CAD/CAM FABRICATION

AND 3D PRINTING
• Dr Patrick Hanratty invented
the first numerical control
system ,which is later became
the CAD
• MIT's Computer-Aided
Design Project developed
software for architectural
design.
•The integration of CAD and
CAM systems became more
common.
•3D CAD systems started to
gain popularity.
•3D printing and additive Artificial intelligence and
manufacturing technologies machine learning started to
gained prominence. play a larger role in CAD/CAM,
•Cloud-based CAD solutions and enabling generative design
collaboration tools became and automation.
more prevalent.

1960’s 1970’s 1980’s 1990’s 2000’s 2010’s 2020’s

• The development of CAD
software began.
• Dr. Patrick Hanratty created
the first commercial CAM
software, known as PRONTO.
The advent of parametric
modeling in CAD software
allowed for greater design
flexibility.
•The use of simulation tools for
virtual testing and analysis of
CAD models expanded.
•Augmented reality (AR) and
virtual reality (VR) were
integrated into CAD/CAM
workflows.
•CAD: computer-aided design;
software that crafts virtual
models of parts and part
assemblies that will later be
manufactured.
•CAM: computer-aided
manufacturing; software that
directs the actual
manufacturing of said part(s)
by communicating with a
numerically controlled (NC)
manufacturing machine.
•3D printing: the process of
building parts by laying
material on a base or on other
material in a predetermined
motion.
• Computer-aided design (CAD) involves creating computer models
defined by geometrical parameters. These models typically appear on
a computer monitor as a three-dimensional representation of a part
or a system of parts, which can be readily altered by changing
relevant parameters. CAD systems enable designers to view objects
under a wide variety of representations and to test these objects by
simulating real-world conditions.

• Computer-aided manufacturing (CAM) uses geometrical design data

to control automated machinery. CAM systems are associated with
computer numerical control (CNC) or direct numerical control (DNC)
systems. These systems differ from older forms of numerical control
(NC) in that geometrical data are encoded mechanically. Since both
CAD and CAM use computer-based methods for encoding geometrical
data, it is possible for the processes of design and manufacture to be
highly integrated. Computer-aided design and manufacturing systems
are commonly referred to as CAD/CAM
General manufacturing process :
Design
The process starts with the creation of a 3D digital model
of the object to be printed.
This design can be created using computer-aided design
(CAD) software or obtained from existing 3D models.
Slicing:
The 3D model is sliced into thin horizontal layers (slices)
using slicing software. This software generates a set of
instructions, known as G-code, that guides the 3D printer
on how to build each layer.
Material Selection:
Choose the appropriate printing material, such as plastics
(e.g., PLA, ABS), metals (e.g., aluminum, titanium),
ceramics, or even biological materials for bioprinting.
3D Printing:
The 3D printer, equipped with a print head or nozzle, starts to create the object layer by layer based on the G-code instructions.
Different 3D printing technologies use various methods to deposit and solidify the material

Different technologies

Fused Deposition
Stereolithography
Modeling (FDM):
(SLA): Uses a UV laser
Extrudes
to cure liquid resin
thermoplastic
layer by layer.
filament layer by
layer.

Selective Laser
Powder Bed Fusion
Sintering (SLS):
(PBF): Melts or sinters
Utilizes a laser to
metal powder layer by
sinter powder
layer.
material layer by
layer.
Electron Beam Melting
(EBM): Uses an electron Binder Jetting:
beam to melt metal Deposits a
powder layer by layer. binding agent
onto powder to
create layers.

Post-Processing (optional):
Depending on the 3D printing technology and material used, post-processing may be required. This can include tasks like removing support structures,
sanding, polishing, or additional curing steps
Quality Control:
Inspect the printed object for defects, accuracy, and adherence to design specifications.
Assembly (if needed):
Assemble multiple 3D-printed parts, if applicable.
Final Finishing (if needed):
Apply additional finishing touches, such as painting, coating, or surface treatments.
3D PRINTING IN CONSTRUCTION
Types of 3D printers
Robotic arm

• Automatically controlled printer that allows freedom of

movement and flexibility to schedule multiple tasks.
• The arm is capable of printing from multiple angles,
allowing the realization of complex geometries and curves,
and printing in larger sizes compared to other 3D printing
methods.

Gantry system

• The contouring method marks the beginning of 3D printing

in construction.
• This process deposits building material to form a 3D model
and create large-scale structures with a smooth surface
finish.
• It works with rails placed around the floor of the building
that act as a guide to direct the robotic arm in the
application of the concrete layer by layer.
Methods

There is no one-size-fits-all 3D printing construction technology.

Depending on the specifics of the project, different printing methods can
be employed. The most common are:

1.Extrusion:
• Extrusion is the most common 3D printing technique as it can be
used in almost all environments.
• Commonly used for modeling, prototyping and production
applications.
• this method creates an object by layering material back and forth
through one or more nozzles mounted on a robotic arm, gantry system
or crane.
2.Spray:
• The autonomous robot sprays the construction material under
pressure in the desired shape and repeats the process layer by layer.
• This method allows to fill the spaces of the structure with concrete, and
its use is currently being studied for vertical and outstanding
applications such as facades or ceiling decorations.
3. Powder Bonding:
• Contrary to other 3D printer construction methods, powder
bonding uses powdered raw material as its main component.
There are two methods:

A. Powder bed jetting

• It is characterized by melting dust particles with a laser on the
desired object layer by layer, while a coating sheet adds more
material for each new layer.

B. Binder jetting.
• The binder jetting uses a print head that deposits a liquid adhesive
agent on the powder printing bed.
• The liquid binds the powder particles together to form each layer
of the desired object.
• Then a new layer is added, and the process is repeated layer by
layer. This one allows printing with a higher level of accuracy and
can handle more complex prints.

https://www.youtube.com/watch?v=HoQOz04VEkI
Materials
Recent advances in construction 3D printing
have increased the number of different
materials available. The material selected
should depend on the type of project in
question, however, the most common
materials used are:
•Standard concrete,
•Proprietary concrete mixes- Lavacrete is a
proprietary material created by ICON's
material science team to be both highly
printable and incredibly strong. Lavacrete has
gone through rigorous testing and
development yielding an extremely durable
building material.
•Mortar,
•Plastic,
•Metal, and
•Local natural materials (stone, sand, mud, rice
waste, etc.)
 Plastics • Polylactic acid [PTA] Ceramics:
• Polyethylene Terephthalate Glycol-Modified[PETG 3D printing with ceramics is used for creating intricate and
• Acrylonitrile Butadiene Styrene[ABS] heat-resistant objects, including components for the
• Nylon aerospace and medical industries.
• Thermoplastic Polyurethane[ TPU]
• Polyether Ether Ketone[PEEK]

Metals • Stainless steel Resins

• Aluminium • SLA (Stereolithography) Resins: SLA resins are
• Titanium photopolymer materials that cure when exposed to UV
• Inconel light. They are used for high-detail and smooth-surface
• Cobalt chrome Materials prints, often in applications like jewelry and dental
devices.
• DLP (Digital Light Processing) Resins: Similar to SLA
resins, DLP resins also cure with light. They are used for
Biocompatible rapid prototyping and dental applications.
Materials: • SLS (Selective Laser Sintering) Powders: SLS
These materials are technology uses powdered materials such as nylon,
used for medical and Composites: polyamide, or thermoplastic elastomers to create strong
dental applications Composites can and durable parts.
and include combine different • MJF (Multi Jet Fusion) Powders: MJF technology uses
biocompatible resins materials to achieve fine powders, often nylon-based, to create functional
and metals for specific mechanical parts with good mechanical properties
implants and properties. For
prosthetics. example, carbon fiber-
Other Specialized Materials:
reinforced filaments
There are specialized materials for unique applications, such as conductive
for increased strength.
filaments, magnetic materials, and more
3D Printing With Concrete
• 3D concrete printing uses extremely large-scale 3D
printers, often measuring 30 feet in height and
length to extrude concrete from a nozzle. These
machines generally come either as gantry or robotic
arm systems.
• Traditional concrete is usually unsuitable for 3D
printing because it would clog the printer nozzle and CyBe Mortar material sets in 3 WinSun 3D printed house wall
not adhere properly to the previous layers . minutes and achieves
• In 2021 Mexican cement giant Cemex devised a structural strength in only 1
method of using conventional ready-mix concrete hour
during the 3D-printing process by adding
a substance called D.fab, which turns concrete into
a malleable material.
• Drying time - There are materials, such as those by
construction 3D printer companies Mighty Buildings
and Icon, that are cured using UV light. These kinds
of materials cure almost instantly and can be printed
horizontally without supports. CyBe Constructions 3D printable
Lavacrete building material by Icon mortar
 Uses

• Architecture and
construction
• Product design and
development
• Aerospace and
automotive
industries
• Medical and dental
applications
• Jewelry and fashion
• Prototyping and
rapid
manufacturing
• Art and sculpture
• Electronics

CAD/CAM
• Precision and Accuracy
• Faster Product Development
• Complex Geometries
• Digital Prototyping
• Customization
• Collabration
• Cost reduction [combined
cad/cam and 3d printing]
• Sustainability
Advantages
3D Printing CAD/CAM and 3d
Printing
Seamless Workflow: CAD/CAM
• can be directly integrated with 3D
Rapid prototyping
• printing, allowing for a seamless
complex structures
• transition from design to
Reduced material waste
• manufacturing.
Tool less manufacturing
• Rapid Iteration: Design changes
Customization
• can be quickly implemented in
On demand manufacturing
CAD and directly printed
[just in time ]
Reduced Lead Time: The
combination of CAD/CAM and 3D
printing significantly reduces the
lead time
Cost-Effective Prototyping:
Prototyping and small-batch
production
Complex Geometry Production

CAD/CAM
• Initial cost
• Complexity
• Dependence on software
• Over reliance on automation
• Interoperability issues
[compatibility and data
exchange between different cad
systems]
Disadvantages
3D Printing
• Limited material choice
• Speed
• Surface finishing
• Size constriants
•
Complex support structures
• High energy consumption
CAD/CAM and 3d
Printing
• Complexity and skill
requirements
• Costs
• Over production
• Quality control
• Material limitations
 MARKET STUDY Exploring the Market for 3D Home Printers

Growth Potential Design

The market for 3D home printers is growing With advances in materials and design, 3D 3D home printers offer a new level of design
rapidly, with more companies entering the home printers have the potential to be a flexibility, allowing architects and builders to
market to offer consumers a range of major disruptive force in the construction create more complex and intricate designs.
options. industry.

Types of 3D Home Printers

Fused deposit modeling The most common type of 3D home printer that melts plastic and deposits it in layers.

Powder bed fusion Uses a laser to fuse powdered materials together to create a solid object.

Stereo lithography The first 3D printing technology that uses a liquid resin that's cured with an ultraviolet light source.
Expenses of 3D Home Printers in Construction
Initial Investment
The upfront investment for a 3D home
printer can be significant, ranging from
$5,000 to $40,000 depending on the size
and features.
Maintenance Material Expenses
Maintenance costs can add up over time, including The cost of materials can vary depending on the type
cleaning, calibration, and replacement parts. of printer and the material used, but can range from
$50 to $500 per kilogram.

Challenges and Limitations of 3D Home Printers in Construction

Technical Limitations
The size of 3D home printers can limit the
size of projects, and the technology is still
working out some kinks, like printing with
multi-materials.
Expertise Requirements Regulatory Considerations
Working with a 3D home printer requires technical Local building codes may not account for the unique
skill and knowledge, which can be a barrier for some design possibilities and integration of 3D printing,
builders and architects. which can create regulatory hurdles.

Type of material

The materials that you choose matters when it comes to the cost of 3d printing. There are tons to choose from so we are going to focus on the popular ones,
thermoplastics and resin.
Thermosets: Resin
Resin is the best 3d printing material out there. It's versatile for almost any
complex project, and it would give you the best quality 3d print. But at the same
time, resin material can get quite costly. Standard resin, on average, cost $50 per
liter, and some resin materials can go up to $300 per liter.

Thermoplastics: Filaments and Powder

These filaments can cost between $20 to $70 per kg. Although they are cheap,
getting a high-quality 3d print out of them is not easy. It will take hours of post-
processing time to get smooth finishing from these prints.