Digital Assignment 1

Name: Prajari Ghosh

Reg. No.: 17BME1290

 Aerospace
The Aerospace industry is a great example of utilization Additive Manufacturing
(AM) (commonly referred to as 3D Printing) with a clear value proposition and the
ability to create parts that are stronger and lighter than parts made using traditional
manufacturing.

The table below summarizes the recommended materials for applications specific
to the aerospace industry:
Case study - Production of Satellite Parts

Currently satellites include geometrically specific brackets that link the body of the
satellite with reflectors and feeder facilities mounted at each end. Engineers at
Airbus in its Defense and Space division faced two key challenges regarding the
construction of the brackets:

Primarily, the brackets must affix the component securely to the satellite’s body.
Secondly, the main function of the brackets is to mitigate the vast temperature
fluctuations experienced outside of earth’s atmosphere.

The brackets are critical functioning as an insulating component: the temperature

ranges from –170 to +100°C, hence, the stress on the part is extremely high. Very
few materials are able to meet these requirements. However, as often the case in
the aviation and aerospace industry, titanium turned out to be the engineer’s
choice.
The end result ended up covering the entire spectrum of the advantages of 3D
printing as an alternative to traditional manufacturing:

I. Utilized premium material with little waste = cost savings

II. Part consolidation = fewer man hours required for assembly
III. Optimised geometry = higher performance designs not subject to traditional
constraints
IV. Lightweight components = fuel savings over the life of the project

From technical advantages to targeted cost reductions, many milestones were

achieved: savings purely in production were more than 20%. Additionally, the
engineers successfully decreased part mass: the weight advantage is over 300 g,
which means nearly one-kilogram reduction per satellite.

 Automotive
Additive manufacturing is already being used to great effect in the automotive industry, but
experts predict that the new of this technology will explode even further in the near future. A cost
effective option, additive manufacturing offers a possibility for even small producers to be able to
create new parts and keep up with the market.
Unlike more traditional types of engineering and design, the process enables the production of
automotive components far more quickly. The lengthy design process can be vastly shortened,
with simply a click of the mouse to change part of the model.
This allows parts to get out onto the market far more quickly and also enables changes to be made
with the minimum of fuss.

Different manufacturers might choose to use the available technology in different ways, but there
are a number of different components which could be produced by this method.
Exhausts and emissions
Aluminium alloys are typically used for this application, via selective laser melting to create
cooling vents.
Fluid handling
Selective laser melting and electron beam melting are utilised with aluminium alloys. These
techniques can be used to make pumps and valves within the fluid handling system.
Exterior
Using selective laser sintering, polymers are currently used to manufacture wind breakers and
bumpers.
Manufacturing process
Hot work steels and polymers can be used together with a variety of additive manufacturing
processes such as selective laser sintering, selective laser melting and fused deposition modelling
for prototypes, casting and customised tooling.
The above uses in the automotive industry are used from both small companies and large
international conglomerates.

Case Study-
Renishaw produces a prototype nose tip for the BLOODHOUND Supersonic
car

BLOODHOUND's aim is not only to break the sound barrier but also to be the first land vehicle to
exceed 1000 miles per hour (1609 km/hr) - at this speed it will be travelling the length of 4.5 football
pitches every second.

Background

BLOODHOUND and Renishaw have collaborated to produce a prototype for a

critical component of the Supersonic Car.
The majority of the cockpit and nose is made from carbon fibre reinforced epoxy.
During the record attempt the car will experience more than 20000 kg of skin drag.
However as the nose tip is on the ‘leading edge' it will experience a greater
proportion of this load; up to 12000 kg/m².
Extremely good accuracy of complex surfaces

Although the outer surfaces of the polyhedron appear flat, there are in fact subtle
curves which contribute to the aerodynamics. Renishaw calibrates its laser which
makes the part to an accuracy of ± 50 µm over the 250 mm bed so is able to
reproduce accurately the geometry in the CAD model.
Hollow taper

The hollow pocket depth is 130 mm, and tapers. If the nose tip is to be machined,
as a deeper cut is made, a thicker cutter is required to maintain stiffness and this
dictates the shape that can be made. With additive manufacturing, although some
design rules apply, there is much more scope to manufacture novel shapes with
ease.
Titanium alloy, minimal waste

Titanium alloy, Ti-6Al-4V, is easily processed using additive manufacturing, and

complexity can be built in at no additional cost. Exotic materials take the same
time to process as more standard materials, and, as only the material required is
consumed, it may be more cost effective than expected. The honeycomb internal
structure is more complex than a uniform wall and uses less material so is cheaper
to manufacture.

Strong design

The hexagonal honeycomb is an intrinsically strong design; to manufacture this on

internal surfaces would be very difficult in any other way. Currently, physical
manufacturing capabilities outstrip digital design capabilities. Software is rapidly
improving to capitalise on this new design potential - expect to see more designs
inspired by nature (some of the best qualified), as well as iterative methods such as
topological optimisation.
Production ready

Although great for prototypes, Renishaw is keen to emphasise that this technology
can also provide a production-ready solution and currently uses it in-house to
manufacture dental implant bridges and custom dental abutments, as well as mould
tool inserts. The parts are ‘fully dense', that is to say better than castings, greater
than 99.5%, and suitable for many applications. Hot Isostatic Pressing (HIP) is a
well-established post processing technology which can be employed to ensure
density and further improve material properties. This can be used if parts are likely
to be pushed to their design limit.
 Smart solutions

Renishaw provides a design review service to anyone considering Renishaw's laser

melting systems as a production solution. Your component or assembly will be
reviewed by Renishaw's applications engineers who can make recommendations
on DfM (Design for Manufacture), digitally process the model, and grow a sample
component in one of the on-site AM250 machines. A pre-build report, inspection
report, and component price estimate can also be provided on request.

 Biomedical
3D printing has many functions in a variety of industries, however, in the medical field it has
four main applications. Allie Nawrat found out how this technology could be used to replace
human organ transplants, speed up surgical procedures, produce cheaper versions of required
surgical tools, and improve the lives of those reliant on prosthetic limbs.

There are four core uses of 3D printing in the medical field that are associated with recent
innovations: creating tissues and organoids, surgical tools, patient-specific surgical models
and custom-made prosthetics.

I. Bioprinting tissues and organoids

One of the many types of 3D printing that is used in the medical device field is bioprinting.
Rather than printing using plastic or metal, bioprinters use a computer-guided pipette to layer
living cells, referred to as bio-ink, on top of one another to create artificial living tissue in a
laboratory.

These tissue constructs or organoids can be used for medical research as they mimic organs
on a miniature scale. They are also being trialled as cheaper alternatives to human organ
transplants.

II. Surgery preparation assisted by the use of 3D printed models

Another application of 3D printing in the medical field is creating patient-specific organ

replicas that surgeons can be use to practice on before performing complicated operations.
This technique has been proven to speed up procedures and minimise trauma for patients.

This type of procedure has been performed successfully in surgeries ranging from a full-face
transplant to spinal procedures and is beginning to become routine practice.

III. 3D printing of surgical instruments

Sterile surgical instruments, such as forceps, hemostats, scalpel handles and clamps, can be
produced using 3D printers.
 Not only does 3D printing produce sterile tools, some are based on the ancient Japanese
practice of origami, meaning they are precise and can be made very small. These instruments
can be used to operate on tiny areas without causing unnecessary extra damage to the patient.

One of the main benefits of using 3D printing rather than traditional manufacturing methods
to produce surgical instruments is the production costs are significantly lower.

IV. Custom-made prosthetics using 3D printing

3D printing in the medical field can be used to produce prosthetic limbs that are customised
to suit and fit the wearer. It is common for amputees to wait weeks or months to receive
prosthetics through the traditional route; however, 3D printing significantly speeds up the
process, as well as creating much cheaper products that offer patients the same functionality
as traditionally manufactured prosthetics.

The lower price point of these products makes them particularly applicable for use with
children, who quickly outgrow their prosthetic limbs.
Case Study:
Additive manufacturing for spinal implants

Global engineering company, Renishaw, collaborated with two innovative technology

companies to demonstrate the capability of metal additive manufacturing (AM) technology to
produce lightweight spinal implants that mimic the mechanical properties of bone. As part of
the project, manufacturing research organisation Irish Manufacturing Research (IMR)
designed and manufactured a series of representative spinal implants. IMR designed the
implants using software from nTopology and produced them on a Renishaw RenAM 500M
metal AM system.
Renishaw, IMR and nTopology joined forces to produce implants for the cervical spine (c
spine) that incorporate lattice structures using AM. The project name for the implant type
being Anterior, Cervical, Interbody Device, or ACID.
First, IMR created a design envelope to identify the unique opportunities presented by AM to
improve patient outcomes. nTopology then provided the software needed to design the
complex geometry of the spinal implants and Renishaw's RenAM 500M machine was used to
manufacture the implants using AM.
IMR conducted extensive research to identify the appropriate dimensions for the specified
case and the loading conditions the implants must withstand in day to day life. And also in
extreme situations such as running or jumping. This data was combined with the known
material properties of bone in patients with diseases known to create the need for a spinal
implant. The three companies then worked together to design the mechanical characteristics
of the device, which are largely a function of the geometry of the unit cells used in the lattice
structure, to achieve mechanical properties closer to those of human bone and to optimise the
porous lattice for osseointegration.
Once the design parameters for the implants were decided, IMR produced the design files
using nTop Platform. nTopology and Renishaw worked together closely to ensure their
products were compatible, so that a design could be seamlessly translated from the nTop
Platform to the RenAM 500M.
IMR then used the RenAM 500M to produce prototypes from grade 23 titanium (Ti 6Al-4V
ELI).

 Jewellery

By using 3D digital and 3D printing technology, the transformation from traditional

production model to digital and rapid jewelry production solution in jewelry industry could
be realized.
The applications of 3D printing technology in jewelry industry are listed as follows:
I. Design communication and demonstration: make enough models rapidly for
assessment by 3D printing equipment at the beginning of design stage of product,
it not only saves time but also reduces design defect.

II. Assembly test and function test: realize the targets that function of product is
improved, cost of production is reduced, quality is better and market acceptance of
product is promoted.
III. Meet the customization demand of personalized product: with the
characteristic of high efficiency, 3D printer could help buyer make quick response
to the demand of customer’s customization and seize the high-end market, such as
jewelry customization.
IV. Produce jewelry parts directly: since 3D printing technology more and more
popular applied, amazing jewelry products began to emerge endlessly, such as 3D
 printed jewelry, costume appeared in several international fashion weeks, which
impressed people greatly and bring people a wonderful world.
V. Use printed wax model in lost wax casting: with the aids of 3D printing
technology, it could omit complicated manual steps and speed up the production
of wax models.

Case Study:

Produce The Primary Model For Fine Jewelry Faster

With 3D Printing
By profession, Victor Tsai is an assistant professor of design at the Shu Te
University in Kaohsiung (Taiwan). He has been lecturing on 3D jewelry design for
many years. He is a tech-savvy jewelry designer by nature, whose passion and
efforts in the design and creation of jewelry is supported through the use of 3D
printing technology.
He understands the various SLA & DLP printer technologies and is familiar with
the various types of resins and ABS/PLA materials currently available. He has
published three tutorial books on 3D jewelry design with RhinoGold 3D software.
Since he was first exposed to and experimented with 3D printing in 2007, he has
been inspired by what this new technology could achieve. He believes that as this
technology will eventually be available to everyone as it becomes more widely
used and implemented.
 CHALLENGES / NEEDS

Although Victor appreciates that 3D printing produces jewelry in a smaller timeframe with
fewer errors compared to traditional methods, he is seeking a 3D printer that can improve
print quality and user experience. In terms of quality, he hopes for smooth surfaces on
prototypes without visible traces of printing layers. Printing traces on prototypes transfer to
the metal replica, leaving visible marks and resulting in unnecessary time loss and material
waste.
The prototype printed (left) shows traces of printed layers which will be duplicated to the primary
model (right) through the casting process.

 SOLUTIONS

Victor has recently selected the CastPro100 xP as the printer he will use to create the models
and printed examples in his third tutorial book on 3D printing technology and design.
Based on DLP® technology, the CastPro100 xP comes with in-house materials that are
created especially for high quality applications requiring meticulous detail. Besides providing
high printing quality, it also provides users with an improved process experience, from design
to finalization. CastPro100 xP’s software also automatically creates support structures for
objects when prompted, saving time and ensuring that delicate designs aren‘t damaged during
extraction and handling.

The
support structure is automatically added to the 3D file. The piece of jewelry and the support structure
are printed simultaneously, saving the user time from doing it manually.
RESULTS

The result produced by the CastPro100 xP far exceeded Victor’s expectations. Not only were
there no traces of printing layers, the support structures created for models were very thin and
easy to remove, something which is impossible through the use of traditional handcrafting
methods alone.
The CastPro100 xP also allowed Victor begin the printing process much faster using the
automatically-created support structure function within the software. These structures can be
easily removed without destroying the printed design structure and eliminated the need for
additional finishing and post-processing tasks. The biggest surprise for Victor was the overall
cost of ownership, which is very competitive compared to similar offerings in the industry.
The CastPro100 xP is the ideal 3D printer for jewelry designers, as its relative affordability
allows most jewelry designers to own and operate one.

The prototype printed with CastPro100 xP has a smooth surface without any traces of printed layers,
eliminating efforts to sand away traces.

CastPro100 xP creates a thin support structure which can be easily removed, avoiding damage to the
design structure during the removal process.
  Consumer electronics
Although 3D printing electronics is still in its infancy, customised electronic enclosures, USB
stick cases and keyboards are already a reality. 3D printing can be used to create electronic
enclosures with a personalised touch, with complex shapes and various colours, graphics and
sizes available.
Dutch 3D configurator company, Moogue, has already seen success in this area, providing
customers the opportunity to create their own customised 3D-printed phone cases. Customers
are able to choose between a wide range of colours, images and patterns, and then get their
unique designs 3D printed.
Looking way ahead, it is also possible to envision a future in which consumer
electronic products are entirely 3D printed: including the casing and electronic
components. This will require an advanced multi-material printing technology that is
capable of depositing plastic material for the enclosures as well as conductive and
insulating materials for the embedded PCBs.

Csae Study-

Recently, researchers from the University of California San Diego made headway on a
project in which they are using Stratasys’ Objet350 Connex 3 multi-material 3D
printing to produce a soft robotic form with electronic properties. These researchers
relied on existing materials (one carbon-reinforced material has weak conductive
properties), but they have shown that if more conductive materials come to market, it
could be possible to print embedded sensors and electronics into 3D printed objects.
  Home Appliances
The advent of 3D printing technology has already had a major effect on the kitchen
equipment and appliance industry. After all, the possibility of 3D printing fruit, desserts, and
other classic items at the touch of a button is an incredibly appetizing idea. However, the
impact of 3D printing stretches far beyond the food itself. The technology has carved out a
significant niche in the specific equipment utilized in food manufacturing, including
refrigerators, meat cookers, and other significant kitchen equipment.

3D printing has staked its claim as an effective and innovative tool for food processing, with
several companies taking advantage of the limitless benefits that integrating the technology
can provide. These benefits range from faster lead times for developing prototypes to the
ability to implement complex and durable mechanical designs that would otherwise be
impossible to create. 3D printing also provides reliable cost-effective manufacturing
processes because of the substantially reduced material cost regardless of the complexity of
the design.

Case Study-

ARMOR INOX – THERMIX SYSTEM

Armor Inox, located in Mauron, France, has been a subsidiary of Middleby Corporation since
December 2011. Middleby is a leading manufacturer of cooking and industrial process
equipment based in Elgin, Illinois. Armor Inox has recently joined its public parent company
as a premier equipment manufacturer in the food industry. Armor specializes in cooking and
material handling technologies for ready-meals and cooked meats such as pork, poultry, beef,
and ham. The company is consistently looking to identify and integrate the most cutting-edge
industry trends into their manufacturing processes, including the continual improvement of
their 10,000 square meter manufacturing facility that features the latest in 3D printing
technology across a myriad of applications including laser cutting, welding, and
manufacturing.

Armor Inox has become the premier brand for fully-automated, thermal processing
applications for cooked meats and ready-meals, due in large part to their highly innovative
Thermix system. The Thermix system is adept at handling every aspect of cooking/chilling
processes, from shaping to storage and the loading/unloading and all else in between. The
processors can produce between 20 and 200 metric tons per day with as little as two
employees, combining its incredibly high throughput with the additional benefits of
production flexibility, performance quality, and low operating costs that include increased
energy savings in addition to ensuring food safety with complete traceability. The resounding
success of the Thermix system has made Armor Inox the world’s number one manufacturer
for automated cook and chill systems for ham and other cook-in-bag products. The brand
further exemplifies the value of additive manufacturing in the development of these types of
solutions.