3D PRINTING (ADDITIVE MANUFACTURING)

SHIVAJI SAGAR, DEPARTMENT COORDINATOR, MECHANICAL ENGG, ASET, AMITY UNIVERSITY MUMBAI
INTRODUCTION

 3D printing or additive manufacturing is a process of making three dimensional solid objects from a digital file.
 The creation of a 3D printed object is achieved using additive processes.
 In an additive process an object is created by laying down successive layers of material until the entire object is
created.
HISTORY

 The process of 3D printing was evolved way back in 70’s but became quite popular in past decade.
 The reason behind this was the set up required to carry out this process was costly compared to other
conventional process.
 But as time passed by the low cost machines were developed also the patent’s regarding this process expired in
90’s.
 Due to the versatility of printing different types of objects, this technique was attracted by the manufacturers and
researchers.
 WORKING (FORMING 3D PRINTABLE MODEL)

 A printable model can be formed either by using a computer Aided

Designing software package or using a 3D scanner.
 The CAD software might be used to form a design of a model
according to user input.
 While a 3D scanner is an industrial robot which scans a particular
object and records it’s dimensions and provides input to the printer.
 But there are some common features for all Addictive Manufacturing,
such as usage of computer together with special 3D modelling
software.
 PRINTING THE MODEL
 Depending on the design data provided the printer lays down several layers of powder, liquid, paper, polymer, plastic
or other material depending on the material required.
 Printer resolution describes layer thickness and X-Y resolution in micrometers.
 3D printers give designers and concept development teams the ability to produce parts and concept models using a
desktop size printer.
 FINISHING OF THE MODEL

 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 .
 In this process the supports would be dissolved which might be used to support overhanging features in the model
to be printed.
 TYPES OF 3D PRINTERS

 Stereolithography (SLA)
 Digital Light Processing(DLP)
 Fused deposition modeling (FDM)
 Selective Laser Sintering (SLS)
 Selective laser melting (SLM)
 Electronic Beam Melting (EBM)
 Laminated Object Manufacturing (LOM)
 STEREOLITHOGRAPHY (SLA)

 Very high end technology utilizing laser technology to cure

layer-upon-layer of photopolymer resin (polymer that
changes properties when exposed to light).
 The build occurs in a pool of resin. A laser beam, directed
into the pool of resin, traces the cross-section pattern of the
model for that particular layer and cures it.
 During the build cycle, the platform on which the build is
repositioned, lowering by a single layer thickness. The
process repeats until the build or model is completed and
fascinating to watch.
 Specialized material may be needed to add support to some
model features. Models can be machined and used as
patterns for injection molding, thermoforming or other
casting processes.
 DIGITAL LIGHT PROCESSING(DLP)

 It uses digital micro mirrors laid out on a semiconductor chip. The technology
is applicable for movie projectors, cell phones and 3D printing.
 For 3D printing DLP as well as SLA works with photopolymers. DLP 3D
amateurs generally use more conventional sources of lights such as arc lamps.
The other important piece of process is a liquid crystal display panel, that is
being applied to the whole surface of building material during single run of
DLP process.
 The material to be used for printing is liquid plastic resin that is placed in the
transparent resin container. The resin hardens quickly when affected by large
amount of light.
 The printing speed is pretty impressive. The layer of hardened material can be
created with such printer in few seconds. When the layer is finished, it’s
moved up and the next layer is started to be worked on.
 The results of such printing are robust and have excellent resolution. Big
advantage of DLP over SL is much less materials to be used for detail
production, that results in lower cost and less waste.
FUSED DEPOSITION MODELING (FDM)

 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 and the head can be moved in both
horizontal and vertical directions.
 Various polymers are used, ncluding acrylonitrile butadiene styrene(ABS),
polycarbonate(PC), polylacticacid (PLA),high density polyethylene (HDPE),
PC/ABS, and polyphenylsulfone (PPSU). In general the polymer is in the form
of a filament, fabricated from virgin resins.
 SELECTIVE LASER SINTERING (SLS)

 It’s a 3D printing technique that uses high power CO2 lasers to fuse particles together.
 The laser sinters powdered metal materials (though it can utilize other materials too, like white nylon powder,
ceramics and even glass)
 SELECTIVE LASER MELTING
 It does not use sintering for the fusion of powder granules but will completely melt the powder using a high-energy
laser to create fully dense materials in a layerwise method with similar mechanical properties to conventional
manufactured metals.
 ELECTRON BEAM MELTING (EBM)
 The same as SLM, this 3d printing method is a powder bed
fusion technique. While SLM uses high-power laser beam as its
power source, EBM uses an electron beam instead, which is the
main difference between these two methods. The rest of the
processes is pretty similar.
 The material used in EBM is metal powder that melts and
forms a 3D part layer by layer by means of a computer, that
controls electron beam in high vacuum. Contrary to SLS, EBM
goes for full melting of the metal powder. The process is usually
conducted under high temperature up to 1000 °C.
 Comparing to SLM the process of EBM is rather slow and
expensive, also the availability of materials is limited. So the
method is not so popular though still used in some
of manufacturing processes. Currently the most well spread
materials that are used for EBM are commercially pure
Titanium, Inconel 718 and Inconel 625. The application of EBM
is mainly focused on medical implants and aerospace area.
 LAMINATED OBJECT MANUFACTURING (LOM)
 Laminated object manufacturing (LOM) is one more rapid prototyping system that
was developed by the California-based company Helisys Inc.
 During the LOM process, layers of adhesive-coated paper, plastic or metal laminates
are fused together using heat and pressure and then cut to shape with a computer
controlled laser or knife.
 Layers of adhesive-coated paper, plastic or metal laminates are fused together using
heat and pressure and then cut to shape with a computer controlled laser or knife.
 After the layer is finished, the platform is moved down by about one-sixteenth of
an inch. A new sheet of the material is pulled across substrate and adhered to it
with a heated roller.
 The process is repeated over and over again until 3D part if fully printed. When any
excess material has been cut the part can be sanded or sealed with a paint.
 LOM is not the most popular 3D printing method but one of the most affordable
and fastest.
 The cost of printing is low due to low cost raw materials.
CONCLUSION

 3D printing is an important emerging manufacturing process with which the companies should get familiar to
remain in competition in future.
 Though this technique is not good enough from mass production point of view, but manufacturing some complex
items which instead would take many days in workshop can be created using this technique.
 Many low cost 3D printers and their designs are now available in market .
 Fields like aerospace industry, automobile industry, civil structure, medical aids, defence , even household things
are welcoming this technique happily.
 The studies regarding this process is being made in many universities to make this process more popular and user
friendly.
 Components like guns, microphones, teeth, bones, pipes and many more are successfully manufactured using this
process till date.
 THANK YOU

Contact For Further

Information/Assistance:
Email: sssagar@mum.amity.edu
Phone: +91-9043807271