MANUFACTURING PROCESS-II

Lab Manual 01

Submitted to
Sir Farhan Raza

Submitted by
Abdul Rehman (2019-IM-37)
Experiment # 1 To demonstrate and familiarize the students with the capabilities of 3D
printer in terms of generating a prototype.

AIM

This study is aimed at providing a student with a thorough understanding of 3D printer as

a rapid prototyping system.

A. Methodology

Rapid Prototyping (RP) refers to the layer by layer fabrication of three dimensional (3D)
physical models directly from a computer-aided design (CAD). This additive manufacturing
process provides designers and engineers the capability to literally print out their ideas in
three dimensions. The RP processes provide a fast and inexpensive alternative for
producing prototypes and functional models as compared to the conventional routes for
part production.

The advantage of building a part in layers is that it allows you to build complex shapes that
would be virtually impossible to machine, in addition to the more simple designs. RP can
build intricate internal structures, parts inside of parts, and very thin-wall features just as
easily as building a simple cube.

An RP may consist of three consecutive steps;

A. Pre-processing (it involves generating an idea in the form of a CAD file usually
called the .stl)
B. Processing (RP takes very less time to complete a prototype with a merit of
having unattended series of layered manufacturing until the machine completes
prototype)
C. Post-processing (A prototype may need a final touch of cleaning it with the help
of various accessories/tools which are associated with RP machine)
B. Description of Procedure
Binder printing methods were developed in the early 1990s, primarily at MIT. They
developed the 3D Printing (3DP) process in which a binder is printed onto a powder
bed to form part cross sections. Contrast this concept with SLS, where a laser melts
powder particles to define a part cross section. A recoating system similar to SLS
machines then deposits another layer of powder, enabling the machine to print binder
to define the next cross section. A wide range of polymer, metal, and ceramic materials
have been processed in this manner. Several companies licensed the 3DP technology
from MIT and became successful machine developers, including ZCorp and Ex One. Z-
printer and prototypes from this printer are shown in Figure 1 and Figure 2.

This RP technology was developed at Massachusetts Institute of Technology. Three-

dimensional printing (3DP) builds the part in the usual layer-by-layer fashion using
an ink-jet printer to eject an adhesive bonding material onto successive layers of
powders. The binder is deposited in areas corresponding to the cross sections of the
solid part, as determined by slicing the CAD geometric model into layers. The binder
holds the powders together to form the solid part, while the unbonded powders
remain loose to be removed later. While the loose powders are in place during the
build process, they provide support for overhanging and fragile features of the part.
When the build process is completed, the part is heat/glue treated to strengthen the
bonding, followed by removal of the loose powders. To further strengthen the part,
a sintering step can be applied to bond the individual powders.
The part is built on a platform whose level is controlled by a piston. There may be
three steps required to describe the process for fabricating one cross section: (1) A
layer of powder is spread on the existing part-in-process. (2) An ink-jet printing head
moves across the surface, ejecting droplets of binder on those regions that are to
become the solid part. (3) When the printing of the current layer is completed, the
piston lowers the platform for the next layer.
 Fig. 1 Z-printer 510

Fig. 2 Prototypes manufactured by Z-printer

Starting materials in 3DP are powders of ceramic, metal, or cermet, and binders that
are polymeric or colloidal silica or silicon carbide. Typical layer thickness ranges from
0.10 to 0.18 mm (0.004 to 0.007 in). The ink-jet printing head moves across the
layer at a speed of about 1.5 m/s (59 in/sec), with ejection of liquid binder
determined during the sweep by raster scanning. The sweep time, together with the
spreading of the powders, permits a cycle time per layer of about 2 seconds.
Exercise Questions
1. List the types of RP techniques.
2. What is 4D Printing? Explain it.
3. Why do we use ceramic materials in the 3D printer? Add the practical
engineering applications.
4. Which rapid manufacturing (RM) techniques are used for metallic materials?
5. List the types of custom-made RP techniques.
LAB SESSION #1
1. List the types of RP techniques.
Additive rapid prototyping
The different types of additive RP technologies can be categorized into three types: liquid based
(SLA and Inkjet based Printing), solid based (FDM), and powder based (SLS). These are just a
few examples of the different RP technologies in existence. Regardless of the different types of
RP technologies, all of them require the 3D CAD model’s STL file for fabrication. These STL
files are then used to generate to 2D slice layers for fabrication. [1]
2. What is 4D printing? Explain it.
3D printing, also known as "additive manufacturing", converts digital blueprints layer by layer
into physical objects. 4D printing is based on this technology. With one big difference: It uses
"programmed" special materials and sophisticated designs to signal its 3D print to change its shape.
So, basically, 4D printing is a renovation of 3D printing, in which the special material prints the
objects that change the shape post-production. A trigger can be water, heat, air and other forms of
energy. [2]
3. Why do we use ceramic materials in the 3D printer? Add the practical
engineering applications.
Ceramics have good thermal properties and their high melting point can pose a challenge in 3D
printing. Unlike metals and thermoplastics, ceramics cannot fuse easily in the same way these
materials are when heat is applied. However, they have the ability to resist high temperatures up
to 600 ° C or 1112 ° F. This means that they are suitable for 3D printing of various objects and can
undergo various finishing processes like other materials.
Currently, ceramic is the only known 3D printing material that is food safe. In the process of
making and polishing the material, they use a type of glitter that is non-toxic and is lead free. This
means that you can use it to print utensils such as cups, plates, bowls, and other kitchen appliances.
Basically, you can safely print tableware and home decor in which you are going to serve food or
beverages. Otherwise, it is commonly used to make vases, candle holders, art, and many more.
Engineering applications
• Architecture and construction
• Maritime industry
• Healthcare and medical
• Mechanics [3]
4. Which rapid manufacturing (RM) techniques are used for metallic materials?
Commercially available options for the direct fabrication of metal parts by rapid prototyping are
extremely limited. Metal parts made by rapid prototyping processes are being used to make
injection molds. RP technology can provide great time and monetary savings, as well as
functionality, which would otherwise be impossible to achieve.
Laser engineer net shaping (LENS), solid phase sintering, liquid phase sintering, reaction binding
and related processes offer direct fabrication of fully compacted steel parts. Final machining is
necessary before using the parts. Moreover;
• Direct metal laser sintering (DMLS)

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 • Selective Laser Sintering (SLS)
• Fused Deposition Modeling (FDM) [4]
5. List the types of custom-made RP techniques.
• Stereolithography (SLA)
• Solid Ground Curing (SGC)
• Multiphase jet solidification (MJS)
• Laminated object manufacturing (LOM) [5]

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References

[1 [Online]. Available: https://www.twi-global.com/technical-knowledge/faqs/faq-manufacturing-what-

] is-rapid-
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3D
%20printing.. [Accessed 10 April 2021].

[2 [Online]. Available: https://all3dp.com/1/4d-printing/. [Accessed 10 April 2021].

]

[3 [Online]. Available: https://www.sculpteo.com/en/applications/. [Accessed 10 April 2021].

]

[4 [Online]. Available: https://prototechasia.com/en/what-is-rapid-manufacturing. [Accessed 10 April

] 2021].

[5 [Online]. Available:
] https://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=&ved=2ahUKEwit0-
f62_PvAhXKTsAKHXt2DyQQFjABegQIAhAD&url=https%3A%2F%2Fwp.optics.arizona.edu%
2F optomech%2Fwp-content%2Fuploads%2Fsites%2F53%2F2016%2F10%2F521-
Tutorial_WeiRen.pdf&usg=AOvVaw12Nghv0. [Accessed 10 April 2021].