3D Printing Invented?

The first documented iterations of 3D printing can be traced back to the early
1980s in Japan. In 1981, Hideo Kodama was trying to find a way to develop a rapid
prototyping system. He came up with a layer-by-layer approach for manufacturing,
using a photosensitive resin that was polymerized by UV light.

Although Kodama was unable to file the patent requirement of this technology, he is
most often credited as being the first inventor of this manufacturing system, which is
an early version of the modern SLA machine.

Across the world a few years later, a trio of French researchers was also seeking to
create a rapid prototyping machine. Instead of resin, they sought to create a system
that cured liquid monomers into solids by using a laser.

Similar to Kodama, they were unable to file a patent for this technology, but they are
still credited with coming up with the system.
That same year, Charles Hull, filed the first patent for Stereolithography (SLA). An
American furniture builder who was frustrated with not being able to easily create
small custom parts, Hull developed a system for creating 3D models by curing
photosensitive resin layer by layer.

In 1986 he submitted his patent application for the technology, and in 1988 he went
on to found the 3D Systems Corporation. The first commercial SLA 3D printer, the
SLA-1, was released by his company in 1988.

But SLA wasn’t the only additive manufacturing process being explored during this
time.

In 1988, Carl Deckard at the University of Texas filed the patent for Selective Laser
Sintering (SLS) technology. This system fused powders, instead of liquid, using a
laser.

Fused Deposition Modeling (FDM) was also patented around the same time by Scott
Crump. FDM, also called Fused Filament Fabrication, differs from SLS and SLA in
that rather than using light, the filament is directly extruded from a heated nozzle.
FFF technology has gone on to become the most common form of 3D printing we
see today.

These three technologies are not the only types of 3D printing methods that exist.
But, they are the three that serve as the building blocks that would lay the
groundwork for the technology to grow and for the industry to be disrupted.

1990-2010: Growth

In the 90s, many companies and startups began popping up and

experimenting with the different additive manufacturing technologies. In 2006, the
first commercially available SLS printer was released, changing the game in terms of
creating on-demand manufacturing of industrial parts.

CAD tools also became more available at this time, allowing people to develop 3D
models on their computers. This is one of the most important tools in the early
stages of creating a 3D print.

During this time, the machines were very different from those that we use now. They
were difficult to use, expensive, and many of the final prints required a lot of
post-processing. But innovations were happening every day and discoveries,
methods, and practices were being refined and invented.

Then, in 2005, Open Source changed the game for 3D printing, giving people more
access to this technology. Dr. Adrian Bowyer created the RepRap Project, which was
an open-source initiative to create a 3D printer that could build another 3D printer,
along with other 3D printed objects.
In 2008, the first prosthetic leg was printed, propelling 3D printing into the spotlight
and introducing the term to millions across the globe.

Then, in 2009, the FDM patents filed in the 80s fell into the public domain, altering
the history of 3D printing and opening the door for innovation. Because the
technology was now more available to new companies and competition, the prices of
3D printers began to decrease and 3D printing became more and more accessible.

3D Printing Now

In the 2010s, the prices of 3D printers started to decline, making them

available to the general public. Along with the lowering prices, the quality and ease
of printing also increased.

The materials that printers use have also evolved. Now there are a variety of plastics
and filaments that are widely available. Materials like Carbon Fiber and Glass Fiber
can also be 3D printed. Some creatives are even experimenting with printing
materials like chocolate or pasta!

In 2019, the world’s largest functional 3D printed building was completed. 3D printing
is now consistently used in developing hearing aids and other healthcare
applications, and many industries and sectors have adopted the technology into their
everyday workflow.

It’s safe to say that the history of 3D printing is still being written.

Significance of 3D Printing Software

Software plays a critical role in 3D printing, transforming designs into executable

instructions for the printer. This process involves Computer-Aided Design (CAD),
slicing, and sometimes simulation software to ensure optimal results​.

Together, specifications and software form the backbone of 3D printing technology,

driving advancements across a range of industries. Specifications ensure that the
hardware performs at its best, while software adds intelligence, flexibility, and control
to the process. This synergy enables the creation of high-quality, efficient, and
innovative products, revolutionizing the way we think about manufacturing and
design.
Foundations of 3D Printing Technology

1. Additive vs. Subtractive Manufacturing

- Additive manufacturing builds objects layer by layer, minimizing material
waste.
- Subtractive manufacturing removes material from a larger block (e.g., CNC
machining)​.

2. Material Properties
- Thermoplastics like PLA and ABS are common, each requiring specific
temperature ranges.
- Advanced materials like metals or resins are used for specialized applications​.

3. Resolution and Layer Height

- Defines the level of detail in the printed object. Lower layer heights (e.g., 0.1
mm) produce finer details but increase printing time​.

Key Terminologies

1. Slicing

The process of converting a 3D model into horizontal layers for printing. This
is done using slicing software like Cura or Simplify3D​.

2. G-Code

The programming language used to direct the 3D printer’s movements,

temperature settings, and other parameters​.

3. Build Volume

The maximum size of the object that a printer can produce, determined by the
printer’s physical dimensions​.

4. Infill

The internal structure of the printed object, which can vary in density to
balance strength and material use​.

5. Nozzle Diameter
 Determines the thickness of the extruded material. Common sizes are 0.4
mm, but they can range from 0.2 mm to 1 mm​.

6. Support Structures

Temporary materials used to support overhanging parts during printing. These

are removed after the object is complete​.

7. Thermoplastics

Common materials used in 3D printing, such as PLA, ABS, PETG, and TPU.
Each has unique properties suitable for different applications​.

Software for 3D Printing

1. CAD Software

Used to design 3D models.

Examples: AutoCAD, SolidWorks, and Fusion 360.

2. Slicing Software

Converts CAD files into printable instructions.

Examples: Ultimaker Cura, PrusaSlicer, and Simplify3D​.

3. Simulation Software

Helps visualize and optimize prints before actual production.

Examples: ANSYS Additive Suite, Autodesk Netfabb.

By understanding these fundamental concepts, terminologies, and software

applications, you can effectively plan and execute 3D printing projects tailored to
specific requirements.

Practical Applications in Various Industries

1. Healthcare
- Customized prosthetics, dental implants, and tissue engineering (bio-printing).

2. Automotive and Aerospace

 - Lightweight components, rapid prototyping, and on-demand spare parts.

3. Consumer Goods
- Jewelry, fashion, and customized home décor​.

Challenges in 3D Printing

1. Material Limitations
- Limited availability of advanced materials for specific applications.

2. Surface Finish
- Post-processing is often needed to achieve smooth surfaces.

3. Time and Cost

- Although it's faster than traditional manufacturing for prototyping, large-scale
production can still be expensive​.

Experiments and Videos

Summary

3D printing is a cutting-edge technology that has transformed modern manufacturing,

offering unparalleled design flexibility, reduced material waste, and faster prototyping
capabilities. By understanding its specifications and leveraging advanced software
tools, users can achieve precision and efficiency in diverse applications.
References:

https://www.bcn3d.com/the-history-of-3d-printing-when-was-3d-printing-invented/

https://www.3dsourced.com/rigid-ink/ultimate-3d-printing-glossary/

https://www.xometry.com/resources/3d-printing/3d-printing-guide/

https://www.protolabs.com/en-gb/resources/blog/an-a-to-z-guide-of-3d-printing-termi
nology/