3D PRINTING

By

NAGENDRA KARANTH P
5WA11MDZ11 3rd Sem PDM,Mtech Under the guidance of

DR K J RATHANRAJ
DEPARTMENT OF PG STUDIES & RESEARCH CENTRE DEPARTMENT OF INDUSTRIAL ENGINEERING & MANAGEMENT B.M.S COLLEGE OF ENGINEERING VTU PG EXTENSION CENTRE BANGALORE-560019

OVERVIEW
INTRODUCTION GENERAL PRINCIPLES OF 3D PRINTING DIFFERENT TYPES OF 3D PRINTING TECHNOLOGY 3D PRINTING AND OTHER MANUFACTURING TECHNIQUE ADVANTAGES, LIMITATIONS AND APPLICATIONS 3D PRINTING IS GAME CHANGER? CONCLUSION
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INTRODUCTION

Additive manufacturing also known as 3D printing is defined by ASTM as the "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. The technology for printing physical 3D objects from digital data was first developed by Charles Hull in 1984. He named the technique as Stereo lithography and obtained a patent for the technique in 1986
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INTRODUCTION (contd)

Stereo lithography systems had become popular by the end of 1980s, other similar technologies such as Fused Deposition Modeling (FDM) andz Selective Laser Sintering (SLS) were introduced. In 1993, MIT patented another technology,named "3 Dimensional Printing techniques", which is similar to the inkjet technology used in 2D Printers.In 1996, three major products
"Genisys" from Stratasys, "Actua 2100" from 3D Systems and "Z402" from Z Corporation, were introduced.
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a)
b) c)

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In 2005, Z Corp. launched a breakthrough product, named Spectrum Z510, which was the first high definition color 3D Printer in the market. Another breakthrough in 3D Printing occurred in 2006 with the initiation of an open source project, named Reprap, which was aimed at developing a self-replicating 3D printer.

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Introduction (contd)

There are several technologies -differing mainly in the way layers are built to create parts. Some melt or soften material to produce layers (SLS, FDM), while others lay liquid materials thermosets that are cured with different technologies. Lamination systems cut thin layers to shape and join them together.
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Two important aspects distinguish 3-D printing from other rapid prototyping technologies.

The first distinction is cost. While a 3-D printer can cost as little as $2500, a rapid prototype machine can cost as much as $100000. Desktop 3-D printers now run from $2500 to more than $100,000. Current 3-D printer manufacturers include Zcorp Stratasys (www.stratasys.com), and 3D Systems (www.3dsystems.com) ]

The second major difference between these technologies is that 3-D printers seamlessly integrated with computerassisted design (CAD) software and other digital files like magnetic resonance imaging.
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GENERAL PRINCIPLES
With 3D Printing the machine reads in data from a CAD data and lays down successive layers of liquid, powder, or sheet material, and in this way builds up the model from a

series of cross sections

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Construction of a model with contemporary methods can take from several hours to several days, depending on the method used and the size and complexity of the model.
Some additive manufacturing techniques use two materials in the course of constructing parts. The first material is the part material and the second is the support material

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DIFFERENT TYPES OF 3D PRINTING TECHNOLOGY

1.3D Printing with color option

Fig:-ZCorp 650 3D Color Printer

In this type printer, to object made using ink jet technology in three dimensions. As its name implies it is a close cousin to traditional 2D printing. These printers work by layering powder a powder substrate and binding it with pigmented glue. This is the only 3D printing technology capable of printing in full color. The major manufacturer of this type 3D printing equipment is ZCorp.
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2.Fused Deposition Modeling

Fused Deposition Modeling (FDM) creates models by heating and extruding a filament of plastic material. Stratasys commercialized this technology and owns the trademark. It is one of the cheaper forms of 3D printing with systems starting at $5K.
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3.Stereo lithography

Stereolithography produces models by tracing a beam of UV light over a photosensitive pool of liquid. Over time the part is lowered into the bath and the final product is produced. The major benefit of this 3D printing technology is the high level of detail and surface finish it enables. Stereolithography technology also provides the most interesting product reveal. Once the part is done printing it is lifted elegantly out of the photopolymer solution
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4. Selective Laser Sintering

Selective Laser Sintering (SLS) is the awesome union of 3D printing and Lasers. The process is similar to stereolithography replacing the UV light with a laser and a vat of liquid with a powdered base. The major benefit of SLS is the ability to produce parts in a variety of materials ranging from plastics to ceramic to metals. In some case SLS technology can be used in lieu of more expensive tooling processes. The Sinterstation by 3D Systems is an example of this technology in practice. BMSCE,IEM DEPT 14 11/30/2013

3D PRINTING AND OTHER MANUFACTURING TECHNIQUE 1. 3-D printing and mass customization In 3-D printing argue that this technology similar to mass customization, it allows economically build custom products in smaller quantities While both processes are more profitable for limited-quantity lot sizes and share other benefits in terms of manufacturing technologies, logistics and producing special parts. materials in mass customization are typically component parts, whereas in 3-D printing uses such raw materials as plastics; resins; super alloys, such as nickel-based chromium and cobalt chrominium; stainless steel; titanium; polymers; and ceramics.
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3D printing and injection molding and cutting-based machinery technique

Advantages relate to cost effectiveness and speed. In contrast to injection molding processes that require costly molds, 3D printing entails relatively low fixed costs. Since 3D printing does not require expensive tooling, forms, or punches, it is particularly cost effective for very small production runs. This enables firms to profitably use 3D printing to economically fill custom orders and serve niche markets.

Elimination of setup time is possible with 3D printing Faster rate production.

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In comparison to subtractive technologies, which use multi-axis cutting machines to carve plastics and metals to the desired shape, there is less waste material with 3-D printing: no scrap, milling, or sanding. According to one source, the waste material in metal applications associated with 3-D printing is reduced by 40% in comparison to machining/subtractive technologies. In addition, 95% - 98% of waste material can be recycled in 3-D printing . Other sources state that subtractive technologies can remove as much as 96% of the raw material when creating a product.
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ADVANTAGES, LIMITATIONS AND APPLICATIONS

Can economically build custom products in small quantities as if mass production were used. Sources of cost effectiveness include: No need for costly tools, molds, or punches No scrap, milling, or sanding requirements Automated manufacturing Use of readily available supplies Ability to recycle waste material Minimal inventory risk as there is no unsold finished goods inventory Improved working capital management as goods are paid for before being manufactured Ability to easily share designs and outsource manufacturing Speed and ease of designing and modifying products
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Current limitations

Higher costs for large production run relative to injection molding and other technologies Reduced choice for materials, colors, and surface finishes Lower precision relative to other technologies Limited strength, resistance to heat and moisture, and color stability
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Applications
1. Product formation is currently the main use of 3D printing technology 2. In Medical Field, Surgeons are using 3D printing machines to print body parts for reference before complex surgeries 3. Architects need to create mockups of their designs 4. 3D printing allows artists to create objects that would be incredibly difficult, costly, or time intensive using traditional processes

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Continued

Based on their size of application

a) Small production runs applications of 3-D printing These applications are typically high-value objects that are either customized or produced in very small quantities. custom-made shoes can be designed specifically for an individual based on his/her foot size and walking gait Timberland used to spend roughly $1,200 and 1 week of time in designing a new sole for one of its shoe models. Using a 3-D printer, however, a model can be produced in 90 minutes for a cost of $35
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According to Alessi, an Italian manufacturer of high-quality housewares, 3-D printing cut 5 6 weeks from its new-product development process. It also costs Alessi about 70% less than the traditional method of making prototypes. According to the founder of a firm that specializes in architectural applications of 3-D printing, it used to take 2 months and $100,000 to build models; now, the firm is building $2,000 models in one evening with 3-D printing ideal technology for making replacement parts for washing machines and food processors, as well as camera lens accessories and small gears

within hours, a custom-made hearing aid shell can be produced from liquid photopolymer via 3-D printing
Dental labs are able to complete a dental restoration within 3 days of the intraoral scan
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b) Medium production run applications of 3-D printing In this category 3D printing is done simultaneously along with 3D model.3-D printing is also used in bridge manufacturing, bridging the time span from when a part design is complete and when the part is ready for mass production. Bridge manufacturing using 3-D printing is commonly employed when tooling operations are complex, costly, and time consuming

Caterpillar has used bridge manufacturing to make a new oil-filter assembly

The firm has also used 3-D printing to produce hundreds of wiring harness assemblies in between design completion and mass production readiness.

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3D PRINTING IS GAME CHANGER?

Today, 3-D printing works with plastics, resins, and metals, with a precision of around one-tenth of a millimeter As the prices of raw materials drop and material quality gets better, the use of 3-D technology will expand beyond its present scope. Applications that can increase include bridge manufacturing, to fill orders prior to product commercialization and to fill emergency orders; custom manufacturing for jewelry and hobby applications; parts for machinery and aircraft, where strength is a major issue; emergency shipments of parts; and situations where inventory carrying costs are high relative to production costs.
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contd

A secondary promise of 3-D printing lies in separation of product design from product manufacturing. As 3-D printing evolves, consumers will be able to purchase designs online and then build products at home. A large number of firms will soon offer CAD-CAM designs for downloading by final consumers, as well as retailers. These designs will enable final consumers to produce customized products at home and allow firms to produce replacement parts on an as-ordered basis

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Ultimately, 3D PRINTING has the potential to be as disruptive as the personal computer and the internet. The digitization of physical artifacts allows for global sharing and distribution of designed solutions. It enables crowd-sourced design (and individual fabrication) of physical hardware. It lowers the barriers to manufacturing, and allows everyone to become an entrepreneur.

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Contd

Uncertain pace of change over the next 20 Years!!??

At what point could a product as complex as an iPhone or a jet engine be printed in a single process?

There will also be the benefit of needing to print far fewer of a particular product because it is being manufactured closer to the consumer and on-demand benefits which may more than compensate for the cost-savings of mass production at one plant and global distribution from that production platform
Printing a few thousand iPhones on demand at a local facility that can manufacture many other products may be far more cost effective than manufacturing ten million identical iPhones in China and shipping them to 180 countries around the world.

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Contd

Advances in environmental protection and possible fundamental shift in the global economy

The transportation and manufacturing carbon footprint of many products could be reduced as designs, rather than products, are shipped around the world carbon footprint of the final product would be further reduced by scaling back or eliminating complex supply chains of parts produced by dozens if not hundreds of suppliers scattered around the globe localization of production could potentially reduce global economic imbalances as export countries surpluses are reduced and importing countries reliance on imports shrink with a new form of import substitution taking hold.

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Briefing all points

3D Printing helps in economic perspective. Reduce global economic imbalances. Use local materials that are more appropriate for local consumption, including recycled materials. Force relative decline in powerhouse production nations such as China, Japan and Germany that have built their prosperity and political power on export-led growth.

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Innovation-based Manufacturing through 3D Printing could:

Shift work-force requirements, with likely reduction in traditional manufacturing jobs Change economic power centers toward leaders in design and production of AM systems and in design of products to be printed

Fuel a renaissance in innovation, design, IP exports, and manufacturing in the U.S., Europe and OECD (Organization for Economic Co-operation and Development )countries Drive developing countries more rapidly toward becoming developed and less dependent on others

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CONCLUSION

3D Printing is on track to move beyond a mere emerging technology into a truly transformative technology

Even though the future is certainly hard to predict, prescience and advanced planning are necessary in preparation for the disruptive technology of 3D Printing.
The trend toward increasing competition for resources and even a zero-sum global economy could be slowed or reversed

In addition, international efforts to address environmental challenges, especially climate change, could receive a boost as the cost to take better or mitigating actions could be reduced There could be a geopolitical impact of 3D Printing in terms of economy and environment aspect. BMSCE,IEM DEPT 33 11/30/2013

REFERENCES

3-D printing: The new industrial revolution Published in Sciencedirect.com

Could 3D Printing Change the World? Strategic foresight report from Atlantic Council, Washington, October 2011
3D printing Technology http://nicsu.up.nic.in/knowdesk/3D-PrintingTechnology.pdf Different types of 3D printing http://replicatorinc.com/blog/2009/02/4-types-of-3dprinting/ Printer and ink related article. http://printerinkcartridges.printcountry.com
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