3D Printing

Girum Tesfaye
EmTe 1012
(UGR/2443/12)
 3D printing

Table of Contents
Introduction...............................................................................................................................................2
1. 3D Printing........................................................................................................................................2
1.1. What is 3D printing and how does it work?..........................................................................2
1.1.1. Methods..............................................................................................................................2
1.1.2. Materials.............................................................................................................................2
1.1.3. Steps of 3D Printing..........................................................................................................2
2. Types of 3D Printing........................................................................................................................3
3. Applications of 3D Printing.............................................................................................................3
4. Challenges for 3D Printing..............................................................................................................3
References..................................................................................................................................................4

By: Girum Tesfaye Gedecho (UGR/2443/12)

Student at Addis Ababa University, Pre-engineering at EiABC
Section C

1
 3D printing

1. Introduction
3D printing is the process of producing objects from computer-aided design (CAD) model data,
usually adding layer upon layer, in contrast to conventional subtractive manufacturing
methods that involve the removal of material from a starting work piece.

3D printing is also called additive manufacturing, additive fabrication, or free-form fabrication.

These new techniques, while still evolving, are projected to exert a profound impact on
manufacturing. They can give industry new design flexibility, reduce energy use, and shorten
time to market. In this paper, I revisit brief concepts of 3D printing.

2. 3D Printing
2.1. What is 3D printing and how does it work?
3D printing, also known as additive manufacturing, was developed in the 1980’s as a process
used to make three dimensional objects. Additive manufacturing creates parts from the ground
up by fusing together layers of material. Its counterpart, subtractive manufacturing, begins with
material and removes excess until only the desired shape remains.

2.1.1. Methods
There are several methods of 3D printing. The most commonly recognized is called Fused
Deposition Modeling (FDM). This method uses a single nozzle head to extrude melted material,
typically, plastic, layer by layer onto a build platform according to the 3D data that has been
supplied to the printer. One of the most familiar printers in this space, the MakerBot, uses the
FDM method. Other 3D printing processes, like Stereolithography (SLA), fuses together liquid
material by curing it with a UV laser; while Binder Jetting fuses together powder material with
a binding spray. Today, these methods are still more expensive and specialized than FDM.1

2.1.2. Materials
The materials used in 3D printing are often dependent on the method. Binder Jetting for
instance, might use sandstone material, while SLA and FDM typically use plastic or resin. But
what was once a small list of printable materials has been rapidly expanding. Plastics today
include stronger substances like nylon, as well as biodegradable plastic. Paper, ceramics, and
metals are growing in popularity and helping to expand applications for 3D printing. Most
recently on the scene are food materials like chocolate, sugar and even meat.

2.1.3. Steps of 3D Printing

It’s important to note that the process of 3D printing has many steps and is not as automated as
some might think. From file preparation (e.g., creation, conversion), to actual printing, to the
finishing work post-print (e.g., sanding, coating, removing support material), the output of 3D
printing takes time. However, open-source file sharing on sites like Thing-verse and Grab CAD
are making it faster for designers to get started.

3. Types of 3D Printing
Fused Deposition Modeling, is an additive manufacturing technology commonly used for
modeling, prototyping, and production applications.

2
 3D printing

 Advantages: Cheaper since uses plastic, more expensive models use a different (water
soluble) material to remove supports completely. Even cheap 3D printers have enough
resolution for many applications.
 Disadvantages: Supports leave marks that require removing and sanding. Warping,
limited testing allowed due to Thermo plastic material.

SLA – Stereolithography, Stereolithography is an additive manufacturing process which

employs a vat of liquid ultraviolet curable photopolymer "resin" and an ultraviolet laser to build
parts' layers one at a time. For each layer, the laser beam traces a cross-section of the part
pattern on the surface of the liquid resin. Exposure to the ultraviolet laser light cures and
solidifies the pattern traced on the resin and joins it to the layer below.

 Advantages: Speed is one of the advantages of stereolithography; functional parts can be

manufactured within a day and can produce a wide variety of shapes.
 Disadvantages: It has often been expensive; the cost of photo-curable resin has long
ranged from $80 to $210 per liter, and the cost of stereolithography machines has ranged
from $100,000 to more than $500,000.

SLS - Selective laser sintering, is an additive manufacturing technique that uses a high-power
laser (for example, a carbon dioxide laser) to fuse small particles of plastic, metal (direct metal
laser sintering), ceramic, or glass powders into a mass that has a desired three-dimensional
shape.

 Benefits: SLS allows for more rigorous testing of prototypes. Since SLS can use most
alloys, prototypes can now be functional hardware made out of the same material as
production components.

4. Applications of 3D Printing
 Biomedical Engineering, scientists and engineers have already been able to use 3D printing
technology to create body parts and parts of organs.
 Aerospace and Automobile Manufacturing, aerospace and automobile manufacturers have
been using 3D printing as a prototyping tool for some time now.
 Construction and Architecture, Architects and city planners have been using 3D printers to
create a model of the layout or shape of a building for many years.
 Product Prototyping, 3D Printing revolutionized the industry by allowing designers to
create and the next day see and touch their design.

5. Challenges for 3D Printing

To achieve a wider range of applications for 3D printing, efforts will need to overcome some
key technical challenges, including the following:

 Process control. Feedback control systems and metrics are needed to improve the precision
and reliability of the manufacturing process and to increase throughput while maintaining
consistent quality. Feedback control is especially challenging for 3D printing processes, with
rapid deposition rates. The ability to tailor the material microstructure in situ could improve
performance properties.

3
 3D printing

 Processing speed. While low-volume production is faster than CM, higher volumes are
considerably slower. For example, a new generation of 3D printing machines is needed to
replace injection molding and casting machines. Making parts in parallel production (side-
by-side in the machine) may speed up the process, allowing 3D printing to compete with
CM methods such as injection molding.
 Electrical power. The impact of power quality on 3D printing equipment is not well
understood. Power variations and interrupts can impact the quality of the item produced
using 3D printing by introducing defects that may not be detected. Research is needed to
evaluate the power quality characteristics of 3D printing equipment and develop a better
understanding of the design and makeup of this new type of manufacturing system.
 Material compatibility. Materials that can be used with 3D printing technologies are
currently limited to a relatively small set of compatible materials. There is a need for new
polymer and metal materials formulated for 3D printing to provide materials properties,
such as flexibility, conductivity, transparency, safety, and low embodied energy.

6. References
1. Quadrennial Technology Review 2015, Innovating Clean Energy Technologies in
Advanced Manufacturing, ©US Department of Energy
2. Additive manufacturing, Indian Institute of Technology KanPur, by N. Sinha
Department of Mechanical Engineering.
3. Domain Group 3D Printing Workshop Notes, European Social Fund 2007-2013
ministry for education and employment.
4. Additive Manufacturing, by Stelian Coros, 2018
5. An Introduction to 3D Printing, A whitepaper provided by ©pii September 2015
6. Cover page image credit: ©Cuberlab https://cuberlab.com/program-desgin-
optimisation-additive-manufacturing/

By: Girum Tesfaye Gedecho (UGR/2443/12)

Student at Addis Ababa University, Pre-engineering at EiABC
Section C