3d printing & prototyping

A SEMINAR ON

3d- printerAS A PRODUCT

Indian Institute Of Information Technology Design & Manufacturing, Kancheepuram.

BySikharam Uday Kiran

EDS12M008

IIITDM KANCHEEPURAM 2

Introduction: Brief history of invention

Technical details: Additive Layer Manufacturing Manufacturing Methods Working Black Art Of ALM

Market details: The consumer market Application Information Pros & Cons Reference

PRESENTATION OUTLINE

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‘Even without changing the component at all, additive-layer manufacturing (ALM) means that you’re extracting 26 times less material out of the ground to make it’.

- Dan Johns.

There’s a huge investment in the process to make a product: heat-treating it, rolling it, reheating it, cutting it up and bringing it to the machine.

INTRODUCTION

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CEO of Stratasys Inc., Scott Crump

Between 1987 and 1988 when

Scott Crump had a vision of an

easier way to create prototype

components.

Which resulted in the invention of a

technique called fused deposition

modeling (FDM), also be referred

to as “additive” technology.

Its own prototyping system to

market in 1987.

Brief history of invention

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It works in a similar way to a laser printer.

The technique builds a solid object from a series of

layers - each one printed directly on top of the previous

one.

The raw material for ALM is a powder:

Thermo polymer or a metal.

Aluminium, stainless steel and titanium 6, 4 are

common. Other ALM machines use electron beams rather than

lasers.

Additive-Layer Manufacturing

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Other ALM machines use electron beams rather than lasers.

As they are capable of transmitting more energy. It melt the powder faster. These machines work at room temperature, again

speeding up the process.

However, they produce pieces with a rougher surface finish that requires further machining and residual stress isn’t eliminated.

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Other way is Subtractive Manufacturing

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Additive-Layer Manufacturing Methods

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Selective Laser Sintering (SLS)1. Deposit layer of powder on platform.2. The CO2 laser solidifies part cross-section3. Lower platform by t4. Deposit new layer of powder above previous layer5. Repeat steps 2-4 to complete part5. Shake away surrounding powder (re-used)6. Bake model in oven to sinter (melting point – d)*7. Diffuse lower MP metal to fill pores**

Source:(www.3Dsystems.com)

3d-printer Available In Our Institute

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Working

Modeling:

Additive manufacturing takes virtual blueprints from computer aided design (CAD).

"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 platform until material/binder layering is complete and the final 3D model has been "printed“.

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A standard data interface between CAD software and the machines is the STL file format.

An STL (Stereo Lithography) file approximates the shape of a part or assembly using triangular facets. Smaller facets produce a higher quality surface.

PLY (Polygon File Format) is a scanner generated input file format, and

VRML (Virtual Reality Modeling Language or WRL) files are often used as input for 3D printing technologies that are able to print in full color.

The printing chamber is generally heated to 10ºC below the melting point of the material.

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’Black Art Of ALM‘

The process starts with

1. CAD file.2. Modelling the component in three

dimensions.3. Once the solid model is in place, engineers

have to make manufacturing decisions.

The most important of which is the orientation of the layers from which the component will be built. This is still very much a matter of judgment and there are no automated or computerized shortcuts.

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RP Sequence

CAD solid model ‘.STL’ file Slicing the file Final build file Fabrication of part Post processing

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There were enough customers looking for a competitive edge, particularly those in:

Aerospace.

Medicine.

Automotive.

Applications Information

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(Credit: Frank Wojciechowski via Princeton University)

http://www.salon.com/2013/09/17/mit_researchers_unveil_a_smarter_way_to_3%E2%80%93d_print_newscred/

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3D printer maker Voxel jet's shares double in debut

"It is a small company with a new product that has the largest 3d print capacity in the industry and therefore has good growth potential.”

A German maker of commercial 3d printers that created Aston martin copies for a James bond film, 

Shares of Exone co (xone.O), which makes industrial 3D printers, have doubled since the company's debut in February. Larger rival 3D systems Corp's (DDD.N) shares have also more than doubled in the last year, while Stratasys ltd's (SSYS.O) shares have gained about 70 percent.

Source: http://www.reuters.com/article/2013/10/18/us-voxeljet-ipo-

idUSBRE99H0HS20131018

Pros & Cons

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The first working blueprint to produce a plastic gun with a 3D printer in May 2013, the United States Department

Example: Plastic Gun

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THE CONSUMER MARKET

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Z-motion

Melting head withXY-motion

Build materialwire spools:(a) Part (b) Support

Extrusion nozzles

Part

SupportFoam base

Part constructed by deposition of melted plastic 1. A 0.05” wire of plastic pulled from a spool into head.2. Plastic is melted (1ºF over MP).3. Molten plastic extruded through the pen nozzle to build layer.

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When Hewlett-Packard launched an ‘affordable’ desktop 3D printer earlier this year, critics scoffed at its £11,200 price tag. This was not the people’s printer that some had been hoping for.

Their largest machines can create parts up to 36” by 24” by 36”.

‘Within 10 years I can’t see any reason why we won’t have a sub- £500 machine’.

-Additive-industry consultant Dr. Phil Reeves.

THE CONSUMER MARKET

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Comparing ALM & SM

Advantage for SM Advantage for ALM

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Report: 3D printer shipments to grow 49% in 2013, huge potential for India and China.

Source: http://www.techinasia.com/global-3d-printer-shipments-growing-with-potential-for-india-china/

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References:

http://www.theengineer.co.uk/in-depth/the-big-story/the-rise-of-additive-manufacturing

http://www.reuters.com/article/2013/10/18/us-voxeljet-ipo-idUSBRE99H0HS20131018

http://www.howstuffworks.com/3-d-printing.htm

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Thank you…

BySikharam Uday Kiran

EDS12M008