3D printing course overview

3D printing
3D printing referred to as additive manufacturing, creates 3D objects from digital models by layering and
bonding the material.

Objects created using 3D printing

3D printing is used to create high-quality products and prototypes.

Several types of objects can be created using 3D printing:

Lightweight objects
3D printing is used to create high-impact, lightweight objects. In automotive and aerospace
industries, reduced weight improves fuel efficiency and the range of the vehicle.

Complex objects
3D printing creates complex parts that can’t be created using other manufacturing techniques. Parts
can be combined reducing the total number of parts.

Customized Objects
3D printing is often used to create unique objects that require customization or are variations of
standardized items.

Rapid prototypes
A common use of 3D printing is creating objects or models for testing a product design prior to
production.

How is 3D printing different from traditional manufacturing?

There are three types of manufacturing:
Formative
In formative manufacturing, a part is created by molding or pressing it into the desired shape.
Formative manufacturing is used to create parts simple in design in high volume. Since creating a mold or
die is costly, this method is more cost effective for high volume parts production
Subtractive (CNC)
In subtractive manufacturing, a part is created by cutting away material from a solid block of that material.
Subtractive manufacturing is used to create parts that have simple designs in low to medium volume. It
results in a lot of waste from the large amount of material removed.
Additive (3D printing)
In 3D printing, a part is created from digital models by layering and bonding material.
Additive (3D printing) is used to create complex, lightweight or highly customized parts in low to medium
volume.

How do I select the manufacturing process?

Criteria to select the type of manufacturing include:
• Cost per part
• Number of parts to be manufactured (volume)
• Complexity or other design criteria

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• Material required

Examples of products being created by 3D printers

3D printing is being used to create a wide range of products.

Consumer products
3D printing is used to create fast prototypes and customized products such as:
• Clothes
• Shoes
• Jewelry
• Eyeglasses
• Technology accessories
• Artisan/decorative items
• Sports equipment

Healthcare
3D printing is also used for creating customized healthcare products such as:
• Hearing aids
• Prosthesis
• Implants
• Tissue and organ fabrication
• Dental corrections
• Orthotics
• Surgical models

Transportation
• Aviation
3D printing is used to create lightweight engine, airframe and other parts to improve fuel
efficiency.
In a turboprop engine design, 855 conventionally manufactured parts were replaced with 12 3D-
printed parts, resulting in 10% more horsepower, 20% fuel savings, a shorter development cycle
and lower design costs.
• Maritime
The US Coastguard is using 3D printers on ships to produce spare parts.

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Benefits of 3D printing for entrepreneurs

3D printing provides new and exciting opportunities for entrepreneurs.

Fast
Speed up business processes such as prototyping or local production.
New
Develop new design solutions for products that can’t be produced using formative or subtractive
manufacturing processes.
Customization
Create highly customized products that meet consumers’ demand for fast and personalized services.
Lower Production Costs
Reduce inventory by producing products on demand. Products can be made close to the customer’s
location, reducing shipping costs.
Reduced Investment
Low start-up costs compared to investment in traditional manufacturing equipment.
Access
Easy access to 3D printing services online.

Accessing 3D printers and 3D marketplace

There are a wide range of opportunities and resources available to 3D printing entrepreneurs.

• Desktop 3D printer
One option for an entrepreneur is to purchase or lease a desktop 3D printer. These are small
devices that provide less precision. However, they can be used to produce simple models with less
durable materials and print small, simple objects.

• Large format 3D printers

Large format 3D printers are industrial printers that enable production of advanced fully functional
prototypes and products.

• Content libraries
There are several online content libraries that provide access to free, open-source software and
paid SLT CAD files developed by hobbyists and engineers.

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• 3D printing service bureaus

These are locally based 3D printing service providers that are ideal for entrepreneurs to use to print
3D objects for use or sale.

• 3D printing marketplaces
3D printing marketplaces are web portals with directories listing 3D printing service bureaus.

• Forums
3D printing forums provide opportunities for entrepreneurs to discuss 3D printing topics and get the
help of local 3D printing groups.

3D printing processes and technologies

• Material extrusion
o Description
▪ A plastic filament is driven and melted through a heated nozzle.
▪ The printer deposits the melted material layer by layer on a platform.
▪ The material bonds and solidifies to form a solid object.
o Technologies
▪ The main technology is Fused Deposition Modeling (FDM)
▪ This technology is also called FFF (Fused Filament Fabrication)
o Applications
▪ DIY Projects
▪ Concept Models
▪ Toys and art decoration

• Powder bed fusion

o Description
▪ A high-power laser induces the fusion of very small plastic powder particles, layer by
layer over the surface of a "powder bed"
▪ Each layer is bonded to the previous one, and the process is repeated until the object is
produced
▪ Unfused material is removed during post-processing
o Technologies
▪ SLS (Selective Laser Sintering) is the most common powder bed fusion 3D printing
technology
o Applications
▪ Aerospace parts
▪ Medical and healthcare
▪ Electronics: packaging and connectors
▪ Functional proof of concept prototypes and design evaluation models

• VAT Polymerization
o Description
▪ Vat polymerization cures a liquid photopolymer resin with ultraviolet (UV) light layer by
layer
▪ The photopolymer resin is placed in a vat supported by a platform that moves
downwards after each layer is cured on top of the previous one
▪ After the object is produced, the resin is drained from the vat, leaving the printed object

o Technologies
▪ SLA (Stereolithography) uses ultraviolet laser

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▪ DLP (Digital Light Processing) utilizes traditional light-sources like arc lamps
o Applications
▪ Dental applications
▪ Hearing aids
▪ Injection mold-like polymer prototypes
▪ Jewelry
• Binder Jetting
o Description
▪ Powder is spread out in the build chamber in layers
▪ Binder is applied through jet nozzles that “glue” the powder particles, creating the shape
of the object layer by layer
▪ The finishing consists of leaving the object in the unused powder to cure and strengthen
it
o Technologies
▪ Sand Binder Jetting
▪ Metal Binder Jetting
o Applications
▪ Sand molds for castings
▪ Complex ceramic parts
▪ Functional metal parts
▪ Orthopedics
▪ Custom Tools
▪ Tools for Avionics

Materials used in 3D printing

Plastics:

• ABS
• PLA
• PVA
• Nylon
• Others

Metal:

• Aluminum
• Steel
• Brass
• Copper
• Bronze
• Sterling silver
• Gold
• Platinum
• Titanium

Others:

• Ceramic

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• Gypsum
• Food
• Biomaterial used in medical applications

3D printing process for Fused Deposition Model (FDM)

There are three steps in 3D printing – modeling, printing and finishing.
1. Modeling
During the modeling step, 3D modeling software is used to create a 3D representation of an object. The
3D model is then “sliced,” which converts the 3D drawing into a “G-code” file that contains the “slices”
required by the 3D printer to produce the object layer by layer.
2. Printing
Next, the G-code data file is sent to the printer, which creates the object layer by layer. The layers are
then fused together to create the solid object.
3. Finishing
Last, the printed object may require finishing. This entails sanding to smooth or polish the object’s
surface, painting the object the desired color, or removing any supporting materials required by the
printing process.

Case studies

Tochukwu: Inventor, engineer and 3D print service business owner.

Overview
Tochukuwu created Clintonel Technologies, a 3D print service, that provides 3D design, modeling and
prototyping for businesses and individuals. As an inventor and engineer, Tochukwu works with customers
to design and prototype their visions, as well as consults on existing designs.

Starting in 3D printing
While an engineering student in Nigeria, Tochukwu had a vision to solve technical problems with innovative
solutions. He invented a battery-powered, lighted reading device designed to improve the reading culture
and students’ academic performance in Nigeria.
Tochukwu learned about 3D printing technology and Design Thinking during 3D Africa, a Youth for
Technology Foundation (YTF) program for aspiring young entrepreneurs that teaches human centered
design, prototyping and 3D printing.

With support from YTF, he created a prototype of his reading device using 3D printing. He continued
advancing his 3D printing skills and entered several design competitions. His success led him to create
Clintonel Technologies, a place where innovative ideas are incubated into products using Advanced
Engineering Skills (AES) and Advanced Manufacturing Technologies (AMT).

Participants in 3D Africa, like Tochukwu, are taught the fundamentals of 3D modeling, manufacturing and
prototyping as well as design thinking and practical applications empowering them to use 3D printing to
create and expand their existing businesses.

Keys to success
• Follow your passion, persevere and be open to new opportunities
• Be creative to overcome obstacles
• Be a change agent

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Because Tochukwu wants 3D printing to prosper in Nigeria, he has chosen to open source his invention,
making them available to other inventors.

Innovative Shoes: Interest in the 3D shoe market is rapidly growing among entrepreneurs.

Overview
Entrepreneurs are finding ways to utilize 3D print technology to meet the needs of individuals seeking a
personalized solution to their footwear through rapid prototyping and customization. There are several
reasons why an individual might seek customized shoes:
• Foot size and shape
• Enhanced foot support
• Athletic training requirements
• Aesthetics
Whatever the reasons, custom shoes are a growing market, with the perfectly fitting shoe offering huge
appeal to consumers.

Market success
Examples of 3D printed shoe successes range from the manufacture of insoles to completely customized
shoes. Several 3D printed shoe companies are making their presence felt in the market.

Feetz shoes are custom designed and perfectly fitted to the individual user’s taste. Feetz products are
made using recycled and recyclable materials, are sustainable, and require zero water in the production
process.
Phits 3D printed insoles are customized to support the athlete’s every move. Phits takes a detailed scan
of the customer’s foot and then analyzes the scan to determine the user’s specifics needs for extra support.
A model of the insole is created and 3D printed.
3dshoes.com is an online 3D printed shoes marketplace that sells digital designs, insoles, and software
for 3D printing shoes.
Nike Flyprint is the first 3D-printed shoe in performance footwear with a textile upper.
FitStation analyzes a customer’s feet using a 3D scanner to provide off-the-shelf shoe recommendations
and custom 3D printed insoles.

Advantages
The main advantage of using 3D printing technology to create shoes is that it enables exact measurement
of the foot for fit and structure, personalized to the individual’s needs. This means that shoes that need to
be “broken in” or shoes that are uncomfortable no matter how long you wear them, will be a thing of the
past.
Another advantage is that athletic footwear companies’ high start-up costs for creating new sole unit molds
for new brands or styles can be greatly reduced. Using 3D printing, sole unit molds can be created in all
standard sizes, as well as customized sizes, for a fraction of the cost.
Additionally, 3D modeling for shoes can show potential weak spots in the shoe before it is made; and new
ideas related to designs can be applied immediately.

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Endless design potential: 3D printing is used to design and create.

Overview
3D printing is an excellent tool for entrepreneurs, artisans and designers to create their visions. 3D printing
enables intricate, complex and customized designs. 3D printing can be used to prototype the design and to
create the final product.

Market success:
Examples of companies and artisans using 3D printing.
Sheyn, a 3D printing jewelry company that creates jewelry with unconventional geometries.
Blueberries, a 3D printing jewelry company known for their organic and geometrical jewelry. Their
favorite metals are silver and brass.
Chocodiem, 3D printed artisan and customized chocolates.
Restoration of historical sites and buildings, a 16th century pagoda near London was restored with 250
3D printed dragons.
Wang & Söderström, 3D printed vases.

Advantages:
3D printing provides many advantages to designers such as:
• Creation of unique designs and complex shapes that can’t be easily created using other methods
• Limitless design possibilities
• Rapid and inexpensive way to test designs and to create the final product
• Many material choices and more than 1 material can be used
• Customized, one of a kind creation

Downloadables for the course

• 3D printing marketplaces - services – resources
• 3D printing application areas
• 3D printing materials
• 3D printing processes and technologies
• 3D printing tips

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