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Materials Today: Proceedings 5 (2018) 14489–14498 www.materialstoday.com/proceedings

ICAFM_2017

Design and Fabrication of Industrial Components Using 3D Printing

T. Sathisha*, M. D. Vijayakumarb, Anshumaan Krishnan Ayyangarc
a
Research Scholar, Department of Mechanical Engg, St. Peter’s University, Avadi, Chennai, Tamilnadu, India
b
Associate Professor, Department of Mechanical Engg, Chennai Institute of Technology, Kundrathur, Chennai, Tamilnadu, India
c
Final Year Mechanical Engg Student, Chennai Institute of Technology, Kundrathur, Chennai, Tamilnadu, India

Abstract

In the product design and development process, prototyping or model making is one of the necessary steps to finalize a product,
which helps in realization of a conceptualized design. The 3D Printing, as a prototyping method, has been used widely since the
2000s, once it became popular as an additive manufacturing method. This paper aims at revolutionizing the previous method
further, to 3D print final components, instead of just prototypes, in all areas applicable, using some industrial components as
samples. This paper provides the further scope of research into the possibilities of replacing metallic parts with non-metallic
ones, due to the rising costs and dwindling resources, so as to sustain the same utility of product without any compensation on
durability and quality.
© 2017 Elsevier Ltd. All rights reserved.
Selection and/or Peer-review under responsibility of ICAFM’17.

Keywords:additive manufacturing; design; fabrication; 3D Printing; industrial components; FDM; ABS; ABS-FR; modeling; finishing; rapid
prototyping;

* Corresponding author. Tel : +91 9952047764

E-mail address:sathish.sailer@gmail.com

2214-7853© 2017 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of ICAFM’17.
14490 T. Sathish/ Materials Today: Proceedings 5 (2018) 14489–14498

1. Introduction

Manufacturing procedures are relevant in all aspects of day to day life so much that regularly don't understand or
consider it. From the vehicles drive, the cases of food arrive in, the TV's, PCs and different gadgets use, control
devices, warmers, ventilation systems, the channels that convey water and the rundown continues forever to
incorporate pretty much everything portraying the advanced society. These things are altogether made or worked
from fabricated segments. Producing hardware itself should likewise be made. The assembling procedure utilized is
dictated by an assortment of elements. The crucial thought of assembling or generation is to make (or deliver)
something that has a valuable frame. This frame is in all probability foreordained and computed, with a specific
physical geometry. Generally this geometry has certain resilience that it must meet with a specific end goal to be
viewed as satisfactory. A resilience blueprints the geometric exactness that must be accomplished in the assembling
procedure. The "snugness" of the resilience, or at the end of the day the permitted fluctuation between the made item
and the perfect item, is an element of the specific use of the item. Assembling is that the creation of stock to be
utilized or deal exploitation work and machines, instruments, compound and natural process, or definition. The term
may talk about with a spread of human activity, from craftsmanship to high specialized school, however is most
conventionally connected to modern creation, amid which crude materials ar modified into completed stock on a
larger than average scale. Such completed stock is likewise utilized for delivering diverse, a ton of cutting edge
stock, or oversubscribed to wholesalers, WHO progressively pitch them to retailers, WHO then pitch them to
complete purchasers and customers. Creating alternates beneath a wide range of financial frameworks. In a free
economy, manufacturing is ordinarily coordinated toward the generation of stock available to clients at a benefit. In
an exceptionally collectivist economy, creating is a considerable measure of times guided by the state to give a
halfway arranged economy. In blended market economies, creating occurs underneath a state of state control.
Popular delivering incorporates every single middle of the road procedure required for the get-together and joining
of an item's parts. A few businesses, similar to semiconductor and steel producers utilize the term manufacture. The
work phases in 3D Printing is shown in fig 1.

Fig. 1. Work phases in 3D Printing.

2. Manufacturing Methods

2.1. Subtractive Manufacturing

Subtractive Manufacturing is a procedure by which 3D particles are developed by progressively removing

material from a strong piece of material. Subtractive manufacturing should be possible by physically cutting the
material. However, is most regularly finished with a CNC Machine. Progressed CNC machines use different
apparatuses and cut around no less than three (x, y, and z) tomahawks with the end goal that they limit the
prerequisite for originators to flip the square. One of the central focal points to subtractive assembling is the capacity
to machine to a great degree thin bit of plastic into a living pivot. This sort of process is essentially not yet
conceivable in a 3D printer. For those models that require living pivot segments it is helpful to create certain parts
utilizing added substance producing while at the same time utilizing the CNC machine for strength segments like a
living pivot.
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2.2. Additive Manufacturing

Additive Manufacturing alludes to different procedures used to incorporate a three-dimensional question. It is a

term to depict set of innovations that make 3D protests by including an endless supply of material. Materials can
shift from innovation to innovation. The term additive manufacturing holds inside such advancements like Rapid
Prototyping (RP), Direct Digital Manufacturing (DDM), Layered Manufacturing and 3D Printing. There are some
regular components for all additive manufacturing, for example, utilization of PC together with extraordinary 3D
demonstrating programming. In the first place thing to begin this procedure is to make CAD portray. At that point,
AM gadget peruses information from CAD record and fabricates a structure layer by layer from printing material,
which can be plastic, fluid, powder fibers or even sheet of paper. The comparison of Traditional Manufacturing vs.
3D Printing is shown in fig 2.

Fig. 2. Traditional Manufacturing vs. 3D Printing.

3. 3D Printing

3.1. Principle of 3D Printing

In 3D printing, successive layers of material are formed under computer control to create an object. These objects
can be of almost any shape or geometry and are produced from a 3D model or other electronic data source. The fig 3
shows the process flow.
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Fig. 3. Process Flow

3.2. Types of 3D Printing

There are different 3D printing methods that were developed to build 3D structures and objects. Some of them
are very popular nowadays; others have been dominated by competitors. The Fig. 4 gives the FDM Process.
The various types of 3D Printing are:
• Stereolithography (SLA)
• Digital Light Processing (DLP)
• Selective Laser Sintering (SLS)
• Selective Laser Melting (SLM)
• Electronic Beam Melting (EBM)
• Laminated Object Manufacturing (LOM)
• Fused Deposition Modelling (FDM)

Fig. 4. FDM Process

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3.3. 3D Printer

Fig. 5. 3D Printer setup (general)

A 3D printer is a sort of modern industrial robot. It is a computer-aided manufacturing (CAM) gadget that makes
three-dimensional articles. Like a conventional printer, a 3D printer gets computerized information from a PC as an
input. Be that as it may, rather than printing the outcome on paper, a 3D printer manufactures a three-dimensional
model out of a custom material. 3D printers utilize a procedure called added substance assembling to shape (or
"print") physical articles layer by layer until the model is finished. This is not the same as subtractive assembling, in
which a machine reshapes or expels material from a current shape. Since 3D printers make models starting with no
outside help, they are more effective and create less waste than subtractive manufacturing gadgets. The way toward
printing a 3D display differs relying upon the material used to make the question. For instance, when constructing a
plastic model, a 3D printer may heat and circuit the layers of plastic together utilizing a procedure called fused
deposition modelling (FDM). While making a metallic protest, a 3D printer may utilize a procedure called direct
metal laser sintering (DMLS). This strategy shapes diminishes layers of metal from metallic powder utilizing a
powerful laser. While 3D printing has been conceivable since the 1980s, it has been essentially utilized for extensive
scale modern purposes. Notwithstanding, lately, 3D printers have turned out to be considerably less expensive and
are presently accessible to the customer market. As the innovation turns out to be more far reaching, 3D printers
may turn into a feasible means for individuals to make their own home items and new parts. The general 3D printer
setup is shown in fig 5.

3.4. Specifications of the 3D Printer used

• Extruder: MK10 Dual-Extruders

• Filament Size: 1.75mm Dedicated
• Layer Capability: 0.1mm - 0.5mm
• Build Envelope: 225mm x 145mm x 150mm
• Build Surface: Heated Build Plate with Glass Bed
• Filament Capabilities: PLA, ABS, PVA, NinjaFlex, Nylon, LayWoo-D3, LayBrick, CopperFILL,
BronzeFILL, MOLDLAY, Conductive, plus more.
• Compatible Software/Firmware: ReplicatorG (Opensource), Sailfish (Opensource), Simplify 3D (Details).
• Frame Colour: Black Steel Exoframe.
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4. Materials Selected

4.1. ABS

ABS, with its composition of [(C8H8) x• (C4H6) y• (C3H3N) z] could be a typical thermoplastic compound
formula. Its glass transformation temperature is exactly 105°C (221 °F). ABS is formless and in this way has no
genuine temperature. ABS could be a terpolymer made by polymerizing cinnamene and nitrile within the sight of
polybutadiene. The extents will differ from fifteen to thirty-fifth nitrile, five to half-hour hydrocarbon and forty to
hour cinnamene. The outcome defines an extended chain of polybutadiene befuddles with shorter chains of poly-
styrene-co-acrylonitrile. The nitrile groups from neighbouring chains, being polar, draw in each other and tie the
chains along, making ABS more grounded than immaculate polystyrene. The cinnamene offers the plastic a glossy,
impermeable surface. The polybutadiene, a rubbery substance, gives durability even at low temperatures. For the
majority of utilizations, ABS will be utilized amongst −20 and 80°C (−4 and 176 °F) as its mechanical properties
differ with temperature. The properties range unit made by elastic toughening, wherever fine particles of stuff region
unit dispersed all through the inflexible network. The principal essential mechanical properties of ABS range unit
affect resistance and sturdiness. A spread of adjustments will be made to lift affect resistance, sturdiness, and
warmth resistance.
The effect resistance will be opened up by expanding the extents of polybutadiene as to cinnamene and conjointly
nitrile, however, this causes changes in option properties. Affect resistance doesn't tumble off rapidly at lower
temperatures. Security underneath load is incredible with limited hundreds. In this way, by dynamical the extents of
its parts, ABS will be prepared in a few evaluations. Two noteworthy classes might be ABS for expulsion and ABS
for infusion forming, then high and medium effect resistance. Commonly ABS would have supportive attributes
inside a temperature fluctuate from −20 to 80°C (−4 to 176 °F). Comprehensive properties will be impacted to some
degree by the conditions underneath that the texture is prepared to a definitive item. For instance, shaping at a hot
temperature enhances the gleam and warmth resistance of the stock while the best effect resistance and quality
region unit acquired by embellishment at temperature. Strands (as a rule glass filaments) and added substances will
be blended inside the natural compound pellets to make a definitive item powerful and lift the agent change to as
high as 80°C (176 °F). Shades may likewise be additional, on the grounds that the staple unique shading is clear
ivory to white. The maturing attributes of the polymers zone unit generally impacted by the polybutadiene
substance, and it's customary to fuse cell reinforcements inside the creation. Elective elements encapsulate
introduction to bright that added substances likewise are reachable to shield against. ABS polymers region unit
insusceptible to paired compound acids, salts, centered hydrochloric and substance component acids, alcohols and
creature, vegetable and mineral oils, be that as it may, they're swollen by icy carboxylic corrosive, tetrachloride and
sweet-smelling hydrocarbons and range unit assaulted by centered component and gas acids.
They're dissolvable in esters, ketones, olefin bichloride, and CH3)2CO. Despite the fact that ABS plastics range
unit utilized generally for mechanical capacities, they even have electrical properties that region unit genuinely
consistent over an expansive differ of frequencies. These properties zone unit next to no torment by temperature and
part wetness inside the satisfactory agent fluctuate of temperatures. ABS is inflammable once it's presented to high
temperatures, similar to a wood hearth. It'll diminish then bubble, at that reason the vapours blasted into extreme,
hot flares. Since unadulterated ABS contains no incandescent lamp, its ignition doesn't by and large fabricate any
persevering natural toxins, and furthermore, the most toxic result of its burning or move territory unit carbon
monoxide gas and substance compound. ABS is moreover broken by daylight. This brought on one in all the far-
reaching and expensive vehicle remembers in North American country history inferable from the debasement of the
safety belt unleash catches. ABS will be reused and it is not acknowledged by all utilization facility.

4.2. ABS-FR

Fire-resistant ABS is a blend of ABS and PVC, polyvinyl chloride. This composite was created to agree with a
hefty portion of unbending combustibility norms built up for the PC protection, electronic information preparing
hardware, fast travel insides, and an expansive scope of other fire resistant delicate applications. This remarkable
composite of ABS-PVC creates a thermos formable sheet that is perceived under the segment program of
 T. Sathish/ Materials Today: Proceedings 5 (2018) 14489–14498 14495

underwriters Laboratories, Inc., with a grouping of 94 VE1 at .062" thickness. ABS-FR keeps up a large portion of
the physical and mechanical properties of ABS, and like ABS has fantastic thermoforming capacities. A watchful
review decision through the comprehension of these alternatives can ensure the client's generally satisfied.
• Thermal stability: Since the self-suffocate properties of the flame administrator, ABS could come about
because of the heat decay of fire retardants all through consuming, fire specialist ABS will have poor heat resistance
contrasted with general ABS. particularly, since fire retardants will most likely deteriorate once framed at
temperature of 230oC or on top of, embellishment at lower temperatures than required with general ABS is
suggested. Cheil Industries restriction has built up the innovation to give Starex fire specialist ABS with great
stability to heat and fire retardancy. Starex fire operator ABS, especially VH-0853 and VH-0800, is helpful for
geometrically propelled molds.
• Weather resistance: Since ABS contains hydrocarbon to bolster the bearing strength, it will be recolored if
presented to daylight for an old. Furthermore, this keeps its quality with such O.A. applicances as portable
workstation screens, printers, and photocopying machine. joined of the main partnerships inside the generation of
ABS natural compound. Cheil has made the bother to determine these issues, and it's with achievement made a fire
operator ABS arrangement with heavenly environment stability. Among the arrangement, VH-0853, VE-0812,VE-
0855 or VE-0856 will be the best option for applications stern weather stability.

• Blooming and plating-out: All through infusion forming, fire retardants will diffuse unflinching the surface
and cause shape pollution. Since this improvement turns out to be more regrettable with darker hues, it's proposed to
not utilize fire specialist ABS review tars with dull shading shades. Nonetheless, developing isn't found through
exploitation all Starex fire operator ABS review exceptVH-0853. Starex fire specialist ABS grades with their
sublime qualities yield flexible part styles.
• Heat resistance: Thermal resistance infers that the stock isn't at risk to twisting while being presented to a
substantial temperature fluctuate. The magnificent heat resistance of Starex fire authority ABS makes it feasible to
amplify the dependableness of infusion shaped item. Be that as it may, care ought to be taken to pick the correct
review of Starex fire professional ABS for definite utilization. For value decrease and enhanced infusion
profitability, the VE-arrangement will be the best option as an associate in Nursing engineering plastics substitute,
while the VH-arrangement is fitting once handle capacity is extra essential style issue than heat resistance.
• Flammability: Typically, flammability will be rated consistent with UL-94 VB standards. Cheil produces
numerous flame agent ABS's with variable flammability levels to fulfill the necessities of specific applications.
• Flame retardants: PBDE is one in everything about first very much enjoyed mixes utilized as associate in
Nursing added substance to showcase the fire retardancy of plastics. There was a pattern to farthest point PBDE's
utilization as a fire operator compound because of the shot that PBDE may initiate nephrotoxic hydrocarbon or
difuran subsidiaries at associate in Nursing raised temperature condition. yet it's been hypothesized that PBDE isn't
hence risky, most electrical and electronic enterprises still evade exploitation PBDE as a fire expert. Starex fire
operator ABS saps don't contain such dubious fire specialist mixes. In this manner, Starex fire operator ABS will be
utilized for external applications.

5. Component Design and Calculations

5.1. Design Objectives

The core objectives of designing the components are as follows:

• To ensure proper scaling (if needed) from the existing size of the component
• To give proper geometric tolerances for manufacturing of the component
• To satisfy the working conditions for their respective applications

5.2. Design Considerations

The following are the considerations made before designing the components using the selected materials:
14496 T. Sathish/ Materials Today: Proceedings 5 (2018) 14489–14498

• Size of the component

• Physical stresses (if any) on the component
• Thermal stresses (if any) on the component
• Working conditions (environment) of the component
• Durability (life span) of the material
• Chemical reactivity of the material
• Economic feasibility of material
• Ease or difficulty of manufacture
The components chosen for being replaced with non-metallic material via this project are as follows:
• Oil Sump Drain-Sieve
• Air Filter Wingnut
• Lubricant Flow Relay Splitter
• CNC Coolant Venturi Nozzle
• Mini Lathe Gear Model 001
• Mini Lathe Gear Model 002
The Addis "Sumpy" is a plastic product that can be used to drain oil out of a car without leaving a big mess. It
also helps to store the old oil before disposing of it safely. The problem is that the sump plug can fall out and into
the drum. So this model is a 3D printable sieve that can be used to block large particles from going into the drum.
The fig 6 shows the Oil Sump Drain Sieve.

Fig. 6. Oil Sump Drain Sieve

A wingnut or wing nut is a type of nut with two large metal "wings", one on each side, so it can be easily
tightened and loosened by hand without tools. A similar fastener with a male thread is known as a wing screw or a
wing bolt. The Air Filter Wingnut is shown in fig 7.
Types of conventional manufacturing process of wingnut:
• Type A are cold forged or cold formed produced in regular, light and heavy dimensional series.
• Type B are hot forged solid nuts available in three different wing styles.
• Type C are die cast nuts available in three wing styles with variances between regular and heavy
dimensional series
Type D are stamped sheet metal nuts available in three wing styles.

Fig. 7. Air Filter Wingnut

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When you must to split a single hydraulic line into two or more identical flow paths, a tee or several tees can be
the first solution. However, if the resistance in all the branches is not identical, flow can vary greatly in each path.
Adding flow controls at the tee outlets makes it possible to change resistance and equalize flow in each branch, but
as the machine operates, work resistance changes often require constant flow modifications. A device called a flow
divider splits flow and compensates for pressure differences in most cases. A flow divider can split flow equally,
unequally, and into more than two paths. One design maintains a constant flow for one outlet and directs any excess
flow to a second outlet. In fig 8 the Lubricant Flow Relay Splitter is given.

Fig. 8. Lubricant Flow Relay Splitter

The Venturi effect is the reduction in fluid pressure that results when a fluid flows through a constricted section
(or choke) of a pipe. The Venturi effect is named after Giovanni Battista Venturi (1746–1822), an Italian physicist.
A nozzle is a device designed to control the direction or characteristics of a fluid flow (especially to increase
velocity) as it exits (or enters) an enclosed chamber or pipe. A nozzle is often a pipe or tube of varying cross
sectional area, and it can be used to direct or modify the flow of a fluid (liquid or gas). Fig 9 shows the CNC
Coolant Venturi Nozzle.

Fig. 9. CNC Coolant Venturi Nozzle

Mini lathe is conventional type machine used to fabricate jewellery parts and other mechanical smaller
components like nuts, bolts, screws, etc. Mini lathe is used in small scale industries as it is more conventional and
economical than other lathes, simply because bigger lathes are not necessary for these end products. Various
operations that can be done in this machine include turning, facing, boring, etc. The fig 10 and 11 shows the Mini-
Lathe Gear Model #1 and #2 respectively.

Fig. 10. Mini-Lathe Gear Model #1

14498 T. Sathish/ Materials Today: Proceedings 5 (2018) 14489–14498

Fig. 11. Mini-Lathe Gear Model #2

6. Conclusion

Design and modelling are one of the criteria before actualizing a final product manufacture, the modelling of the
product is to understand the complex structure of product before get manufactured. The objective of this study is to
print 3D components instead of modelling the prototypes and it is an additive manufacturing process to create
components from a design or model. This paper defines by not experiencing unnecessary load utilized in metals for
manufacturing small components. This results in producing same components using the unconventional material,
which is much lighter than metal, but equally stronger and durable. 3D Printing is not the ideal method for mass-
production but has been used here just to produce one unit of each component to demonstrate the product longevity
and quality due to change of material. Also, not all metal components can be replaced by ABS or its counterparts,
but only the technically and economically viable ones can, considering the design, working conditions, and stresses
subjected to. Thus this research motivates to use 3D printing techniques instead of modelling a prototype, which
consumes more time used for fabricating a product.
Reasons for failure of Gear Model #2:
• Inability to withstand forces produced due to torque of second shaft of mini lathe’s gearbox.
• Insufficient resilience for the applied moment.
• Unideal hollow shaft thickness for retention of strength when manufactured additively.

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