Title: Fabrication of with worth Quick Return Mechanism with 3D Printing Technology

Abstract:
The Quick Return Mechanism (QRM) is a vital component in mechanical systems, particularly in
reciprocating machinery such as shapers and stamping presses. This mechanism allows for an
efficient return stroke, minimizing non-productive time and increasing overall operational
efficiency. In this study, we explore the fabrication of a Quick Return Mechanism using advanced
3D printing technology.

The utilization of 3D printing in mechanical engineering has revolutionized traditional

manufacturing processes, offering unprecedented design flexibility and the ability to create
complex geometries with high precision. In this research, we present the development of a Quick
Return Mechanism through additive manufacturing techniques, specifically focusing on the
advantages of 3D printing in terms of design optimization, cost-effectiveness, and rapid
prototyping.

The design process involves creating a virtual model of the Quick Return Mechanism using
computer-aided design (CAD) software, taking advantage of the unique capabilities of 3D printing
to implement intricate features that may be challenging or impossible with conventional
manufacturing methods. The selected 3D printing technology allows for the fabrication of the
mechanism in a single, integrated piece, reducing the need for assembly and improving structural
integrity.
 A MINI PROJECT REPORT
On
FABRICATION OF WITH WORTH QUICK RETURN MECHANISM BY USING 3D PRINTING
TECHNOLOGY

Submitted to Jawaharlal Nehru Technological University for the partial fulfillment of the
requirement for the degree of

BACHELOR OF TECHNOLOGY
In

MECHANICAL ENGINEERING

Submitted by
1. R, SREETEJA - 21FH5A0320
2. B.RAVIKUMAR - 21FH5A0305
3. S.IRFAN- 20FH1A0331
4. S.SUBHAN BASHA-21FH5A0330
5. G.VAMSEEDHAR- 21FH5A0310
6. S.CHIRANJEEVI- 21FH5A0324

Under the Esteemed Guidance of

Mr. SAGARKUMAR(associate professor)

Associate Professor, MECHANICAL Department

AUTONOMOUS
DEPARTMENT OF MECHANICAL ENGINEERING

Dr. K.V. SUBBA REDDY INSTITUTE OF TECHNOLOGY(Approved by

AICTE, Affiliated to JNTUA, Anantapuramu & ISO 9001:2008 Certified)

DUPADU VILLAGE, NH-44, KURNOOL (Dist.), AP-518218

2020-24
 Dr. K.V. SUBBA REDDY INSTITUTE OF TECHNOLOGY
(Approved by AICTE, Affiliated to JNTUA, Anantapur & ISO 9001:2008Certified)

DUPADU VILLAGE, NH-44, KURNOOL (Dist.), AP-518218

AUTONOMOUS

CERTIFICATE
This is to certify that A mini project Report on “ Fabrication of with worth mechanism by using 3-D
manufacturing technology” is the Bonafede work carried out and submitted by R.SREE TEJA
(21FH5A0402) ,B. RAVIKUMAR (21FH5A0305) S. SUHAN BASHA(21FH5A0330),S.IRFAN (20FH1A0331),
S. CHIRANJEEVI (21FH5A0324), G. VAMSEEDHAR(21FH5A0310) in partial fulfilment of the requirement
for the degree of “BACHELOR OF TECHNOLOGY IN MECHANICAL ENGINEERING” JNTUA, Anantapur
during 2021-20234.

PROJECT GUIDE HEAD OF DEPT.ME PRINCIPAL

MR. K.SAGAR KUMAR A. SALMON DR.J.KANNA KUMAR
Associate Professor Associate Professor professor
 ACKNOWLEDGEMENT

We wish to express our gratitude to A .Salmon M . E , Associate Professor ofMechanical Engineering,

forsupervising with his valuable and intellectual suggestions.

We express our thanks to A.Salmon M.E, Head of the Department, for extending hiscooperation and
infrastructure to complete our project successful.

We extend our gratitude to Dr.K.V.S.R.I.T Management and Dr. J. KANNA KUMAR, MTech, Ph.D.,
Principal for giving this opportunity to do this mini project work.

We are grateful to Non-teaching Staff who has given their continuous support during the external work.

We express our acknowledgement to all the faculty and non-teaching staff of Mechanical Engineering
Department for their cooperation and encouragement throughout our graduation and to our family members and
friends who have helped in one way or the other.

6
 INTRODUCTION
Additive Manufacturing :

Additive manufacturing was first used to develop prototypes in the 1980s — these objects were not
usually functional. This process was known as rapid prototyping because it allowed people to create a
scale model of the final object quickly, without the typical setup process and costs involved in creating
a prototype. As additive manufacturing improved, its uses expanded to rapid tooling, which was used
to create Molds for final products. By the early 2000s, additive manufacturing was being used to create
functional products. More recently, companies like Boeing and General Electric have begun using
additive manufacturing as integral parts of their business processes.

Additive manufacturing is the process of creating an object by building it one layer at a time. It is the
opposite of subtractive manufacturing, in which an object is created by cutting away at a solid block
of material until the final product is complete. Technically, additive manufacturing can refer to any
process where a product is created by building something up, such as moulding, but it typically refers
to 3-D printing.

Working of Additive Manufacturing :

To create an object using additive manufacturing, someone must first create a design. This is typically
done using computer aided design, or CAD, software, or by taking a scan of the object someone wants
to print. Software then translates the design into a layer by layer framework for the additive
manufacturing machine to follow. This is sent to the 3-D printer, which begins creating the object
immediately. “You go directly from digital to physical, which is quite a change,” said MIT Sloan
senior lecturer Thomas Roemer, who is the executive director of MIT’s Leaders for Global Operations
program Additive manufacturing uses any number of materials, from polymers, metals, and ceramics
to foams, gels, and even biomaterials. “You can use pretty much anything,” said Arvind Kalidindi, a
materials science and engineering PhD candidate at MIT. “As long as you find a way to locally join
two parts, you can 3-D print it.”

The actual process of additive manufacturing can be done in a number of ways, all of which can take
several hours to several days, depending on the object’s size. One common method uses a nozzle to
lay successive layers of material on top of each other until the final product is complete. Another
process uses powders, typically made from metal. This works by “filling a bed with powder, and
melting the parts of the powder that you want to form a solid part layer by layer. After you do this, all
the loose powder falls away from your final part,” Kalidindi said. This is usually done using lasers or
electron beams, but another technique involves using a polymer to adhere layers of powder together.
The part is then placed in a furnace where the plastic melts away and the powders sinter together,
forming the final part

7
 Fig : 1 working principle of additive manufacturing

Types of technologies :
Although media likes to use the term “3D Printing” as a synonym for all Additive Manufacturing
processes, there are actually lots of individual processes which vary in their method of layer
manufacturing. Individual processes will differ depending on the material and machine technology
used. Hence, in 2010, the American Society for Testing and Materials (ASTM) group “ASTM F42 –
Additive Manufacturing”, formulated a set of standards that classify the range of Additive
Manufacturing processes into 7 categories (Standard Terminology for Additive Manufacturing
Technologies, 2012).

VAT Photo polymerisation:

Vat polymerisation uses a vat of liquid photopolymer resin, out of which the model is constructed
layer by layer. Find out more here.

Material jetting:

Material jetting creates objects in a similar method to a two dimensional ink jet printer. Material is
jetted onto a build platform using either a continuous or Drop on Demand (DOD) approach.

Binder jetting :

The binder jetting process uses two materials; a powder based material and a binder. The binder is
usually in liquid form and the build material in powder form. A print head moves horizontally along
the x and y axes of the machine and deposits alternating layers of the build material and the binding
material.

Material extrusion:

Fuse deposition modelling (FDM) is a common material extrusion process and is trademarked by the
company Stratasys. Material is drawn through a nozzle, where it is heated and is then deposited layer
by layer. The nozzle can move horizontally and a platform moves up and down vertically after each
new layer is deposited.

8
Power bed fusion:

The Powder Bed Fusion process includes the following commonly used printing techniques: Direct
metal laser sintering (DMLS), Electron beam melting (EBM), Selective heat sintering (SHS), Selective
laser melting (SLM) and Selective laser sintering (SLS).

Sheet lamination :

Sheet lamination processes include ultrasonic additive manufacturing (UAM) and laminated object
manufacturing (LOM). The Ultrasonic Additive Manufacturing process uses sheets or ribbons of
metal, which are bound together using ultrasonic welding.

Direct energy deposition :

Directed Energy Deposition (DED) covers a range of terminology: ‘Laser engineered net shaping,
directed light fabrication, direct metal deposition, 3D laser cladding’ It is a more complex printing
process commonly used to repair or add additional material to existing components.

9
 WORKING MODEL

WITH WORTH QUICK RETURN MECHANISM:

The Quick Return Mechanism is a mechanical system that enables a reciprocating motion where the
return stroke is faster than the forward stroke, commonly used in machines like shapers and certain
types of presses. This mechanism is widely used in shaping, cutting, and stamping machines, where
speed is crucial for increased productivity. By employing a unique arrangement of linkages and gears,
the quick return mechanism allows machines to perform tasks rapidly in one direction and then swiftly
return to the starting position, significantly reducing the cycle time.
Components :

The various components of a Quick Return Mechanism are:

o Crank - The crank is connected to the pinion wheel or motor and rotates with a
uniform angular velocity.

o Slider & Slotted Bar - The slider is pivoted at the end of the crank, allowing free movement
into the slotted bar. Its function is to convert the circular motion of the crank into
the oscillating motion of the slotted bar.

o Connecting Rod - The connecting rod is responsible for converting the oscillating motion of
the slotted bar into reciprocating motion.

o Ram - The ram moves back and forth in the horizontal direction along the line of stroke,
completing the reciprocating motion.

Fig : 2 components of with worth quick return mechanis

10
Manufacturing of components:
Step 1 :
Design procedure for components in CATIA V5 R20 Software
Open CATIA V5:
Start CATIA V5 and create a new Part Design document.
Create a Base Part:
Extrude or revolve the sketch to create a 3D solid.
Design the Crankshaft:
1.Use the Sketch tools to create the base part of your quick return mechanism. This could be a frame
or a supporting structure
2.Create a new sketch on a plane perpendicular to the base part.
3.Draw the crankshaft profile using lines and arcs.
Extrude or revolve the sketch to create the crankshaft.
Design the Connecting Rod:
Create a new sketch for the connecting rod.
Draw the connecting rod profile, ensuring it connects to the crankshaft.
Extrude the sketch to create the connecting rod.
Add a Slider Mechanism:
Create a new sketch for the slider mechanism on the connecting rod.
Design the slider and its path, ensuring it achieves the desired reciprocating motion.
Extrude or create a surface along the slider path.
Assembly:
Create an assembly document in CATIA V5.
Insert the base part, crankshaft, connecting rod, and slider mechanism as components.
Use constraints (such as coincident, parallel, or tangent) to assemble the parts correctly.
Define Joints:
Define joints or connections between the crankshaft, connecting rod, and slider.
Specify the rotational joint for the crankshaft and translational joint for the slider.
Define Parameters:
Define parameters for the crankshaft angle and other relevant dimensions.

11
This will allow you to simulate the motion of the quick return mechanism by changing the
parameters.

Animate and Test:

Use the Assembly Design workbench to animate the mechanism.
Test the motion and ensure that the quick return mechanism functions as intended.
Refine and Optimize:
Make any necessary adjustments to optimize the design.
Refine the dimensions, improve the motion, and check for interferences.
Document the Design:
Create detailed drawings with dimensions, annotations, and views.
Add any necessary information for manufacturing and assembly.
Save and Share:
Save your CATIA V5 document.
If needed, export files for sharing or further analysis.
Save the file .STL File format

Fig 3.1 base frame Fig 3.2 connecting rod

Fig 3.3 sliding bar Fig 3.4 crank

12
Step 2 :
Import the saved file from CATIA V5 soft ware into STL File
Step 2 :
Import the saved file from CATIA V5 soft ware into STL File
Launch CATIA V5 and open the file you want to export to STL.
Navigate to the Part Design Workbench:
Ensure you are in the Part Design workbench as STL export is typically done from this environment.
Check and Clean the Model:
Before exporting to STL, ensure that your model is free from errors and any unwanted features. Use
CATIA's analysis and validation tools to identify and fix any issues.
Save the CATIA V5 File:
Save your CATIA file to ensure that you have the latest version of your model.
Export to STL:
Go to "File" in the menu.
Choose "Save As" or "Export".
Select "STL" as the file format.
Specify STL Options:
A dialog box will appear with options for exporting to STL. You may need to specify the unit of
measurement (milli meters, inches, etc.) and other export settings.
Set the desired resolution for the STL file. Higher resolution means more triangles and a larger file
size.
Define the Export Range:
Choose whether you want to export the entire model or a specific range.
Define any specific export options, such as whether to include only visible components or the entire
assembly.
Specify File Name and Location:
Choose a location to save the STL file.
Provide a name for the file and make sure the extension is ".stl".
Confirm and Export:
Review your settings to ensure they are correct.
Click "Save" or "OK" to initiate the STL export.

13
Check the STL File:
Open the exported STL file in a viewer or 3D printing software to verify that the geometry has been
accurately transferred.
By following these steps, you should be able to successfully export your CATIA V5 model to an
STL file for use in 3D printing or other applications that support the STL format. Keep in mind that
the exact steps may vary slightly depending on the version of CATIA you are using.

Step 3 :
Slicing operation procedure
Import STL File:
Open the slicing software.
Import your STL file by using the "Open" or "Import" option.
Position and Scale:
Adjust the position and scale of your 3D model on the virtual build plate within the slicing software.
Ensure that the model fits within the print volume of your 3D printer.
Set Printing Parameters:
Configure printing parameters such as layer height, infill density, print speed, and support structures.
These settings may vary based on the desired print quality and the specific requirements of your 3D
print.
Generate Supports :
If your 3D model requires support structures, enable support generation in the slicing software.
Adjust support settings based on your model's geometry.
Select Print Quality/Resolution:
Choose the desired print quality or layer resolution. A finer layer height produces higher-quality
prints but may take longer.
Preview Slices:
Use the software's preview mode to inspect each layer of the sliced model.
Check for any potential issues, such as overhangs or support structure placement.
Slice Model:
Initiate the slicing process within the software to generate the G-code file.
The G-code file contains instructions for the 3D printer on how to build each layer of the model.
Save G-code File:

14
Save the generated G-code file to your computer or directly to an SD card or USB drive compatible
with your 3D printer.
Transfer G-code to 3D Printer:
Transfer the saved G-code file to your 3D printer, either through a direct connection or by inserting
the storage medium into the printer.
Start Printing:
Load the filament into the 3D printer.
Start the printing process using the printer's control interface or the slicing software (if it supports
direct printing).

15
Materials are used in additive manufacturing :

Three types of materials can be used in additive manufacturing: polymers, ceramics and metals.
All seven individual AM processes, cover the use of these materials, although polymers are most
commonly used and some additive techniques lend themselves towards the use of certain materials
over others. Materials are often produced in powder form or in wire feedstock.

Other materials used include adhesive papers, paper, chocolate, and polymer/adhesive sheets for LOM.
It is essentially feasible to print any material in this layer by layer method, but the final quality will be
largely determined by the material. The processes above can also change the microstructure of a
material due to high temperatures and pressures, therefore material characteristics may not always be
completely similar post manufacture, when compared to other manufacturing processes.

1) Polymers:

Common plastics can be used in 3D printing, including ABS and PC. The common structural polymers
can also be used, as well as a number of waxes and epoxy based resins. Mixing different polymer
powders can create a wide range of structural and aesthetic materials. The following polymers can be
used:

Examples of polymers

ABS (Acrylonitrile butadiene PLA (polylactide), including soft

styrene) PLA
PC (polycarbonate) Polyamide (Nylon)
Nylon 12 (Tensile strength 45 Mpa) Glass filled nylon (12.48 Mpa)
Epoxy resin Wax
Photopolymer resins

2)Metals :

A range of metals can be used, including a number of options suitable for structural and integral
component parts. Common metals used: Steel, Titanium, Aluminium, Cobalt Chrome Alloy (DMLS
materials, 2014).

Maraging steel 1.2709 (Tensile Titanium alloy Ti6AI4V (Tensile

Strength 1100 Mpa)
15-5ph stainless steel
Strength: 1150 Mpa)
Aluminium alsi10mg
Strength 445mpa)
Strength: 1150 Mpa)
(Tensile Cobalt chrome alloy, Co28Cr6Mo
(Tensile Strength 1300 Mpa)
(Tensile Gold and Silver

3) Ceramics :

Ceramic powders can be printed, including

16
  Silica/Glass
 Porcelain
 Silicon-Carbide

17
Comparison Between traditional manufacturing and additive manufacturing :
As technology develops, additive manufacturing continues to gain momentum and introduces several
advantages over traditional manufacturing methods.

 Complex Geometries:

AM allows for the creation of complex patterns, including intricate internal structures and
organic shapes, which are challenging or impossible to produce with traditional methods.

 Customization:

It enables easy customization and personalization of products, while conventional methods are
suited for mass production. Using AM, each item can be tailored to specific requirements
without incurring additional tooling costs or production delays.

 Waste Reduction:

AM processes generate minimal waste material since they add material selectively, using only
what is necessary to build the object. This also reduces material costs and environmental
impact.

 Simplified Equipment:

Traditional manufacturing processes often involve multiple steps, each using different
machines. Yet, in additive manufacturing, a single device handles all aspects of creation. For
example, metalworking often uses a combination of turning, milling, and drilling to produce a
finished metal part.

 On-Demand Production:

AM allows for decentralized and on-demand production, reducing the need for large
inventories and enabling localized manufacturing. It lowers the barriers to entrepreneurship
and product development. With the help of 3D printers, companies can prototype and produce
their products in a single device instead of investing in an entire factory.

18
Process parameters and conditions for AM
The print quality and structural integrity of 3D-printed building components depends upon several
inter-linked parameters, and researchers are putting forth efforts to optimize the material mixtures and
process parameters. The mechanical properties of 3D-printed concrete elements depend upon a number
of factors including the material deposition rate, material characteristics, printing speed, printing
orientation, and material orientation.

1) Extrudability:

The extrudability and compressive strength can also be improved by fly ash, but it decreases if the fly
ash content exceeds 25% of the cement mass. Ma et al. utilized copper tailing to enhance the
extrudability of concrete, but an increase in copper content reduces the buildability of the mixture. B.
Panda et al. recently performed the investigation on fresh properties of alkali activated slag mixtures
with addition of Nano clay and hydro-magnesite seeds. Addition of 0.4% Nano clay provided
improved extrudability and thixotropy, furthermore, with introduction 2% nucleation seeds authors
were able to print actual 3D structure proving the commercial application of the proposed mixture.

Interlayer adhesion
Interlayer adhesion compliments the yield strength of the printed structure, however, bond strength
between two subsequent layers depends upon material properties and process parameters. Higher
thixotropy of the mixture and longer time between printing of two layers reduces the bond strength,
however, lower standoff distance improves interlayer bonding

. Other parameters
In addition to above-mentioned process parameters, some other parameters related to all extrusion-
based AM processes also affect the print quality, including the nozzle shape, aggregate size, optimum
mixture, printing orientation, and introduction of reinforcements while printing.

Printer nozzle:
The design of the nozzle for the CC process affects the process performance, and some researchers
have pointed out the need for its optimization Finite element simulations have been performed to study
the effects of nozzle shape on print quality. It was concluded that a square-shaped nozzle is best suited
for both interlayer adhesion and surface profile, and this hypothesis was validated through
experimentation. The nozzle standoff distance is another critical parameter for the printed layers'
shapes and properties. Compaction and interlayer adhesion can be achieved by maintaining a nozzle
stand-off distance slightly less than the length of the nozzle opening.

Working area
The size of the working area determines the maximum dimensions of the printed object – both its
weight and dimensions (x, y, z).The most common home 3D printers have a working field in X and Y
of around 200-250 [mm], there are also some in the 300-350 [mm] range, but these are less common.
As for the height in the z-axis, it is usually 200 to 300 [mm].VSHAPER industrial printers have
working area sizes: 250x250x175 [mm] or 420x420x420 [mm]. They make it possible to print more
parts at the same time (small batch production) or to print larger models.

19
Table positioning
Most industrial printers use auto levelling of the table before printing, so that each print is placed on
the working platform in the same way. This eliminates the problems of print detachment and failed
prints. In home printers, the presence of such a sensor is optional and rare. This involves controlling
the alignment of the work platform and adjusting it manually. This is tedious and labour-intensive.

Chamber
Home printers are usually open designs without an enclosed print chamber, this presents problems
when printing materials that have higher shrinkage during cooling such as ABS. This can cause
problems such as corners coming loose on larger prints or even the entire print falling off the work
platform or the model cracking and delaminating .Most industrial machines have a chamber to stabilise
the air in the chamber and minimise the risk of print distortion due to material shrinkage. In addition,
heating systems for such a chamber are often used, which further stabilises the conditions in which the
printing takes place. This makes it possible to print even very demanding materials such as
PEEK.PEEK is a highly specialised material, biocompatible and even used in medicine.

Filaments
Home printing is directly related to materials with relatively lower processing temperatures, i.e. PLA,
PET-G, ABS. There are very few machines that process high-temperature materials such as PEEK.
Firstly, such materials are more expensive and require much more knowledge about their use. PEEK
is a highly specialised material, biocompatible and even used in medicine.

Material feeder
In industrial printers, the most common type of material feed is called Direct. This means that the
material feeder is located above the hotend in the print head. Thanks to the short distance between the
feeder and the nozzle, we are able to feed material more precisely and use materials with less rigidity
such as TPU (rubber). Unfortunately, this is associated with greater weight, this at higher speeds can
affect the speed performance of the machine. Therefore, the XY layout of industrial machines needs
to be stiffer, which comes at an additional cost .More common in home printers is the Long Distance
system, where the feeder is hooked onto the printer’s support structure rather than directly onto the
print head. Material is fed via a tube from the feeder to the head.

20
Temperature
Home 3D printers, by virtue of their lower price, will in most cases have lower temperatures at
which they can melt material. This is due to the use of cheaper and less thermally robust materials, as
well as the open chamber.

Print speeds
FDM printing speeds for both segments – industrial and home printers – are very similar. Radical
differences are not observed, due to the mechanical properties of the materials limiting the printing
speed. However, with industrial prints, time is saved by not having to position the work table before
each print, so more models will be printed in less time.

21
 Applications :

The use of 3D printing has exploded since the turn of the 21st century and has changed the traditional
ways of manufacturing products. With 3D printers, machines that build complex, intricate parts layer-
by-layer, limited only by the designer's imagination and the capabilities of the printed materials,
seemingly anything can be manufactured. 3D printing, compared to traditional manufacturing methods
such as CNC machining or injection moulding, requires less skill and expertise and less upfront
preparation to make parts. From advanced aerospace components and medical implants to tools and
equipment to home decor, the applications of 3D printing are evidently endless. This article will review
10 applications of 3D printing, and briefly discuss different types of 3D printing, the benefits of 3D
printing, and related topics.

1. Prosthetics
3D printing has revolutionized how prosthetics are created. As 3D printing processes and techniques
are refined, the creation of custom, tailored prosthetics becomes more straightforward and more
efficient. Prosthetics can quickly be modeled in CAD (computer-aided design) software and fabricated
by 3D printing. If any errors or defects are found in a 3D-printed prosthetic, it can easily be modified
in CAD, and reprinted. Consequently, 3D printing of prosthetics can lead to better patient outcomes,
comfort, and satisfaction.

2. Replacement Parts
Another application of 3D printing is the ability to fabricate replacement parts easily. This can be
enormously beneficial to consumers since it reduces both the need to travel to pick up parts and the
long lead times to obtain them. 3D printing enables consumers and businesses to maximize the value
of their purchases and spend more time on more important matters.

3. Implants
The 3D printing of implants allows the construction of more specialized products for patients. Patient
outcomes are improved when parts with complex geometries can be fabricated quickly. Items like
tooth implants, heart valves, knee replacements, and maxillofacial implants are all examples of
implants that can be 3D printed. Soon, entire organs could be 3D printed which could dramatically
improve outcomes for patients awaiting transplants. Figure 1 below shows a 3D-printed dental implant

Pharmaceuticals
3D printing can create drugs of different shapes and sizes and can be used to spatially distribute active
and inactive ingredients in the body. This enables 3D-printed drugs to have special delivery profiles
that can be tailored to patients’ specific needs. While only one drug, Spritam®, a levetiracetam
produced by Aprecia Pharmaceuticals has been 3D printed, 3D printing may enable on-demand, local
fabrication of additional drugs in the future.

Emergency Structures
Natural disasters such as hurricanes, wildfires, and tornados can leave many people homeless for an
extended time. 3D printing can help alleviate the hardships of affected families by building houses,
hospitals, and other structures much faster than the time it takes to build these structures by traditional
means.

22
 Aeronautics and Space Travel
As humanity looks to expand its presence in space, 3D printing can be used for the on-demand
fabrication of tools, equipment, and entire structures in space and extraterrestrial environments.
Meanwhile on Earth, 3D printing can be used to produce advanced aerospace components such as
airframes, avionics housings, and more. Overall, 3D printing can help make space travel more cost-
effective and consequently aid in creating a sustainable human presence.

. Custom Clothing
The fashion industry is notorious for the amount of waste generated by discarded apparel. 3D printing
can help alleviate some of this waste by enabling the fabrication of custom clothing. By allowing
consumers the ability to print clothing specific to their measurements and fashion tastes on demand,
consumers can obtain more of what they want with less waste.

8. Custom-Fitted Personal Products

Many of the objects that people encounter every day are designed with the average body type or size
in mind. Items like doors, chairs, clothing, keyboards, and desks are designed to be used by a person
with an average build within a particular region. This is difficult for many people who fall outside of
these “average build” bounds and can lead to discomfort and disability. 3D printing allows the creation
of custom-fitted personal products which improve ergonomics, comfort, and safety for everyone.

Educational Materials
3D printing can be used to provide students with tangible objects that can be used for learning. Items
like topographical maps or biological replicas can be 3D printed to enhance learning. As a result, 3D
printing can be used to catalyse creativity, better learning, and foster collaboration.

Rapid manufacturing:
Advances in RP technology have introduced materials that are appropriate for final manufacture,
which has in turn introduced the possibility of directly manufacturing finished components. One
advantage of 3D printing for rapid manufacturing lies in the relatively quick and inexpensive
production of small numbers of parts.

Rapid manufacturing is a new method of manufacturing and many of its processes remain unproven.
3D printing is now entering the field of rapid manufacturing and was identified as a "next level"
technology by many experts in a 2009 report. One of the most promising processes looks to be the
adaptation of selective laser sintering (SLS), or direct metal laser sintering (DMLS) some of the better-
established rapid prototyping methods. As of 2006, however, these techniques were still very much in
their infancy, with many obstacles to be overcome before RM could be considered a realistic
manufacturing method. There have been patent lawsuits concerning 3-D printing for manufacturing.

Rapid prototyping
Main article: Rapid prototyping
printed object
Industrial 3D printers have existed since the early 1980s and have been used extensively for rapid
prototyping and research purposes. These are generally larger machines that use proprietary powdered
metals, casting media (e.g. sand), plastics, paper or cartridges, and are used for rapid prototyping by
universities and commercial companies

23
Advantages of additive manufacturing :

1. Rapid Prototyping

One of the most significant advantages of additive manufacturing is that it can be used to create
prototypes quickly and efficiently. In the past, creating a prototype could take weeks or even months.
With additive manufacturing, a prototype can be created in a few days. Once the prototype is created,
it can be used to test the functionality and design of a product before it goes into production. This
allows for necessary changes before mass production, saving time and money in the long run.

2. Improved Accuracy

Additive manufacturing also offers improved accuracy over traditional manufacturing. With additive
manufacturing, there is no need for human intervention during the manufacturing process, so there is
less room for error and objects can be created with greater accuracy. In addition, additive
manufacturing processes allow for a higher degree of customisation and flexibility .The ability to
digitally adjust the design of an object before it is printed means that objects can be customised to meet
the specific needs of a customer or application. This is a significant advantage for manufacturers who
must produce precisely customised products for their particular needs.

3. Material Waste Reduction

Another advantage of additive manufacturing is that it generates very little waste material. With
traditional manufacturing processes, such as machining, a large amount of waste material is produced
as excess material is removed from the workpiece. Additive manufacturing processes build objects
from the ground up, reducing the waste material, and sometimes, the only waste generated is the
powder or filament used to create the object. This makes additive manufacturing a much more efficient
and eco-friendly manufacturing process.

In addition, the waste material generated by additive manufacturing processes is often easier to recycle
than the waste generated by conventional manufacturing processes. This is another way that additive
manufacturing can save manufacturers money.

4. Energy Efficiency

Traditional manufacturing processes require a lot of energy to power the machinery and equipment.
The equipment also often requires secondary tools, such as cooling systems, which use even more
energy.Additive manufacturing processes are much more energy efficient. The machines used in
additive manufacturing are smaller and use less energy. In addition, minimal auxiliary equipment is
required, further reducing energy consumption.

This reduced energy consumption can lead to significant cost savings for manufacturers. In some cases,
the energy savings can be so substantial that the cost of the additive manufacturing equipment can be
offset in just a few years.

5. Reduced Costs for Small Production Runs

Small production runs can be very costly with traditional manufacturing. This is because the setup
costs are fixed, regardless of the number of products produced. Additive manufacturing has no setup

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costs and can be used to produce small production runs very efficiently. This is a major advantage for
manufacturers who need to make small quantities of products.

6. Inventory Reduction

Most manufacturers will tell you that one of their biggest concerns is inventory. They need to have
enough stock to meet customer demand, but they must also keep costs under control. Additive
manufacturing can help manufacturers reduce their inventory costs. This is because AM can be used
to produce products on demand, as needed. This means that manufacturers can make only the products
that they need when they need them and don’t have to worry about keeping excess inventory on hand.
This can lead to significant cost savings for manufacturers and reduced risk.

7. Environmentally Friendly

We all know what happens when products are manufactured using traditional methods: pollution.
According to the Centre, carbon dioxide emissions from manufacturing account for 76 per cent of all
industrial emissions worldwide. This pollution takes a toll on the environment and human health.
Additive manufacturing is a much more environmentally friendly manufacturing process. As we’ve
seen, it generates very little waste material and is much more energy efficient than traditional
manufacturing processes.This reduced environmental impact is a major advantage of additive
manufacturing and is something that all manufacturers should consider.

8. Unique Designs

Companies that use additive manufacturing often create unique designs that are impossible with
traditional manufacturing methods. Additive manufacturing allows for much more complex designs
and shapes than conventional manufacturing.This gives companies a competitive advantage, as they
can create products that are not only better and more efficient but also more unique and appealing to
customers.With AM, the sky is the limit when it comes to design. This technique allows the creation
of nearly any geometric form, which would otherwise be impossible or too expensive to produce using
traditional processes.

9. Supply Chain Flexibility

The supply chain for traditional manufacturing is inflexible and often very complex, which can lead
to problems, such as long lead times when demand for a product suddenly increases.

Additive manufacturing is much more flexible, as it can be used to produce products on-demand, as
needed. This means that manufacturers can respond quickly to demand changes without worrying
about the complex supply chain.

Also, because additive manufacturing is so energy efficient, it can be used to produce products locally
without having to transport them long distances. This further reduces the complexity of the supply
chain and can lead to significant cost savings.

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Disadvantages of Additive Manufacturing
1. Limit on Materials

Additive Manufacturing is limited to a handful of materials, which means there can be some
circumstances where it’s not a suitable procedure. For rapid prototyping purposes, this usually isn’t as
much of a problem as parts are simply being produced for early testing and review before final
production can begin. However, with parts that are being produced for use in final assembly, it’s
important to ensure the materials chosen have the correct properties for their application.

2. High Production Costs

Although the cost of additive manufacturing has been falling in recent years, in some cases it can still
be more expensive than traditional manufacturing methods .Another reason for the high cost of
additive manufacturing is the need for specialised raw materials. AM machines often require
exceptionally small or fine particles, which can be expensive to produce, increasing the raw material
cost.

3. High Production Costs

The initial cost of setting up an in-house additive manufacturing operation can be high as you need to
invest in the right equipment and materials and train your staff on how to use the machines. This cost
can be a barrier for small businesses or start-ups that want to use additive manufacturing, and switching
to additive manufacturing can be costly and disruptive for companies that already have a traditional
manufacturing operation.

4. It Can Be Slow

Compared to traditional manufacturing methods, for some components, additive manufacturing can be
relatively slow. While it can produce multiple parts simultaneously, additive manufacturing is still not
the right choice for companies that need to produce large quantities of products quickly, unless you
work with a specialist 3D printing partner like Prototile.

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 Future possibilities of Additive manufacturing

As 3D printing has transitioned from a simple desktop to large industrial-grade systems, the
capabilities, material properties, and 3D printed products have also advanced. Materials science,
automation technologies, artificial intelligence (AI), and deposition processes are continually evolving
and leveraged in 3D printing solutions. Innovation in each of the key areas: 3D printing machines,
materials, and software as well as how they work together is shaping the future of additive
manufacturing.
Companies unfamiliar with additive manufacturing and 3D printing processes may not know 3D
printing is transforming manufacturing across multiple industries. Understanding the future of additive
manufacturing will enable companies to stay competitive and even future-proof their businesses.

Smart Factory
A “smart factory” is a highly automated facility that manufactures products with minimal labor. With
low labour costs, smart factories can be located anywhere – even in traditionally high-cost regions. A
modern smart factory leverages 3D printing to provide a simplified, yet highly scalable manufacturing
process that can also produce a wide range of products. Manufacturing facilities can implement a fully
additive manufacturing model or take a hybrid approach – with traditional and 3D manufacturing
existing side by side – to more easily support scaling production up or down based on demand. As
more 3D printing smart factories come online, more companies can implement an agile manufacturing
approach and respond better to customer demand, while derisking production.

Increased Customization
Many products, such as apparel and medical devices, can benefit from or require some level of
customization. Most dental products are custom e, where one or multiple units are produced to support
the personalized treatment plan. Customization of high-volume products is traditionally complex and
involves long and iterative cycles to get from a prototype to high volume production. The risk to this
approach is that products with high SKU counts can cause tooling and assembly costs to balloon.

Simpler and Faster Production

Newer 3D printing solutions have improved throughput by increasing the speed and build volume as
well as significantly reducing post-processing. One of the recent enablers of greater simplicity and
higher throughput is technology enhancements to DLP 3D printing processes that have implemented
larger build areas and faster Z-printing. DLP printing processes have fewer steps, less post-processing
compared to legacy 3D printing solutions, and can eliminate or reduce assembly for complex designs
– in some cases improving process efficiency by 50-90%. Modern additive manufacturing providers
are focusing on ‘production – first’ and building scalable solutions that simplify manufacturing and
accelerate production.

Higher Accuracy
The most advanced 3D printing systems offer high resolution leveraging the same technology in TV
screens. The best 3D printing systems are accurate at up to 50 microns. Leveraging optical processes
in 3D printing systems is a key element in the future of additive manufacturing as they can be used as
building blocks to increase the print area without impacting performance such as speed, as seen when

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scaling FDM 3D printing. With more advanced projection screens and resin-printing techniques,
accuracy and the ability to print small features or elements will continue to improve.

Advanced Materials
3D printing systems can accommodate almost any design or geometry. Rather than having tooling
determine which products can be manufactured, at additive manufacturing facilities – it will be which
resins are available onsite. Additive manufacturing sites can produce products for many application
areas and industries if they have the 3D printable resins onsite. One example of flexibility is in dental
where one printer can produce many different kinds of dental appliances, such as surgical guides, night
guards, and aligners with a suite of specialized dental resins. 3D printable resins and materials continue
to improve at a rapid pace. The future of additive manufacturing is more productive sites, as each
facility will have a broad range of materials to support diverse product lines.

Automated and Intelligent Software

Innovation in additive manufacturing software, such as generative design, cloud, and automation, and
artificial intelligence (AI) software is simplifying manufacturing. For example, generative design can
bridge the gap between what can be accomplished with traditional and additive manufacturing, and
advancements in dental 3D printing software can heal models. Cloud software can aggregate and
optimize manufacturing capacity across machines as well as allow customers to directly access
available 3D printing machines for on-demand production. In the near future, additive manufacturing
software will become more predictive, identifying machines that will need maintenance or
automatically tuning printing parameters to ensure consistent production from machine to machine
without a human operator.

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 Conclusion

Additive manufacturing techniques are playing a major role for industry to quickly evaluate design
and help in downstream production. Additive manufacturing techniques have much inherent potential
that makes AM tooling very attractive; in particular, complex inserts would pose no challenge for AM
machines. Direct rapid tooling based on improved additive manufacturing techniques is a viable
alternative to conventional production tooling. One of the most important goals of direct rapid
tooling is to respond faster to market needs, and create a new competitive edge. Over the past decade,
as additive manufacturing technology has matured, so have the applications for use in rapid tooling.

In this chapter direct rapid tooling techniques are reviewed and different DRT processes are presented,
along with the most promising methods, and their intrinsic properties are outlined. There is not a single
method to be definitely mature, and all of them need to be improved. The main issue of concern in the
new metal-based processes is the material, especially powders. Necessary research and developments
is described in terms of direct rapid tooling requirements. High-performance tooling has generated
attraction in recent years to cut down moulding cycle time by means of conformal cooling channels.
In fact, creating conformal cooling channels within the tool removes heat from the Mold faster than
straight-line channels used in conventional tools. This can reduce injection-moulding cycle times,
which increases production rates, lowers part costs, and can even improve part quality.

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