3D Printing

Skill Development Presentation

Fundamentals

THE WONDER OF 3D
PRINTING
First Industrial Revolution

Kaizen

The first industrial revolution “began in

Britain in the late 18th century, with the
mechanisation of the textile industry.

Source: http://www.kish.in/the_industrial_revolution/
Second Industrial Revolution

The “second industrial revolution came in the early 20th century, when Henry Ford
mastered the moving assembly line and ushered in the age of mass production.”
Next Industrial Revolution

The third revolution “is under way” and that

consists of manufacturing “going digital.”
A quick overview!

ADDITIVE MANUFACTURING
Additive Manufacturing

Have you heard of these terms?

• 3D Printing
• Additive manufacturing
• Rapid prototyping
• Rapid manufacturing
• Direct manufacturing

All refer to what's called “Additive Manufacturing”

What is Additive Manufacturing

Additive Manufacturing by ASTM (American Society for Testing and Materials ):

“Process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed
to subtractive manufacturing methodologies, such as traditional machining”
What is Additive Manufacturing

• 3D printing – A future where your printer connected to a desktop is

capable of printing a solid object. It’s a process of crafting three
dimensional robust objects from a digital file using additive processes.
An object is created by positioning consecutive layers of material until
the whole object is shaped.
• It is also known as rapid prototyping, a mechanized method where 3D
objects are quickly made on a reasonably sized machine connected to a
computer containing blueprints for the object.
What is Additive Manufacturing

Rapid Prototyping: This term was used in the beginning of the professional use of the technology because
the main application was the manufacturing of prototypes, mock ups and sample parts.

Todays most common terminologies are:

ADDITIVE MANUFACTURING (AM) or 3D PRINTING
What is Additive Manufacturing

• Generate a 3D model
• Software slices the 3D model into thin slices
• Machine builds it layer by layer
Evolution of AM

• This technology is roughly 30 years old

 Manufacturing

Additive Subtractive
Subtractive Manufacturing
Subtractive Manufacturing
– Milling
– Turning
– Drilling
– Computer Numerical Control (CNC)
Machine
 Why 3D Printing is exciting

• According to some futurists, 3D printing is opening up a whole new

world which will make life as we know it today barely noticeable in the
next few decades.
• 3D printers in the hands of consumers will mean the end of
standardization, and the beginning of products personalized to every
individual which helps to create a world where the products we buy
have a better fit, a better match to one’s personal style.
• It’s an amazing explosion of creativity, personal aiding, global
connectivity and disruptive innovation in the material world.

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A quick overview!

WELCOME TO 3D PRINTING
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3D Printing

• 3D Printing can be a household thing in near

future. No doubt, you might have heard
about 3D Printing more often nowadays.
• The technology is deemed to be a catalyst for
another industrial revolution.
• The days when 3D printing will be used for
mass productions in manufacturing sector
may not be far.
• 3D Printing, which has been in
the industry since the late 1980s is bound to
leap beyond modelling and prototyping
application.
What is 3D Printing?

• A form of Additive Manufacturing

– Process of joining materials to make an object
from 3D model Data; layer-by-layer process
What is 3D Printing?

• Digital Fabrication
- it takes a model
└a digital design
└turn into real,

physical Object
Fundamentals

HOW DOES 3D PRINTING WORK?

How Does 3D Printing Works?
• This is an industrial process of making three dimensional solid objects from a digital file.
• A product designer or engineer creates a 3D Model of a product in CAD software and 3D
printers print them layer by layer thereby creating a real three-dimensional object.
• The whole process from CAD modelling to printing is digital, free-form and computer
controlled.
• This can be a common manufacturing process any soon and real products will be
manufactured just by feeding 3D CAD Models to the new generation 3D Printers in the
near future.
How Does 3D Printing Works?
• 3D Printing is a digital process. The 3D Models of
any object in the form of STL (Stereolithography) or
OBJ (object) files are digital files created on a CAD
software.
• The printing is done layer by layer bottom to up on
a base where each layer in the form of a digital
code is sliced from the STL or OBJ file.
• Here, each layer is actually a deposition of
fabricating material on the base in a digitally
defined and computer-controlled manner.
• The digital code of STL or OBJ file determines where
the fabricating material is to be deposited within a
layer and in what quantity and proportion.
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 How Does 3D Printing Works?

• One can imagine each layer as a 2D plane where the adhesive material used for
making the object is deposited in a specific quantity at specific points of the two-
dimensional plane and gets solidified on instant cooling just like pixels are
aggregated to form a 2D image on a digital display.
• The complete 3D object is created by printing several layers on the top of one after
the other.
• The printing is carried out by using additive materials so each layer cements with the
successive layer.
• Therefore, a layer by layer deposition of additive material in a digitally controlled
manner creates a real 3D object.
• Since the object is created from a digital file, the shape, size, and design of the object
can be controlled offering immense scalability.
If it exists since the 1980s, Why it is yet not a common
industrial phenomenon?
There are three major reasons behind this.
• 3D printers are slow! yes, they do create
real 3D objects. But still, it takes hours for
a 3D printer to fabricate a single
prototype or item.
• The prototypes or objects created from
current 3D printers have mechanical
defects. The printing process is not
error-free.
• The material choices are right now
limited to plastics and the real products
are not just fabricated from plastics only.
Why Should You Take Interest in 3D Printing?
• The 3D Printing is still widely used in modelling and
prototyping of products. If you are looking towards a
career in product design and engineering, you must have
a keen eye on all changes and innovations, the 3D
printing is going on.
• Despite mechanical errors and slow operating speeds,
3D printing is a great tool for modelling, prototyping
and testing real product designs.
• Large corporate and manufacturers use the technology
for modelling of their products, creating new prototypes
and real-life testing of these prototypes for their
upcoming products.
• The cost to have a 3D printer has greatly reduced and MakerBot 3D Printer for Rapid Prototyping
one can easily get a low-cost 3D printer for the lab if one
is willing to tweak around with mechanical design of
some could-be products of the future.
Why Should You Take Interest in 3D Printing?

• One can even contribute to the

technology by making a 3D printer of his
own. Many college students and
innovators have successfully strived into
making better 3D printers.
• There are three major components of
the technology -
1. 3D CAD Modelling
2. Slicing and Printer Settings
3. Physical Printing
Fundamentals

CATEGORIES OF 3D PRINTING
Seven Categories of 3D Printing
In 2010, American Society for Testing and Materials (ASTM) group “ASTM F42 – Additive
Manufacturing” acknowledged seven categories of additive manufacturing.

1. Material Extrusion (This is the most common 3D Printing method)

2. Vat Photopolymerisation
3. Binder Jetting
4. Powder Bed Fusion
5. Directed Energy Deposition
6. Material Jetting
7. Sheet Lamination
How far Can You Go with 3D Printing?
• Definitely, additive printing may soon find
application in regular manufacturing.
• From medical industry (Bio-Printing is a form of
3D printing used for medicines), automotives
and aerospace to civil construction, textiles,
defence manufacturing and robotics, 3D
printing is currently used in the wide span of
industries for pre-testing product or parts
designs.
• Definitely, 3D printing will be the face of next
industrial revolution.
3D Printed Models and Prototypes
AM Market size
AM Market size
Advantages

• Additive Manufacturing • Traditional Manufacturing

– Design complexity – Mass Production
– Speed to Market – Choice of materials
– Waste Reduction – Manufacturing large parts
 Thank You
For any Training and Consulting for your business,
please mail me at laxminarayanan.g@iiml.org

www.linkedin.com/in/iimconsultant

+91 99400 20019

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