Course Name: 3D Printing and Design Session No. I 1.0

Course Name
Module 3D Printing and Design
Session No. I
Version 1.0
3D Printing and Design
Material from the published or unpublished work of others which is referred to in the Class
Notes is credited to the author in question in the text. The Class Notes prepared is of 6,370
words in length. Research ethics issues have been considered and handled appropriately
within the Globsyn Business School guidelines and procedures.
Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Table of Contents
1. Introduction ............................................................................................................... 7
2. Concept of 3D Printing ............................................................................................. 7
2.1 Working Procedure of Additive Manufacturing ............................................................ 9
2.2. Tools are Used to Create 3D Printing ..........................................................................12
2.2.1. Material Extrusion ....................................................................................................12
2.2.2. Direct Energy Deposition..........................................................................................13
2.2.3. Material Jetting .........................................................................................................14
2.2.4. Binder Jetting ...........................................................................................................14
2.2.5. Sheet Lamination .....................................................................................................15
2.2.6. Vat Polymerization ...................................................................................................16
2.2.7. Powder Bed Fusion ..................................................................................................17
2.3. 3D Printing Technologies.............................................................................................18
2.3.1. Sintering ...................................................................................................................18
2.3.2. Direct Metal Laser Sintering (DMSL) ........................................................................18
2.3.3. Direct Metal Laser Melting (DMLM) and Electron Beam Melting (EBM) ....................19
2.3.4. Stereo Lithography (SLA) .........................................................................................20
2.4. Material Used in 3D Printing ........................................................................................21
2.4.1. Thermoplastics .........................................................................................................21
2.4.2. Metals ......................................................................................................................22
2.4.3. Ceramics ..................................................................................................................23
2.4.4. Bio-Chemicals ..........................................................................................................24
2.5. 3D Printing Applications ..............................................................................................24
2.5.1. Aerospace ................................................................................................................24
2.5.2. Automotive ...............................................................................................................25
2.5.3. Healthcare................................................................................................................26
2.5.4. Product Development ...............................................................................................27

2.6. Advantage of 3D Printing .............................................................................................28
2.6.1. Affordable Cost of Entry ...........................................................................................28
2.6.2. Innovation to the Forefront .......................................................................................29
2.6.3. Varied 3D Printing Training Program ........................................................................29
2.6.4. Reduction of Waste Production ................................................................................30
2.6.5. Energy Cost Savings ................................................................................................31
3. Simulation ................................................................................................................ 31
3.1. Use of Simulation .........................................................................................................32
3.2. Examples of Simulation ...............................................................................................33
3.2.1. Pilot Training Program..............................................................................................33
3.2.2. Gear Manufacturing .................................................................................................34
4. Concept of Augmented Reality with Example ...................................................... 35
4.1. How Augmented Reality (AR) Works...........................................................................36
4.2. Examples of AR Technology .......................................................................................37
4.2.1. Google Wearing Glasses .........................................................................................37
4.2.2. Colouring Book ........................................................................................................38
4.2.3. Heads-Up Display ....................................................................................................38
4.2.4. Use in Military ..........................................................................................................39
4.2.5. L’Oreal Makeup App ................................................................................................40
4.2.6. AR Technology in the Weather Channel ..................................................................40
5. Application of simulation in Augmented Reality with Example .......................... 41
References ................................................................................................................... 45

List of Figures
Figure 1: 3D Model – Packed up Stadium .................................................................................. 7
Figure 2: 3D Design, Layers....................................................................................................... 9
Figure 3: 2D and 3D Shapes .....................................................................................................10
Figure 4: Additive Manufacturing ...............................................................................................11
Figure 5: Rapid Prototyping 3D Printing Machine ......................................................................12
Figure 6: Material Extrusion ......................................................................................................13
Figure 7: Direct Energy Deposition............................................................................................14
Figure 8: Binder Jetting .............................................................................................................15
Figure 9: Sheet Lamination .......................................................................................................16
Figure 10: Vat Polymerization ...................................................................................................17
Figure 11: Powder Bed Fusion ..................................................................................................17
Figure 12: Sintering process .....................................................................................................18
Figure 13: Direct Metal Laser Sintering .....................................................................................19
Figure 14: Electron Beam Melting .............................................................................................20
Figure 15: Stereolithography .....................................................................................................21
Figure 16: Thermoplastics .........................................................................................................22
Figure 17: Metal ........................................................................................................................23
Figure 18:Ceramics ...................................................................................................................23
Figure 19: Bio-Chemicals ..........................................................................................................24
Figure 20: 3D Printing - Aerospace ...........................................................................................25
Figure 21: 3D Printing - Automotive ..........................................................................................26
Figure 22: 3D Printing - Healthcare ...........................................................................................27
Figure 23: 3D Printing in Product Development.........................................................................28
Figure 24: 3D Printer Training Program ....................................................................................30
Figure 25: Time and Cost Reduction .........................................................................................30
Figure 26: Example of Energy Cost Savings .............................................................................31
Figure 27: Simulation ................................................................................................................31
Figure 28: Simulation and Business Pperation ..........................................................................32
Figure 29: Airplane Driving ........................................................................................................34
Figure 30: Gear Machine Procedures .......................................................................................35
Figure 31: Augmented Reality - Pokémon .................................................................................35
Figure 32: Process of Augmented Reality .................................................................................36

Figure 33: Augmented Reality – Google Glass..........................................................................37

Figure 34: Augmented Reality – Colouring Books .....................................................................38
Figure 35: Example of Augmented Reality ................................................................................39
Figure 36: Augmented Reality in the War ..................................................................................39
Figure 37: AR and L’Oreal Makeup ...........................................................................................40
Figure 38: AR Technology – Weather Condition .......................................................................40
Figure 39: Simulation and Augmented Reality ..........................................................................42
Figure 40: Simulation with Segmented Reality ..........................................................................43
Figure 41: Thermal Vision Googles and Infected Pond .............................................................43
Figure 42: App CAB Direction ...................................................................................................44

1. Introduction
Hope you like playing football. It is your dream to join your favourite club and show your
performance in a packed up stadium. In particular, playing in a packed up stadium is your
dream. You get excited about the ambiance of the stadium. You like the greetings of the
spectators. One day you visit your friend’s architectural firm. After entering the house, you get
astonished. It is because you see a model of a stadium. (See table 1) It looks like a real view
where countless number of spectators sit on the chairs and concentrate at the football match.
You ask your friend about the formation of the model. He tells you that the model has been
developed by employing the latest technology of printing called additive manufacturing which is
now the latest fashion in many engineering firms. First time you hear the term additive
manufacturing and you become curious to know more about it (EOS, 2019).
Figure 1: 3D Model – Packed up Stadium
(Turbosquid, 2019)
2. Concept of 3D Printing
The digital technology introduces a new form of printing where three dimensional solid objects
can be obtained. We all know that there is a shipment of technology from analog to digital and
such a transition has been observed in many fields. These fields are engineering, architecture,
communications, imaging etc. This type of transition occurs also in the field like additive
manufacturing or 3D printing. Now, 3D printing can bring digital flexibility and efficiency to

manufacturing operations. The data computer aided design known as CAD or 3D object
scanner is the two software that can be used by the user in preparing 3D model. Basically,
these software instruct hardware to deposit material, layer upon layer, in precise and geometric
shapes (GE Additive, 2019). We have to gather knowledge about the basic difference between
creating an object in a traditional form and digital form. While preparing a 3D model under the
traditional form, the main focus is laid down towards the removal of the material. Such removal
can be done through milling, machining, carving, shaping, and other measures. However, in the
digital form, such creation emphasizes on the addition of the material. Additive manufacturing is
a vast subject. We are discussing here 3D printing which is a part of additive manufacturing.
The employment of additive manufacturing provides three important aspects of printing
technology. These are improved performance, complex geometrics, and simplified fabrication.
These are recognized as the three pillars in the engineering field and bring abound opportunities
to the users. (See Figure 2)

Figure 2: 3D Design, Layers
(GE Additive, 2019)
2.1 Working Procedure of Additive Manufacturing

In our daily life, we often take out printing documents. If we consciously think about the nature of
such printing, we understand that all such printings are two dimensional. It means the
documents possess two axes. It has no third axis as there doesn’t exist any height of such
documents. The document has only two axes i.e. length and breadth (Study.com, 2019). Now
think when we collect some printing documents and keep these documents one upon one we
shall get a certain height of such shape. It means when 2D printings are kept horizontally one
upon one it takes a three-dimensional shape. (See Figure 3)

Figure 3: 2D and 3D Shapes
(Study.com, 2019)
This additive concept is used through CAD software to achieve 3D model. A particular material
is given on the printing machine so that the user can obtain the 3D shape of such 3D printing. In
the case of additive manufacturing, a user obtains a superfine layer that is formed as a three-
dimensional object. The printing of such a layer is made during one period of time. Each
subsequent layer bonds to the preceding layer. The condition of such layers may be either in
the form of melted material or semi-melted material. Different substances can be used to obtain
such melted or semi-melted materials. These are metal powder, thermoplastics, ceramics,
composites, glass and even edibles like chocolates. In preparing a 3D images AutoCAD is used
by the designers or the engineers. It is one form computer aided-design-software. The
extension on which AutoCAD files are saved is called .dwg. This software is also used to
create. stl files. (.stl) is used to slice the object into ultra-thin layers (3D Natives, 2019). This
extension i.e. (.stl) also controls the path of a nozzle so that the subsequent layer can follow the
preceding layer. When such thing is held the melted material is easily deposited on the
preceding layer and no deviation is held into the series of 3D printing. (See Figure 4)

Figure 4: Additive Manufacturing
(EOS, 2019)
The preliminary version of the 3D printing machine came into force during 80’s. The
implementation of the efficient method when introduced for the first time it sets a benchmark for
subsequent activities. Likewise, when the first 3D machine was set in the manufacturing
process it laid out the base for subsequent production and design activities. This kind of
processing is known as prototyping. Afterward, many modifications happened in this technology.
Anyhow, the manufactures used to deal with this technology to produce prototypes from earlier
days. (See Figure 5)

Figure 5: Rapid Prototyping 3D Printing Machine
(Machine Design, 2019)
There is also an alternative method of 3D printing. In a bed of powdered material, laser or

electric beam can be used. It melts or partially melts such powdered material. As materials cool
or are cured, they join themselves and form a three-dimensional object (CIOB, 2019).
2.2. Tools are Used to Create 3D Printing

There are a variety of 3D Printing processes. These are:
2.2.1. Material Extrusion

It is a mostly used 3D printing process. Spooled polymers are forced out or drawn through a
heated nozzle fixed on a movable arm. The movement of the nozzle is made on a horizontal
form and the movement of the bed is made vertically (Loughboroughuniversity, 2019). These
two movements permit the melted material to be made layer after layer. The temperature is
controlled precisely so the chemical bonding agents. Such controlling ability creates an
environment of accurate adhesion between layers. (See Figure 6)

Figure 6: Material Extrusion
(Loughboroughuniversity, 2019)
2.2.2. Direct Energy Deposition

In this process, an electron beam or laser is used. The nozzle is set on a multi-axis arm inside a
closed frame. This system forcefully delivers the melted material onto the work piece surface.
Afterward, the melted material gets solidified. This process is alike to the material extrusion
process (3D Natives, 2019). This technique is mostly used with metal powders or wire source
materials. This technique is also used on other materials like polymers, ceramics and metals.
(See Figure 7)

Figure 7: Direct Energy Deposition
(3D Natives, 2019)
2.2.3. Material Jetting

Similar to the function of ink jet printers this system follows the working proceeding of 2D
printers to move on x and y axis. In addition, it also moves on z axis to create 3D objects. For
this purpose, it moves back and forth. The layers become harder and are cured when the
ultraviolet ray is applied on the layers (CIOB, 2019).
2.2.4. Binder Jetting

It is one sort of additive manufacturing technique. To join the powder particles liquid binding
agents are used (Varotsis, 2019). These binding agents are deposited in a proper proportion so
that layers get bonded in proper shape and form a 3D object. (See Figure 8)

Figure 8: Binder Jetting
(Varotsis, 2019)
2.2.5. Sheet Lamination

There are two types of lamination methods found in sheet lamination. These are laminated
object manufacturing (LOM) and ultrasonic additive manufacturing (UAM). In the case of LOM
alternate layers of paper and adhesive are used. This technique is used for visual and aesthetic
modeling. In the case of UAM thin metal sheets are used to print 3D object (3DP Lighting,
2019). This technology is used over various metals like titanium, stainless steel and aluminum
which demands the technology having relatively low-temperature and low energy processes.
(See Figure 9)

Figure 9: Sheet Lamination
(3DP Lighting, 2019)
2.2.6. Vat Polymerization

The use of photo polymerization can be observed in this technology. Here, liquid polymers are
excreted that are hit by fiery ultraviolet light where the liquid is converted into solid-state. In this
process, 3D design is made in a 3D software afterward, digital light processing technology is
used in the 3D printer together with ultraviolet light (White Clouds, 2019). With this combined
effort an image is projected over vat of liquid polymers where the state of liquid is transformed
into a solid-state. (See Figure 10)

Figure 10: Vat Polymerization
(White Clouds, 2019)
2.2.7. Powder Bed Fusion

In this technology, lasers, electron beams or thermal print heads are used to melt fully or
partially to the ultra-fine layers in a three-dimensional space. At the end of the process, the
remaining powder, if any, is blasted away from the object (Sciencedirect, 2019). This technology
is used in various AM processes. (See Figure 11)
Figure 11: Powder Bed Fusion
(Sciencedirect, 2019)

2.3. 3D Printing Technologies

There are various technologies used for the purpose of 3D printing. These are:
2.3.1. Sintering
A solid mass is generated from a material when heat is applied in a certain process is known as
sintering. The heat is provided is such a way so that it can avoid liquefying. Like 2D
photocopying, the toner is selectively melted to form an image on the paper (Formlabs, 2019).
In a sintering process liquid is formed however, afterward, such liquid state is dissolved into
solid. (See Figure 12)
Figure 12: Sintering process
(Formlabs, 2019)
2.3.2. Direct Metal Laser Sintering (DMSL)

In this process laser is shot to each layer of metal powder in order to create adherence between
the layers. Three things are built up through DMLS machine (Stratasys, 2019). These are high
resolution object, upgraded surface features, and satisfactory mechanical properties. (See
Figure 13)

Figure 13: Direct Metal Laser Sintering
(Stratasys, 2019)
2.3.3. Direct Metal Laser Melting (DMLM) and Electron Beam Melting (EBM)
The materials are entirely melted under these two processes. Each layer of metal powder is
completely melted under DMLM process. In the case of EBM process, a high-power electron
beams are sent to melt the metal powder (All3DP, 2019). This technology is used in the
manufacturing process where the nature of manufacture is related to dense, non-porous
objects. (See Figure 14)

Figure 14: Electron Beam Melting
(All3DP, 2019)
2.3.4. Stereo Lithography (SLA)

SLA employs the technique like photo polymerization. Here, liquid polymers are excreted where
UV ray is applied in a fiery mode to convert the liquid form into solid form. UV laser selectively
fired into a vat of photopolymer resin (Livescience, 2019). In this way, a certain resistant part is
produced which can withstand extreme temperature. (See Figure 15)

Figure 15: Stereolithography
(Livescience, 2019)
2.4. Material Used in 3D Printing

It is observed that in making 3D printing object several materials can be utilized. These
materials are laid down below:
2.4.1. Thermoplastics
It is regarded as the most popular class of additive manufacturing materials. This is a kind of
polymer. There are several types of polymers found in the category of thermoplastics. These
are Acrylonitrile butadiene styrene; Polylactic acid and polycarbonate. These polymers bear
distinct feature and are separately used in various operations (Formlabs, 2019). For example,
water soluble PVA is used for a specific purpose, known as temporary support structures. The
liquid state is later dissolved away. (See Figure 16)

Figure 16: Thermoplastics
(Formlabs, 2019)
2.4.2. Metals
Different types of metals are used in the additive manufacturing process. Precious metals like
gold, silver can be used for 3D printing purpose (Science Direct, 2019). At same time, strategic
metals like stainless steel is also required in the 3D printing process. (See Figure 17)

Figure 17: Metal
(Science Direct, 2019)
2.4.3. Ceramics
The use of different types of ceramics is observed in the 3D printing process. Zirconia, alumina,
and tri-calcium phosphate are three types of ceramics used in the additive manufacturing
process (Formlabs, 2019). Sometimes the combination of special powdered glass and adhesive
are baked to produce a new kind of glass product. (See Figure 18)
Figure 18:Ceramics
(Formlabs, 2019)

2.4.4. Bio-Chemicals
Bio chemicals comprise of hardened material and soft natural material. The hardened material
section includes the substance like silicon, calcium phosphate and zinc. The hardened material
also includes support of bone structures. Material like bio-ink fabricated substance is fallen
under the section of soft natural material (Formlabs, 2019). It is fabricated from stem cells which
are used to form internal body elements like blood vessels, bladders and many more. (See
Figure 19)
Figure 19: Bio-Chemicals
(Formlabs, 2019)
2.5. 3D Printing Applications

The use of 3D printing can be experienced in different fields. Few of such applications are
described below:
2.5.1. Aerospace
The 3D printing technology provides an advantage by forming a weight saving model. At the
same time, this weight saving model also exhibits the complex geometrical structure that is
helpful for the producer for creating sight, strong aerospace parts. An SLM printed rocket
injector was developed by NASA which was formed to drive a hot fire test. The printed 3D object
was used for the said purpose and 20000 pounds of thrust was produced through such test. In
the year 2015, a 3D printed object was used in a commercial jet engine. A certain leap engine
featured 193D printed fuel nozzles (Schwartz, 2019). Regarding Boeing 787, a structural part

was fabricated by using titanium wire through the application of 3D printing process. (See Figure
20)
Figure 20: 3D Printing - Aerospace
(Schwartz, 2019)
2.5.2. Automotive
In the field of automation, the application of 3D printing model can also be noticed. In the case
of McLaren racing team, it is observed that they introduce 3D printed parts in its Formula1 race
cars. The printed parts are related to the rear window. It is observed that the five weeks’
program is reduced to only 10 days’ program as 3D printing is made successfully to produce
such required parts. By using the technique of 3D printing the team has created 50 different
parts within a few days and saves cost and time. By using the fluid handling system, pumps and
valve manufacturing process can be done by 3D printing technique (Machine Design, 2019).
The use of selective laser sintering brings an opportunity to the producers to manufacture wind
breakers and bumpers. (See Figure 21)

Figure 21: 3D Printing - Automotive
(Machine Design, 2019)
2.5.3. Healthcare
In the field of healthcare, this technology has also put its mark. A multi-colour kidney cancer
model is set up by using 3D printing model. The efficacy of such a model is then examined over
300 patients and later, it is observed that the efficacy level becomes satisfactory as the
surgeons related to this disease get remarkable assistance relating to assessments of the
patient’s condition as well as guidance during the per-operative period (Tractus 3D, 2019). As
you all know that Stryker is a medical device manufacturing company having units across the
globe that have recently announced that they will take the assistance of 3D printing in building
implants for patients who have been suffering from bone cancer. In the health care sector, this
technology contributes promising possibilities in terms of upgraded treatment plus cost-cutting
effectiveness. (See Figure 22)

Figure 22: 3D Printing - Healthcare
(Tractus 3D, 2019)
2.5.4. Product Development

Since we are now aware of the efficiency level of 3D printing technology, the entrepreneurs are
now hopeful to use this technique for product development. This technology unleashes the
creative potential of designers and provides a suitable environment for execution. Earlier,
execution of a simple thing required handful efforts and labour which is now being a past issue.
The unique printing system has captured the imagination of the industrialists and they are eager
to use the technology in different fields (Perdue, 2019). In the case of product development, the
promoters start to invest in innovative projects related to 3D printing as they believe that by
using this technology they can achieve the desired results within a specific time frame that will
not only save time but also save the firm from wastage of money. (See Figure 23)

Figure 23: 3D Printing in Product Development
(Perdue, 2019)
2.6. Advantage of 3D Printing

In the case of the traditional manufacturing process, it is very difficult to carry out the required
things within a short period of time. In particular, when a design is complex it is then too difficult
or too expensive to develop a 3D model by using traditional dies, moulds, milling. It is 3D
printing or additive manufacturing that can put aside these problems as this technology
facilitates the user to develop the model within a short period of time. Moreover, if the design is
complex this technology enables the user to provide the hand out – 3D printing in a correct
manner. Many companies are now depending on additive manufacturing in recent years. More
and more advantageous are now manifested by using such technology (EOS, 2019). Anyhow,
the advantage of 3D printing is described below.
2.6.1. Affordable Cost of Entry

During period 80 when this technology was first introduced it became impossible for the
producer to purchase this technology as the price of the product was unimaginable. The too-
high price of this product compelled the producers to stay at bay from using such technology in
the manufacturing process. Later, the price came down and it became reachable to the
manufacturers. They started to accommodate with this technology and reaped the benefit from
this technology. This technology has provided a huge cost-cutting advantage in terms of capital
reduction. Moreover, affordable prices for purchasing such products may lead to bringing speed

and profitability in the business model followed by the manufacturers. For example, in designing
bridges the engineers always search for the suitable way regarding the reduction of weight and
maximization of strength. When additive manufacturing was introduced it unfolded the door of
opportunities to the engineers in fulfilling their desire. By using this technology, the engineers
realized that by utilizing organic structures reduction of weight could be possible to a large
degree (EOS, 2019).
2.6.2. Innovation to the Forefront

In the past when each company depended on the traditional manufacturing process, the design
and innovation were not received much recognition as it receives nowadays. The introduction of
3D printing enables the designers to receive more attention to their creations without worrying
about cost or time penalties. The 3D printing is now considered as the most effective part of the
manufacturing process, having taken the leading role, which not only reduces the cost of the
manufacturing process but also providing a rapid solution to the producers in terms of
finalization of the required product. In the traditional manufacturing process, if the producer is
required to undergo any modification of the model it requires to spend a significant amount of
money to solve the problem. Moreover, the manufacturer will face time delays in getting the final
3D model from the technicians. 3D printing enables the manufacturer to remove all these
constraints and make the manufacturing process easier and vibrant (CIOB, 2019).
2.6.3. Varied 3D Printing Training Program

There are varied types of 3D printing training programs found under training schedules. The
designers and the manufactures will undergo specific types of training as per their requirement.
They will not face any kind of problem in availing these trainings. Moreover, these training
programs will not hamper the business operations as the schedule of the training is set step by
step considering the continuous flow of the business operations. For example, in the case of
fundamental training those who are acquainted with tools and technology will be imparted such
training. Those who are technicians they will be provided technical training in handling the 3D
printing machine (Study.com, 2019). Under the criterion of advanced training, it will be given to
those employees who are engaged in the post-production process. (See Figure 24)

Figure 24: 3D Printer Training Program
(Study.com, 2019)
2.6.4. Reduction of Waste Production

3D printing technology reduces the wastage near to 90% in comparison with the product
produced under the traditional process. It is because, in 3D printing technology, printing material
gets a joint layer to layer under a certain process. It means addition is held between the
subsequent layer and the previous layer which removes the possibility of material wastage. A
big volume of material gets wasted when the traditional manufacturing process is followed by
the manufacturers. In the traditional process, it is observed that a milling machine works by
removing material from a block in manufacturing a product. After developing the product, the
residual part of the block is considered as wastage as nothing can be obtained further from this
residual part which is then counted as a valueless item. The 3D printing technology has
removed the possibility of such wastage (CMTC, 2019). Time reduction as well as cost
reduction are also observed in the 3D printing process. (See Figure 25)
Figure 25: Time and Cost Reduction
(CMTC, 2019)

2.6.5. Energy Cost Savings

Two significant things happen in additive manufacturing. Less material is used in 3D printing
technology. Secondly, a few steps are required to follow in this technology. In the case of the
traditional manufacturing process, none of these two significant benefits are obtained as
comparatively more materials are required in such a process plus more steps sought to be
followed in completing the entire manufacturing process (CMTC, 2019). Therefore, these two
significant benefits reduce energy usage and act as an eco-friendly component in the
manufacturing process. An example is shown in the following chart in Figure 26.
Figure 26: Example of Energy Cost Savings
(CMTC, 2019)
3. Simulation
Have you ever visited science city in Kolkata? You can get the real driving experience without
using any road or any other ways where you can move your vehicle. Only sitting under the roof
of the time machine you can get the experience of driving. When you sit on the synchronized
chair and see the speed bearing moving images you can feel the thrill of high- speed driving
(Sciencedirect, 2019). Your body movement changes rapidly according to the passing images.
You enter the world of virtual reality. This is nothing but the technology called simulation. (See
Figure 27)
Figure 27: Simulation

From the above example it can be said that the operation of a certain process or system can be
imitated approximately. This kind of imitation is termed as simulation. The simulation makes
such an imitation overtime. In different fields simulation is practiced. These fields are technology
for performance tuning or optimising, safety engineering, testing, training, education, and video
games. To study simulation model it is observed that the researchers follow computer
experiments. Simulation follows the scientific modelling of natural systems or human systems to
understand the functional process therein. Also in economics, simulation plays the similar thing.
Another feature of simulation is that the outcome of the alternative conditions and courses of
action can be perceived through it. The original system may not be operative for several
reasons. These reasons can be either ineffectiveness of the original system or the use of such
system may bring any fatal incident or the system is not yet developed rightly or there may be
no existence of the real system. In such a circumstance simulation is used. As for example,
suppose you want to learn driving. At the same time, you also want to avoid the road as you feel
that road training may lead to bring hazards that is not acceptable. Therefore, you can utilise a
certain model which can give you the real effect of learning driving without facing any hazards
(Celemi, 2019). The preparation of such model is synonymous with simulation. Acquisition of
valid source of information is one of key issue of simulation. Here valid source of information
includes choice of key features and behaviours. The key issues in simulation also includes the
use of simplifying approximations and assumptions and fidelity and validity of the simulation
outcomes. (See Figure 28)
Figure 28: Simulation and Business Pperation
(Celemi, 2019)
3.1. Use of Simulation

The current state of business and its future performance can be gauged through simulation.
This technique is useful for a business owner as it can introduce some new ideas in the

business and improve its performance. In doing so, an entrepreneur can employ mathematics,
statistics or other analytical methods. The performance of the new situation of a business can
be scrutinized through statistical and computer modelling. This modelling technique is also used
to improve the existing set of operations. Simulation is a process that employs such statistical
and computer modelling to check the performance of the business operations. There exist
different process outlines in the business operations. At the same time, different outcomes also
emerged in these operations. A firm prepares modelling that follows these different outlines and
outcomes. The objective behind this preparation is to minimise the risk connected to change
management (Celemi, 2019). At the same time, it equally gives importance to keep up the live
business environment where performance could have been adversely affected.
3.2. Examples of Simulation

Following are the two examples which can justify the simulation technique.
3.2.1. Pilot Training Program

Suppose you want to learn piloting. You know that this kind of driving is not an easy task. Lots
of risks are involved with such driving. It is considered as real-time problems. In such cases it is
required to apply simulation technique. Since simulation is one sort of imitation, so an artificial
circumstance is created where a learner may undergo an experience similar to real-time
experience. A well synchronized chair is given to the learner. Different types of moving images
float in his front. These moving images are similar to real images. The synchronised chair
automatically gets adjusted according to the situation that comes in front of the learner. In this
process, a learner can grab the technique of piloting. When he will drive the aeroplane he will
not face trouble and he will overcome any crisis smoothly. In this way, many real-life problems
can be solved by applying simulation techniques (Science Direct, 2019). It is regarded as the
real experiment to mimic the actual situation. (See Figure 29)

Figure 29: Airplane Driving
3.2.2. Gear Manufacturing

The above example keeps a requirement of an experimental environment where modelling is
prepared to observe real-time experience. In this regard, a suitable simulation example is given
below. In a certain gear shop, four types of gears are produced currently. In the gear workshop,
the gear manufacturing procedures include the following processes apart from inlet and outlet.
These are blank prior heat treatment, rough turning, fine turning, machine keyway, heat
treatment, hole grinding, and gear grinding. The manufacturing procedures take time to produce
the finished item. Moreover, the risk is involved with the finished product as the quality control
department may reject the finished product if it is found that the quality of the product does not
match the standard level (Sciencedirect, 2019). If it is so, in that case, the firm will not only lose
time that it spent on manufacturing the product at the same time lots of money and labour hours
are wasted through the activities. To prevent such an awkward situation, the simple simulation
technique is employed. The simulation environment is set as follows: operating system,
windows XP, CUP at 1.6G, 512M memory and a logistic oriented simulation software i.e.
simulation em-Plant 7.5. This software is designed specifically related to the field like
engineering, production, logistics etc. By applying this software amicable environment of
production can be created which is similar to the gear manufacturing unit. Various performance
indicators get analysed by this software such as average production efficiency, work in progress

level, utilisation of equipment, workers load balance etc. The simulation related to gear machine
procedures are given below: (See Figure 30)
Figure 30: Gear Machine Procedures
4. Concept of Augmented Reality with Example

Figure 31: Augmented Reality - Pokémon
(Bonsor & Chandler, 2019)

You are standing near a beach. It looks normal. You are seeing the waves, feeling the rhythm of
the sound at a certain gap. Your vibe is getting cool then suddenly when you see your mobile
screen you notice that Pokémon is looking at you. However, in reality, there is no existence of
such creature around. Your mobile is showing you all the things around. Additionally, it is also
showing the superimpose picture - Pokémon. How could it possible? It is an exceptional
discovery that adds digital elements to a life view with the use of camera on a smart phone.
Here the viewer can capture Pokémon in any location wherever he moves (Bonsor & Chandler,
2019).
4.1. How Augmented Reality (AR) Works

To construct a local AR environment a computer and a camera is required. The camera
executes two things. It detects markers within its vision. Secondly, it collects the normal picture
around. The activities of the camera are set on the computer where the captured scenes are
displayed along with corresponding virtual objects represented by the markers (Perdue, 2019).
All these two things are happened simultaneously. (See Figure 32)
Figure 32: Process of Augmented Reality
(Perdue, 2019)

AR is one type of technology that superimposes information like sound, images text on the
surroundings that we see. Here we are restricted not to interact with or immerse in the
superimposed figure. The concept of this technology is just placed any interesting picture or text
or any message into the real object to make it more interesting and attractive. When we see the
real-life environment like flowing water or swaying leaves or a walking person we add something
extra with such real things by overlaying any interesting object with the help of augmented
technology. There are various applications of this technology. In the case of snap chat lenses, a
car owner is able to identify his car in a crowded parking lot. For this purpose, an app is required
to store in the mobile set. In the same fashion by installing an app any person can try on clothes
without leaving his residence. Likewise, capturing Pokémon in any location became an
inescapable sensation in the year 2016. In the cricket match, we have observed that a bowling
line suddenly appears in the cricket pitch representing line and length of bowling direction to
persuade the viewers about the bowling action.
4.2. Examples of AR Technology

There are countless examples of AR technology. Few of such examples are given below:
4.2.1. Google Wearing Glasses

In the year 2015 Google used augmented reality on wearing glasses having connectivity with
voice commands. A superimposed impression appears on the user lens where a projector is
fixed in getting a view of the object (Adobe, 2019). These superimposed impressions are called
overlaying images. (See Figure 33)
Figure 33: Augmented Reality – Google Glass
(Adobe, 2019)

4.2.2. Colouring Book

An amazing experience has been observed in employing AR technology on the colouring book.
This book is known as AR colouring book. When any character is coloured on a plain drawing
book the AR technology enables the user to see the 3D view of this character. An app is stored
on the device which detects the coloured character and displays the 3D view on the screen
(Adobe, 2019). If you want to see the virtual furniture in your drawing room use AR technology
and download a certain app in your mobile to get look of this view. (See Figure 34)
Figure 34: Augmented Reality – Colouring Books
(Adobe, 2019)
4.2.3. Heads-Up Display

One of the best example of AR technology is Heads-up Display. This technology is employed to
military applications. A transparent display is set in front of the pilot. All the data related to
atmosphere, airspeed, altitude and the horizon line put forward on the display screen (Bonsor &
Chandler, 2019). Therefore, the pilots are not required to take personal initiative to collect these
data. (See Figure 35)

Figure 35: Example of Augmented Reality
(Bonsor & Chandler, 2019)
4.2.4. Use in Military

The application AR technology is adopted in the USA military force. During war, this technology
can be helpful to distinguish between friendly troops and enemies. It can also facilitate to
identify the enemies in the darkness (INAP, 2019). This technology increases the combat
efficiency in the military operations. (See Figure 36)
Figure 36: Augmented Reality in the War
(INAP, 2019)

4.2.5. L’Oreal Makeup App

This beauty company provides a special mobile App for its users. This App will allow users to
utilise several types of makeup. The App has a certain quality to identify the user’s face. After
such identification, it overlays different shades or colour on the face and shows the user how
she looks like (INAP, 2019). (See Figure 37)
Figure 37: AR and L’Oreal Makeup
(INAP, 2019)
4.2.6. AR Technology in the Weather Channel

The weather department of the USA follows the AR technology. The condition of the weather
largely depends on the AR technology. They observe that interpretation of the weather condition
can be achieved by the application of AR technology. Relating to weather, extreme weather
condition like tornedo can be set together with its effects under this new technology. The virtual
storm is set which shows the height of flooding during the storm surge (INAP, 2019). Further, by
using this technology a moving virtual car is brought into the storm to observe how the car loses
its control in the storm. (See Figure 38)
Figure 38: AR Technology – Weather Condition
(INAP, 2019)

5. Application of simulation in Augmented Reality with Example

There are plenty of examples regarding combined effect of simulation and AR concept. We
have already known that simulation is a sort of imitation process of a certain course of action.
Before manufacturing any product, we use a simulation technique to comprehend whether the
desired finished goods soothes with the manufacturing quality or not. On the other hand,
augmented reality is a technique where a superimposed element is added to the real view to
make it interesting to the viewer. Here a combination is made related to the real world and the
virtual world. In the AR technique, user can connect himself with virtual objects that are
interposed on real scenes around. The use of this techniques provides him an opportunity to
receive the most natural and genuine human-computer interaction experience. While explaining
simulation we got to know a virtual finished product related to gear manufacturing process. In
the AR technology we get to know the combination of the virtual world and the real world. This
technology blend digital components into real world and makes the existing reality more
interesting. Therefore, a model that is developed under simulation (virtual reality) can be
observed in the light of AR technology which enables the producer to make the correct
engineering analysis of the superimposed object with the virtual object similar to real object
generated under simulation. It encompasses to show the similarity and dissimilarity between the
actual result and the virtual result related to the performance of the machine used for
manufacturing purposes. Accordingly, it provides the opportunity to the producer in taking a
decision whether to proceed with the manufacturing process or makes any amendment into the
process (Research Gate, 2019). Therefore, to increase process efficiency and productivity, the
producers nowadays pay attention to employ AR technique in engineering analysis and
simulation. The integration between AR and simulation provides a cognitive and scientific way
for producers to identify the practical problems occurred in the manufacturing process. (See
Figure 39)

Figure 39: Simulation and Augmented Reality
(Research Gate, 2019)
In the airplane driving training program, an effective model can be prepared to train the learners
on how to drive a plane. Physically they are not given training. In lieu of physical training, an
alternative model can be prepared through computer graphics where the trainees will
experience the real effect of driving to an airplane. The creation of the atmosphere alike to the
real situations related to air plane driving is a process called virtual reality. It is also called a
computer-generated simulation. When a trainee sits on the synchronised chair he may get
haptic feedback. It is the vibration and sensation while interacting with graphics and is known as
augmented reality (Research Gate, 2019). Therefore, experiencing the real effect of airplane
driving together with skin sensation put the experience more lifelike. It is happened due to the
combined effect of simulation and augmented reality. (See Figure 40)

Figure 40: Simulation with Segmented Reality
Another example of AR technology along Simulation is given below:

We all know that iOS is a mobile operating system developed by Apple Inc. A popular AR game
is found in this operating system. The application of virtual reality is used in this operating
system where we find that in a pool lots of nuclear waste and a group of pests are dumped. The
pool has been polluted for these hazards. The earth is being affected from the infected pool.
There are some players in this game who are ready to protect the earth from these hazardous
substances (Research Gate, 2019). Here, users utilise the phone to scan the mark. The game
offers night and thermal vision goggles to get a clear view even in the evening to complete the
mission. (See Figure 41)
Figure 41: Thermal Vision Googles and Infected Pond

In most of the developed cities, we experience the navigated rented CAB. In the road of
metropolitan cities like Kolkata, the companies like OLA and UBER are such types of service
providers. In this navigation system, the driver uses the android smartphone’s GPS and camera
by using an augmented reality-powered technology. The app guides the drivers directly by the
virtual path of the camera preview video. It enables the driver to understand the unknown place
very easily and makes a smooth riding without hindering his safety. The passengers can see the
location of the CAB and instruct the driver to take the right path in reaching the right pick-up
point (Research Gate, 2019). A picture is given below: The red colour is the direction of the road
map which is imposed on the virtual path. (See Figure 42)
Figure 42: App CAB Direction

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Course Name: 3D Printing and Design Session No. I 1.0

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Module 3D Printing and Design

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

2. Concept of 3D Printing ............................................................................................. 7

2.1 Working Procedure of Additive Manufacturing ............................................................ 9

2.2. Tools are Used to Create 3D Printing ..........................................................................12

2.2.1. Material Extrusion ....................................................................................................12

2.2.2. Direct Energy Deposition..........................................................................................13

2.2.3. Material Jetting .........................................................................................................14

2.2.4. Binder Jetting ...........................................................................................................14

2.2.5. Sheet Lamination .....................................................................................................15

2.2.6. Vat Polymerization ...................................................................................................16

2.2.7. Powder Bed Fusion ..................................................................................................17

2.3. 3D Printing Technologies.............................................................................................18

2.3.1. Sintering ...................................................................................................................18

2.3.2. Direct Metal Laser Sintering (DMSL) ........................................................................18

2.3.4. Stereo Lithography (SLA) .........................................................................................20

2.4. Material Used in 3D Printing ........................................................................................21

2.4.1. Thermoplastics .........................................................................................................21

2.4.2. Metals ......................................................................................................................22

2.4.3. Ceramics ..................................................................................................................23

2.4.4. Bio-Chemicals ..........................................................................................................24

2.5. 3D Printing Applications ..............................................................................................24

2.5.1. Aerospace ................................................................................................................24

2.5.2. Automotive ...............................................................................................................25

2.5.4. Product Development ...............................................................................................27

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

2.6. Advantage of 3D Printing .............................................................................................28

2.6.1. Affordable Cost of Entry ...........................................................................................28

2.6.2. Innovation to the Forefront .......................................................................................29

2.6.3. Varied 3D Printing Training Program ........................................................................29

2.6.4. Reduction of Waste Production ................................................................................30

2.6.5. Energy Cost Savings ................................................................................................31

3.1. Use of Simulation .........................................................................................................32

3.2. Examples of Simulation ...............................................................................................33

3.2.1. Pilot Training Program..............................................................................................33

3.2.2. Gear Manufacturing .................................................................................................34

4. Concept of Augmented Reality with Example ...................................................... 35

4.1. How Augmented Reality (AR) Works...........................................................................36

4.2. Examples of AR Technology .......................................................................................37

4.2.1. Google Wearing Glasses .........................................................................................37

4.2.2. Colouring Book ........................................................................................................38

4.2.3. Heads-Up Display ....................................................................................................38

4.2.4. Use in Military ..........................................................................................................39

4.2.5. L’Oreal Makeup App ................................................................................................40

4.2.6. AR Technology in the Weather Channel ..................................................................40

5. Application of simulation in Augmented Reality with Example .......................... 41

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Figure 33: Augmented Reality – Google Glass..........................................................................37

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Figure 1: 3D Model – Packed up Stadium

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Figure 2: 3D Design, Layers

(GE Additive, 2019)

2.1 Working Procedure of Additive Manufacturing

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Figure 3: 2D and 3D Shapes

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Figure 4: Additive Manufacturing

Industry4.0/M10SI/v1.0/201219 3D Printing and Design | Session No.: I

Figure 5: Rapid Prototyping 3D Printing Machine