Summer internship programme

Indian Institute of Technology, Goa

3D Printing
By
Vivek Patel
170030021

Faculty Advisor
Dr. Anirudha Ambekar
School of Mechanical Science
IIT Goa, GEC Campus
Farmagudi, Goa

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 Declaration
I declare that this written submission represents my ideas in my own words and where others
ideas or words have been included, I have adequately cited and referenced the original
sources.
I understand that any violation of the above will be cause for disciplinary action by the
institute and can also evoke penal action from the sources which have thus not been properly
cited or from whom proper permission has not been taken when needed.

Vivek Patel
170030021

Acknowledgement
First, I would like to express my special thanks of gratitude to my internship coordinator “Dr.
Anirudha Ambekar” for his able guidance and support in completing my project.
I would also like to extend my gratitude to Dean sir “Dr. Sachin D. Kore” and lab assistant
“Amey Naik” for providing me all facilities that were required.

Vivek Patel
170030021

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 3D Printing

Introduction:
3D printing is a process in which material is joined or solidify with the help of computer
to create a 3D object (material added together) through various processes.

3D printing and additive manufacturing is same for same process. It is basically making
of a 3D object by adding materials layer to layer instead of cutting or subtracting materials to
forming of object.

How 3D Printing Works:

 When you ready for printing then first draw your desired 3D object on your
CAD Program. Your file should be in the format of (.stl). Then, put it on flash
drive or SD Card and put that into the printer.

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 Start the print. In 3D printer,there must have a filament and usually made of
plastic. Then, there is a machining work performed and made your 3D object
in front of you.

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Common 3D Printing Materials :
 Poly lactic Acid (PLA) : One of the most commonly used material for 3D
printing because it is biodegradable , easy to print and also cost effective.

 Acrylonitrile Butadiene Styrene(ABS) Filament : Less brittle than PLA

, handle high temperature and also keep print area ventilated
because it releases fumes when heated.

 Polyethylene Terephthalate (PET) Filament : Used in plastic water bottles

and also one advantage is that object printed by using of PET can recycled as
well.

Processes in 3D Printing:
Large no. of processes are available but the main difference between them are, the way in
which material is deposited to form object and material used in process.

 Binder Jetting : It is basically deposition of binding adhesive agent on layers of

material usually powdered .To produce the piece , printer builds the model using a head
that moves over the plateform base and deposits , one layer at a time ,by spreading a
layer of powder. This is repeated until every layer has been printed . Strength of bonded
powder enhanced with wax or thermoset polymer impregnation.

 Powder Bed Fusion : Another 3D printing approach is the selective fusing of materials
in a granular bed. The technique fuses parts of layer and then moves upward in the
working area , adding another layer of granules and repeating the process until the piece
has built up. The process uses the unfused media to support overhangs and thin walls
in the part being produced which reduces the need for temporary auxillary support for
piece.

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  Material Extrusion : In this, model or part is produced by extruding small beads or
stream of material which harden immediately to form layers . A filament of
thermoplastic or other low melting point material fed into extrusion nozzle head , where
filament is heated to its melting temperature and extruded onto a build table. Plastic is
the most common material used for this printing.

 Lamination : In this paper can be used as build material, that results to lower costs for
printing. During 1990’s some companies marketed printers that cut cross sections out
of special adhesive coated papers using a carbon dioxide lasers and then laminate
together. In 2005 Mcor Technologies limited develop a different process using ordinary
sheet of office papers, a tungsten carbide blade to cut the shape and selective deposition
of adhesive and pressure to bond prototype.

 Direct Energy Deposition (DED)

 VAT Photopolymerization
 Material Jetting

Advantage of 3D Printing:
 Speed: Main advantage is the speed at which objet is produced . This saves the time
which is most important factor in manufacturing process.

 Variation: Complexity and freedom of design which we want.

 Single Step Manufacture

Disadvantage of 3D Printing:
Unhealthy air emissions. According to researchers at the IIT(Illinois Institute of
Technology) this may pose a health risk when used in home (similar to burning a ciggarete).

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Typical 3D Printer:

Reference Links : Wikipedia

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APPLICATION OF 3D PRINTING:
3D printing played important role in manufacturing, medicine, research, industrial etc.
sector. One most fascinating use of 3D PRINTING is to create more 3D printer from 3D printer.

Manufacturing:
 Mass customization : this allows consumers to create customs for their own mobile
phones because companies created services where consumer can customize object and
then order the resulting item as 3D printed.

 Rapid Manufacturing: inexpensive production of small no. of parts and their

promising processes are SLS (selective laser sintering) and DMLS.

 Research: Alternate method to manufacture component for experimental use (

magnetic shielding).

 Food: AM of food is being developed by squeezing out food , layer by layer into 3D
object (chocolate and candy and flat food such as pasta and pizza).NASA also look for
making food that are designed fit an astronaut dietary need. Problems is facing is that
food that are not strong enough to be filed are not appropriate for 3D printing.

Medical :
Fused Filament Fabrication (FFF) has been used to create microstructure with a 3D
internal geometry .3D printing has been used to print patient specific implant.

IN MARCH 2014, SURGEONS IN Swansea used 3D printed parts to rebuild the face
of a motorcyclist.

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(Research is also conducted on method to bio print replacement for lost tissues due to arthritis
and cancer).

Industrial:
 New fashion designer experimenting with 3D printed dresses and shoes.

 NIKE is already used 3D printing techniques for American footballer shoes.

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 Used for manufacturing moulds for making jewellery and even jewellery itself.

 Also used for print spare parts for planes by air forces.

 Constructions, Firearms, Computer and Robots, Educational and 3D selfies.

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Space: Zero – G printer (first to operate in zero gravity)

Domestic use: Ornamental object, working clock, coat hooks door knobs.

RepRap printer:
RepRap is basically a 3D printer that is used to produce a self replicating machines and
other useful parts. RepRap- Replicating Rapid Prototyper. It was founded in England.

Many parts of it is made up of plastic. RepRap print object from ABS, PLA, Nylon,
HDPE, TPE and similar thermoplastic. Already been used for an educational mobile robotics
platform.

Tensile test is also conducted on the design that is made up of ABS and PLA by RepRap
printers which is equivalent to other printers product. Several recyclebots are also designed to
convert waste plastic into a useful filament for printers .Printing electronics is the main goal of
RepRap project so that it can easily make their own circuitary. Using MIG as print head may
be helpful for print materials like steel.

New development in RepRap technology allow same device to perform both additive
and subtractive manufacturing by swapping magnetic mounted tool heads.

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Material that can be 3D Printed:
There is a list of material:

 Nylon(polyamide)
 Resin (Liquid photopolymer cured with UV light)
 Stainless steel
 Gold and Silver
 Titanium
 Ceramic
 Gypsum
 Edible material
 Paper
 Sandstone
 Wood
 Bronze

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Types of 3D Printing:

Stereolithography (SLA): SLA is fast prototyping process. In this process it convert liquid
photopolymers into solid 3D object,one layer at a time. The plastic is first heated to turn it in
semi-liquid and then hardened on contact. It is very precise and accurate method.

Digital Light Processing (DLP): Similar to SLA, also uses photopolymer resins but the major
difference is in using light (SLA-UV light and DLP- traditional arc lamp). DLP is slightly
taking quicker print for most parts because it exposes entire layer at once. DLP is the oldest
and cheaper process.

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Fused Deposition Modelling (FDM): Also known as FFF (Fused Filament Fabrication) .It
uses a continuous filament of a thermoplastic material. Filament is fed from a large coil through
a moving roller and them through heated printer extruder head and then deposited on growing
work. Usually, print head is moved in 2D plane to form a work plane at a time and then either
print head or platform moved vertically to form a new layer. Now, it is most popular process
used in machines.

Process: It involves many different AM technology like material extrusion, binder jetting,
material jetting, DED. This involves manufacture part by depositing material layer by layer.

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Material Extrusion: In this process a feedstock material is pushed through an extruder .In
most FDM machines , feedstock material comes in the form of a filament wound on spool.3D
printer liquefier is the component used in this type of printing . Extruder of these printer have
cold end and a hot end. Cold end pulls material from spool using roller into hot end. Hot end
consists of heating chamber and nozzle. In this region feedstock is melted and transform into
thin liquid and then nozzle allow it to come out to form thin, tacky bead of plastic.

Selective Laser Sintering (SLS): It uses heat fusible powder (also metal). This technique uses
high power CO2 lasers to fuse powdered particle together by sintering process (sinters-partly
melts).Process starts with help of roller matter poured on platform and then laser acts on the
material and makes first layer and the platform goes down and in continuous manner , object
is made. In this extra support is not needed because unsintered material support object. SLS is
similar to SLA regarding speed and durability.

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Selective Laser Melting (SLM) Technology: This technology uses high powered laser beam
to form 3D parts, during the process laser beam melts and fuses various metallic powder
together. When laser beam hits the layer, it joins or welds the particles together and then new
layer and continuous until actual object formed. SLM products stronger because they have no
voids. Used in aerospace and medical industry.

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Electron Beam Melting (EBM) technology: It differ from SLM because EBM used electron
beam in vacuum as a power source. Main advantage of this technology is of freedom of design,
strong and dense makeup and it also takes lesser time.

Laminated Object manufacturing (LOM) Technology: This technology works by fusing or

laminating layer of paper or plastic using both heat and pressure.

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Binder Jetting Technology: It uses ceramics, metals, sand, plastic as a material and it uses
gypsum as a usual material. It also uses colour pigment.

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Material jetting Technology: It is also known as wax casting. Printer add heated wax to
aluminium bed and then UV light helps in curing. Their support can be removed by water flow
or simply hand. Typically only viscous material. This technology mostly uses in dental and
jewellery industries.

Anet A8 Printer:

Introduction: Anet A8 is a cheap 3D printer based on Prusa i3 model and using PLA , ABS,
Nylon and wood as a filament material. It is most popular 3D printer in the fall of 2018.It uses
filament having diameter of 1.75mm and having print volume usually of (220*220*240) mm3
and using acrylic frame for rigidity.

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Model for Anet A8:

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Parts Detail of Anet A8:

Above shown parts are the key parts of Anet A8

 LCD Display: This is where key information about you printer is shown, this included
things like Temprature settings for the Printer head and Bed, access to files stored on
the SD card, fine tuning of settings for the X, Y and Z axis motors etc.

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 Z-Axis lead rod– These are used to lead or drive a component such as the Z-Axis
assembly on a printer.

 X-Axis motor – This motor/belt controls the X-axis travel and the head movement from
left to right.

 Nozzle – This is where your filament appears once it has been heated up to the required
temperature, most printers are fit with a 0.4mm nozzle as standard.

 Mainboard – This is the brains of the operation base on a Arduino processor it also
contains the electronics for the motors, heater elements, USB port for connections to a
computer etc.

 Hotbed – This is where the filament and your printer object is printed onto, typical
operation temperature are in the region of 40-60c.

 Turbo Fan – this provides a controlled airflow to the object being printed ensuring it
cools down correctly avoid you having a large pool of PLA or ABS sitting on the heat
bed.

 Power supply – All the electronics need power, so this is what this unit does, typical
designs provide either 12 or 24V DC at around 20A.

 Y – Axis motor – this controls the hot bed movement during a print using a single
motor and belt in the forward and backward direction.

 Z – Axis motor – This controls the up and down movement of the Head using two
motors connected to the Z-Axis linear rods which in turn are connected to the X-axis
left and right drive assembly.

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Modification :
 Mosfet-

One of the most concerning safety of Anet A8 is fire safety .The MOSFET will help prevent
the motherboard from overheating on taking too much pressure and also provide better voltage
to motors .The most common use of the MOSFET with the Anet A8 3D printer is to regulate
the high workload . The high current of the hot bed can causes to stress for mainboard connector
and increase possibility of fire catching. Adding MOSFET is important if you print with ABS
because it requires heat bed and high extrusion temperature but if you print with low
temperature material like PLA then other use of MOSFET that is voltage regulating comes in
action and ensure that your heat bed isn’t overpower your motherboard.

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  Power Switch-

Actually this seems to be easy but the normally printer does not have power switch , you have
to plug and unplug the printer to control power this is annoying and little bit dangerous.

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  Igus DryLin Bearings-

This is actually reduce the annoying noise of machine by using this bearings instead of
conventional linear bearings. It makes your printer become silent and smooth.

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  Auto level sensor-

This will save your time that is go in doing manual calibration.

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 Two Stroke Engine

Introduction: As the name applies 2 stroke engine perform one cycle (up and down)
movement during one complete crankshaft revolution to generate power. The engine is able to
produce power after one cycle because intake of the fuel and exhaust occurs simultaneously.
Overall, a two-stroke engine contains two processes:

1. Compression stroke: The inlet port opens, the air-fuel mixture enters the chamber and
the piston moves upwards compressing this mixture. A spark plug ignites the
compressed fuel and begins the power stroke.

2. Power stroke: The heated gas exerts high pressure on the piston, the piston moves
downward (expansion), waste heat is exhausted.

The thermal efficiency of these gasoline engines will vary depending on the model and design
of the vehicle. Compared to four stroke engines, two strokes are lighter, more efficient, have
the ability to use lower-grade fuel, and more cost-efficient.

Parts Detail:
Crankshaft: The crankshaft in a two-stroke engine rotates, moving the piston by means of the
connecting rod. These three parts are the only moving parts in a two-stroke engine. All power
produced is a direct result of the action of these three moving parts.

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Connecting Rod: The connecting rod is connected to the crankshaft at one end, and to the
piston at the other. It translates the movement of the crankshaft so that the piston is moved up
and down.

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Piston: The piston is moved up and down inside the cylinder by the crankshaft, which is
connected to the connecting rod. A vacuum is formed as it takes its upward stroke, drawing air
and fuel down through the valve. When the piston reaches the top, the spark plug then ignite
the air/fuel mixture, burning it and generate power and this generated force results in sending
the piston back down. On the downward stroke, the valve gets closed because of the increased
pressure of the fuel and air mixture within, which is being compressed. New fuel and air travel
through the intake port into the cylinder, ready to be burnt. The exhaust is expelled through the
exhaust port, and an unpleasant side effect is that it usually takes some of the unburned fuel
mixture with it.

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Spark plug: It is located on the top of engine case. It is used to ignite the air fuel mixture
during compression and burnt the fuel and releases power and due to this force (hot gas
expansion) piston goes downward and hence produce mechanical rotary movement.

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2 Stroke vs 4 Stroke:
 In a stroke engine, the piston completes 2 strokes during each revolution (one
compression stroke and one exhaust stroke) each being followed by a return stroke. In
a 2 stroke engine, the entire combustion cycle is completed with just one piston stroke,
a compression stroke followed by the explosion of the fuel. During the return stroke,
the exhaust is out and fuel mixture is enters the cylinder.

 Efficiency of 4 stroke engine is more than 2 stroke engine because fuel is consumed
once in every 4 stroke.

 In the 2 stroke engine there is pre mixing of oil and fuel but not in 4 stroke engine.

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Working:
2 stroke engine is a type of IC engine where one power cycle is completed with 2 strokes of
piston during one rotation of crankshaft. There are 4 steps that performed during one cycle –
1. Suction 2. Compression 3.Expansion 4.Exhaust

Suction- The piston is moved downward so that a vacuum is created in upper part of cylinder
and then fresh fuel mixture with air is sucked in cylinder.

Compression - The piston is pushed upward from BDC to TDC and compressed the air fuel
mixture and with the help of spark plug, ignite the fuel mixture.

Expansion- When the spark plug ignite the fuel mixture, the fuel is burnt and then hot air
expand and produces power and moved piston downward and this result to rotary motion.

Exhaust- When the fuel is burnt and piston is moving down then through the outlet port the
residue of the burnt fuel mixture is going exhaust.

Application:
2 stroke engine is preffered where mechanical simplicity and light weight and high power to
weight ratio are priorities. 2 stroke engines are very useful in applications such as chainsaws,
weed eaters, outboards, lawn mowers and motorcycles. Two-stroke engines are also easier to
start in cold temperatures. Part of this may be due to their design and the lack of an oil sump.
This is a reason why these engines are also commonly used in snowmobiles and snow blowers.

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Advantage and Disadvantage of 2 stroke Engine:
Because two-stroke engines can effectively double the number of power strokes per unit time
when compared to four-stroke engines, power output is increased.

Disadvantage is that when there is exhaust then unburnt fuel is also mixed with exhaust gases
and due to this dangerous gases is also emitted and raise the pollution.

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