3D Printing Report

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Seminar Report on 3D Printing Technologies

For 1 Credit Seminar

Bhargava Venkatesh

1PI10EE026

November 20, 2013

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Contents

1 Introduction 3

1.1 The Rise of 3D Printing . . . . . . . . . . . . . . . . . . . . . 41.2 General Principles . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2.1 Modeling . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2.2 Printing . . . . . . . . . . . . . . . . . . . . . . . . . . 6

1.2.3 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 3D Printing Techniques and Materials 8

2.1 3D Printing Techniques . . . . . . . . . . . . . . . . . . . . . . 8

2.2 3D Printing Materials . . . . . . . . . . . . . . . . . . . . . . 10

3 The Future of 3D Printing 13

3.1 3Doodler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.2 3D Printed Organs . . . . . . . . . . . . . . . . . . . . . . . . 15

3.3 3D Printed Food . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Chapter 1

Introduction

The purpose of this document is to provide one with an idea about 3D Print-

ing trends and technologies. Additive manufacturing or3D printing is

a process of making a three-dimensional solid object of virtually any shape

from a digital model. 3D printing is achieved using an additive process,

where successive layers of material are laid down in different shapes. 3D

printing is also considered distinct from traditional machining techniques,

which mostly rely on the removal of material by methods such as cutting or

drilling (subtractive processes). 3D printers are used for rapid prototyping

which involves sending a Computer Aided Design (CAD) to the printer that

is then sliced by a program and printed using a material layer by layer until

the full shape is formed.

Rapid prototyping does not reproduce models with the same quality and

consistency as conventional prototyping methods. This might not be the

case in the future as more and more industries and sectors are adopting this

technology and more R& D is being performed on various technologies in 3D

printing. Also for industries that are design conscious and have time con-

straints 3D printing is a better choice.

3D printing uses additive printing technology to print objects in 3D. Theprinter prints 3D models by adding materials like metals, plastics or poly-

mers layer by layer over each other until the required 3 dimensional shape is

formed. The printers can print with a precision of 0.1 mm or more, giving

the technology to print precise designs with accuracy.

3D printing has already been adopted by industries like aerospace, health-

care, automobile, defense and Hollywood. There is also a growing consumer

market for home based 3D printers.

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Figure 1.1: InMoov, a full-size humanoid robot made from 3D-printed parts,

designed and built by Gael Langevin of Factices Ateliers in France

1.1 The Rise of 3D Printing

Figure 1.2: Charles W. Hull

The concept of 3D printing re-

ally began to be taken seriously

in the 1980s. The man most of-

ten credited with inventing the lan-

guage of modern 3D printer is

Charles W. Hull, who used the

term stereolithographydefined as

a system for generating three-dimensional objects by creating

a cross-sectional pattern of the

object to be formedin a 1984

patent.

Manufacturing can be differenti-

ated into two types:

Additive manufacturing refers to

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technologies that create ob-

jects through sequential layer-ing.

Subtractive manufacturing refers

to the technologies that create objects through the removal of material

by methods such as cutting and drilling.

Figure 1.3: 3D printed Shoes

The 3D printing technology is

used for both prototyping and dis-

tributed manufacturing with appli-

cations in architecture, engineering,

construction (AEC), industrial de-

sign, automotive, aerospace, mil-

itary, engineering, civil engineer-

ing, dental and medical industries,

biotech (human tissue replacement),

fashion, footwear, jewelry, eyewear,

education, geographic information

systems, food, and many other

fields. It has been speculated that 3D printing may become a mass mar-

ket item because open source 3D printing can easily offset their capital

costs by enabling consumers to avoid costs associated with purchasing com-mon household objects.

1.2 General Principles

1.2.1 Modeling

Figure 1.4: 3D Render of the popular

internet meme: Grumpy Cat

Additive manufacturing takes vir-

tual blueprints from computer aided

design (CAD) or animation model-ing software and slices them into

digital cross-sections for the machine

to successively use as a guideline for

printing. Depending on the machine

used, material or a binding material

is deposited on the build bed or plat-

form until material/binder layering

is complete and the final 3D model

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has been printed.

A standard data interface between CAD software and the machines is theSTL file format. An STL file approximates the shape of a part or assembly

using triangular facets. Smaller facets produce a higher quality surface. PLY

is a scanner generated input file format, and VRML (or WRL) files are often

used as input for 3D printing technologies that are able to print in full color.

There are many Softwares you can use for modelling your 3D models that

are 100% free;

- Google SketchUp

- 3DCrafter

- 3Dtin

- Anim8or

- Art of Illusion

- Blender

- BRL-CAD

- Creo Elements/Direct

- DrawPlus Starter Edition- FreeCAD

- GLC Player

- LeoCAD

- K-3D

- Tinkercad

- Wings 3D

1.2.2 Printing

To perform a print, the machine reads the design from an .stl file and lays

down successive layers of liquid, powder, paper or sheet material to build

the model from a series of cross sections. These layers, which correspond to

the virtual cross sections from the CAD model, are joined or automatically

fused to create the final shape. The primary advantage of this technique is

its ability to create almost any shape or geometric feature.

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Figure 1.5: An example of a home 3D Printer, the Makerbot Replicator 2

1.2.3 Finishing

Figure 1.6: The completely printed

Grumpy Cat

Though the printer-produced res-

olution is sufficient for many ap-

plications, printing a slightly over-

sized version of the desired ob-

ject in standard resolution and

then removing material with a

higher-resolution subtractive pro-

cess can achieve greater preci-

sion.

Some additive manufacturing

techniques are capable of using mul-

tiple materials in the course of con-

structing parts. Some are able to

print in multiple colors and color

combinations simultaneously. Some

also utilize supports when building. Supports are removable or dissolvable

upon completion of the print, and are used to support overhanging features

during construction.

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Chapter 2

3D Printing Techniques and

Materials

2.1 3D Printing Techniques

Stereolithography(SLA)

The first commercially available 3D printer (not called a 3D printer back

then) used the stereolithography (SLA) method. This was invented in 1986

by Charles Hull, who also at the time founded the company, 3D Systems. A

SLA 3D printer works by concentrating a beam of ultraviolet light focused

onto the surface of a vat filled with liquid photocurable resin. The UV laser

beam draws out the 3D model one thin layer at a time, hardening that slice of

the eventual 3D model as the light hits the resin. Slice after slice is created,

with each one bonded to the other, and next thing you know you have a

full, extremely high-resolution three dimensional model lifted out of the vat.

Unused resin is reusable for the next job.

Fused Deposition Modeling (FDM)

Also invented in the late 1980s, by Scott Crump, was Fused Deposition Mod-eling (FDM) technology. With patent in hand, he and his wife founded

Stratasys in 1988. With FDM, the object is produced by extruding a stream

of melted thermoplastic material to form layers. Each layer stacks on top of

and fuses with the previous layer as the material hardens almost immediately

after leaving the extrusion nozzle. It is one of the less expensive 3D printing

methods. Most FDM printers print with ABS plastic (think Lego), as well

as PLA (Polylactic acid), a biodegradable polymer, which is produced from

organic material.

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Selective Laser Sintering (SLS)

The 1980s were big for inventing 3D printing technologies. Not only were SLA

and FDM invented and patented then, but so was Selective Laser Sintering

(SLS), by Carl Deckard and colleagues at the University of Texas in Austin.

SLS works similarly to SLA, but instead of liquid photopolymer in a vat,

youll find powdered materials, such as polystyrene, ceramics, glass, nylon,

and metals including steel, titanium, aluminum, and silver. When the laser

hits the powder, the powder is fused at that point (sintered). All unsintered

powder remains as is, and becomes a support structure for the object. The

lack of necessity for any support structure with SLS is an advantage over

FDM/FFF and SLA theres none to remove after the model is complete, and

no extra waste was created. All unused powder can be used for the next

printing.

PolyJet photopolymer

Objet (acquired by Stratasys) developed this technology: much like a tradi-

tional inkjet printer deposits ink, a photopolymer liquid is precisely jetted

out and then hardened with a UV light. The layers are stacked successively.

The technology allows for various materials and colors to be incorporated

into single prints, and at high resolutions.

Syringe Extrusion

Almost any material that has a creamy viscosity can be used in 3D printers

equipped with syringe extruders. This includes materials like clay, cement,

silicone, and Play-Doh. Certain foods like chocolate, frosting, and cheese

can also be printed with these systems. The syringe may or may not need to

be heated, depending on the material; chocolate may need to be kept warm

while silicone can be kept at room temperature.

Other MethodsThere are other variants of these technologies. For example there is Selective

Laser Melting (SLM), which is like SLS but it fully melts the powder rather

than just fusing the powder granules at a lower temperature. This is similar

to Electron Beam Melting (EBM) which uses an electron beam instead of a

UV laser. And then there is a completely different technology called Lami-

nated Object Manufacturing (LOM), where layers of adhesive-coated paper,

plastic, or metal laminates are successively glued together and cut to shape

with a knife or laser cutter.

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Figure 2.1: Sapeways company logo

2.2 3D Printing Materials

Many different materials can be used for 3D printing, such as ABS plastic,

PLA, polyamide (nylon), glass filled polyamide, stereolithography materials

(epoxy resins), silver, titanium, steel, wax, photopolymers and polycarbon-ate.

Shapeways is a Dutch founded, New York based 3D printing marketplace

and service, startup company. Users upload design files, and Shapeways

prints the objects for them or others. Users can have objects printed from a

variety of materials, including food-safe ceramics.

They offer to print your model in the following materials:

Strong and Flexible Plastic

Great starter material-easy design rules, feels a bit rough, but available in

polished finish.

Figure 2.2: Strong & Flexible Plastic

Alumide

Brittle Nylon Plastic thats filled with Aluminum dust.

Figure 2.3: Alumide

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Figure 2.7: Sterling Silver

Other Materials

Their other materials include Brass, Bronze, Elasto Plastic, Full Colour Sand-

stone and ceramics.

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Chapter 3

The Future of 3D Printing

Figure 3.1: The RepRap 3D Printer

Several projects and companies are

making efforts to develop afford-

able 3D printers for home desk-

top use. Much of this work has

been driven by and targeted at

DIY/enthusiast/early adopter com-

munities, with additional ties to

the academic and hacker communi-

ties.

RepRap is one of the longest

running projects in the desktop cat-

egory. The RepRap project aims to

produce a free and open source

software (FOSS) 3D printer , whose full specifications are released under

the GNU General Public License, and which is capable of replicating itself by

printing many of its own (plastic) parts to create more machines. Research

is under way to enable the device to print circuit boards and metal parts.

Because of the FOSS aims of RepRap, many related projects have usedtheir design for inspiration, creating an ecosystem of related or derivative

3D printers, most of which are also open source designs. The availability

of these open source designs means that variants of 3D printers are easy to

invent. The quality and complexity of printer designs, however, as well as

the quality of kit or finished products, varies greatly from project to project.

This rapid development of open source 3D printers is gaining interest in

many spheres as it enables hyper-customization and the use of public do-

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main designs to fabricate open source appropriate technology through con-

duits such as Thingiverse and Cubify . This technology can also assistinitiatives in sustainable development since technologies are easily and eco-

nomically made from resources available to local communities.

Figure 3.2: The MakerBot Cupcake

CNC.

The cost of 3D printers has de-

creased dramatically since about

2010, with machines that used to

cost $20,000 costing less than $1,000.

For instance, as of 2013, several com-

panies and individuals are selling

parts to build various RepRap de-signs, with prices starting at about

400 / US$500. The open source

Fab@Home project has developed

printers for general use with any-

thing that can be squirted through

a nozzle, from chocolate to sili-

cone sealant and chemical reactants.

Printers following the projects de-

signs have been available from sup-

pliers in kits or in pre-assembledform since 2012 at prices in the

US$2000 range. TheKickstarter funded Peachy Printer is designed to

cost $100 and several other new 3D printers are aimed at the small, inexpen-

sive market including the mUVe3D and Lumifold.

As the costs of 3D printers have come down they are becoming more

appealing financially to use for self-manufacturing of personal products. In

addition, 3D printing products at home may reduce the environmental im-

pacts of manufacturing by reducing material use and distribution impacts.

3.1 3Doodler

The 3Doodler is a 3D printing pen developed by Peter Dilworth and

Maxwell Bogue of WobbleWorks LLC. 3Doodler began funding in Febru-

ary 2013 on the crowd funding platform Kickstarter.

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Figure 3.3: 3Doodler Pen

It utilizes plastic thread made of either acrylonitrile butadiene styrene(ABS) or polylactic acid (PLA) that is melted and then cooled

through a patented process while moving through the pen, which can then

be used to make 3D objects by hand. The 3Doodler has been described as

a glue gun for 3D printing because of how the plastic is extruded from the

tip, with one foot of the plastic thread equaling about 11 feet of moldable

material.

Figure 3.4: A 3Doodler Pen being used

3.2 3D Printed Organs

The dream of one day completely doing away with frustratingly long trans-

plant lists in favor of made to order, 3D-printed organs is closer to becoming

a reality. Scientists at Organovo in San Diego have, for the very first time,

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been able to 3D print tiny replicas of human livers.

Figure 3.5: A scientist printing out the liver

At just half a millimeter deep and four millimeters across, the mini livers

can perform most of the same functions as the larger version hanging out over

your gallbladder. Which means that these presumably adorable bile-makers

stand to serve a variety of purposes, the most immediate of which would beusing them to observe how our livers react to certain drugs and diseases.

From here, Organovo plans to move on to the normal-sized organs that

could be transplanted into real, live human bodies. Of course, theyd first

have to solve the problem of how to print larger branches of blood vessel

networks capable of nourishing an entire organ. But if these itty bitty livers

are any indication, the real deal is well on its way.

3.3 3D Printed Food

In a fantastic development, the application of additive manufacturing tech-

nologies that other 3D printing enthusiasts and myself have long been pro-

moting, NASA has recently awarded a $125,000 grant to further explore and

develop the application of 3D printing food for astronauts. Initially aimed

at efficient food storage for long-haul space flights, the creator of this project

Anjan Contractor, a Senior Mechanical Engineer at Systems and Materials

Research Corporation (SMRC) in Austin, Texas, USA hopes this technology

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could ultimately help the continually exponentially increasing population on

Earth.

Figure 3.6: The schematic for a hypothetical 3D food printer.

In the plan, a NASA-modified RepRap printer will be fitted with sev-

eral culinary building blocks, from oil to protein powder, then mixed and

deposited. As 3D printing typically utilises a layer on layer based methodol-ogy, layer-based foods like pizza are first on the menu.

Accordingly, Contractor envisions: customized, nutritionally-appropriate

meals synthesized one layer at a time, from cartridges of powder and oils.

So for the pizza, the 3D printer would mix the appropriate ingredients to

deposit a layer of dough, which would be cooked prior to laying down the

next of tomato sauce (from a mixture of powder, water and oil. Additional

layers of protein can then be added.

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Bibliography

Wikipeda, en.wikipedia.org/wiki/3D_printing

Shapeways, www.shapeways.com

3D Printing Industry, 3dprintingindustry.com

Gizmodo www.gizmodo.com

Wired www.wired.com

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http://localhost/var/www/apps/conversion/tmp/scratch_9/en.wikipedia.org/wiki/3D_printinghttp://www.shapeways.com/http://localhost/var/www/apps/conversion/tmp/scratch_9/3dprintingindustry.comhttp://www.gizmodo.com/http://www.wired.com/http://www.wired.com/http://www.gizmodo.com/http://localhost/var/www/apps/conversion/tmp/scratch_9/3dprintingindustry.comhttp://www.shapeways.com/http://localhost/var/www/apps/conversion/tmp/scratch_9/en.wikipedia.org/wiki/3D_printing

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