3d Report 2015_phcet

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PHCET Department of Electronics & Telecommunication

3D Object Printer For Rapid Prototyping Page 1 of 31

1.Introduction

3D printing or additive manufacturing (AM) is any of various processes for making

a three-dimensional object of almost any shape from a 3D model or other electronic data

source primarily through additive processes in which successive layers of material are

laid down under computer control. A 3D printer is a type of industrial robot.

Early AM equipment and materials were developed in the 1980s. In 1984, Chuck

Hull of 3D Systems Corp, invented a process known as stereo lithography employing UV

lasers to cure photopolymers. Hull also developed the STL file format widely accepted by

3D printing software, as well as the digital slicing and infill strategies common to many

processes today. Also during the 1980s, the metal sintering forms of AM were being

developed (such as selective laser sintering and direct metal laser sintering), although

they were not yet called 3D printing or AM at the time. In 1990, the plastic extrusion

technology most widely associated with the term “3D printing” was

commercialized by Stratasys under the name fused deposition modelling

(FDM). In 1995, Z Corporation commercialized an MIT-developed additive process

under the trademark 3D printing (3DP), referring at that time to a proprietary process

inkjet deposition of liquid binder on powder.

AM technologies found applications starting in the 1980s in product development,

data visualization, rapid prototyping, and specialized manufacturing. Their expansion into

production (job production, mass production, and distributed manufacturing) has been

under development in the decades since. Industrial production roles within the

metalworking industries achieved significant scale for the first time in the early 2010s.

Since the start of the 21st century there has been a large growth in the sales of AM

machines, and their price has dropped substantially. According to Wohlers Associates, a

consultancy, the market for 3D printers and services was worth $2.2 billion worldwide in

2012, up 29% from 2011.

Applications are many, including architecture, construction (AEC), industrial

design, automotive, aerospace, military, engineering, dental and medical industries,

biotech, fashion, education, geographic information systems, food, and many other fields.





3D-Printer is a machine reminiscent of the Star Trek Replicator, something magical that

can create objects out of thin air. It can “print” in plastic, metal, nylon, and over a

hundred other materials. It can be used for making nonsensical little models like the over-

printed Yoda, yet it can also print manufacturing prototypes, end user products, quasi-

legal guns, aircraft engine parts and even human organs using a person’s own cells.

We live in an age that is witness to what many are calling the Third Industrial

Revolution. 3D printing, more professionally called additive manufacturing, moves us

away from the Henry Ford era mass production line, and will bring us to a new reality of

customizable, one-off production.

3D printers use a variety of very different types of additive manufacturing

technologies, but they all share one core thing in common: they create a three

dimensional object by building it layer by successive layer, until the entire object is

complete. It’s much like printing in two dimensions on a shee t of paper, but with an

added third dimension: UP. The Z-axis. Each of these printed layers is a thinly-sliced,

horizontal cross-section of the eventual object. Imagine a multi-layer cake, with the baker

laying down each layer one at a time until the entire cake is formed. 3D printing is

somewhat similar, but just a bit more precise than 3D baking.

In the 2D world, a sheet of printed paper output f rom a printer was “designed” on

the computer in a program such as Microsoft Word. The file - the Word document which

contains the instructions that tell the printer what to do. In the 3D world, a 3D printer also

needs to have instructions for what to print. It needs a file as well. The file, a Computer

Aided Design (CAD) file is created with the use of a 3D modelling program, either from

scratch or beginning with a 3D model created by a 3D scanner. Either way, the program

creates a file that is sent to the 3D printer. Along the way, software slices the design into

hundreds, or more likely thousands, of horizontal layers. These layers will be printed one

atop the other until the 3D object is done.





2. Basic Concepts and Literature Survey

2.1 Literature Survey

Printing engineering is a technology to replace a conventional printing process,

such as photolithography, for manufacturing any electronic devices, such as display,

semiconductor, or visually structure. While the conventional printing process has nine to

ten steps to manufacture the products, the printing engineering process has two to three

steps to produce same products. Because of the short steps, compared to the conventional

printing process, the printing engineering saves material, energy, and manufacturing cost.

Also, the conventional printing process impairs substrate of electronic devices during the

etching process, which is one of the conventional printing steps, and it causes defective

products. On the other hand, printing engineering manufactures the electronic device

without the etching process, so the rate of the defective products is low. For these reasons,

the conventional printing process has been replacing the printing engineering process.

This literature review focuses on the printing engineering process with the following

various issues:

What types of printing technology and printing material are there?

According to a report, Advanced technology and market trend of printed

electronic (Korean Scientist and Engineers Network [KOSEN], 2011). “Printing

engineering can be classified into printing technology and printing material.” Printing

technology is the way to manufacture the electronic devices, and it is classified into

2dimensional (2D) and 3dimensional (3D) printing technology according to structure of

printed product. This paper reviews the types of 2D and 3D printing technology and the

differences of the twotechnologies.First, 2D printing technology prints 2D images on the

surface of a substrate, such as glass, metal, plastic, and so on. The types of 2D printing

are a lot, but this paper focused on ink jet printing, screen printing, gravure printing, and

roll to roll printing. According to

Advanced technology and market trend of printed electronic, the ink jet printing

uses very small droplet of ink. The ink drops on final substrate, and it forms





certain pattern of circuit. The technology can easily print the ink on any spot easily. Also

the price for material and investment cost of the ink jet machine are cheap. However,

nozzles of the ink jet machine are easy to clog, and resolution of final pattern is low.

Also, the technology has limitation on material selection for ink, because it requires only

low viscous material, such as the viscosity is the same as water (KOSEN, 2011, p. 83).

According to The technology road map, Printable materials and printing technology

road map, the gravure printing coats ink on intaglio printing roll, and print the ink, which

is flowed in concaved part of the printing roll on the final substrate. With this technology,

it is possible to continue this process system for a long time. Contrary to ink jet printing,

the gravure printing has no limitation on material selection for ink of the printing

technology. It can use any viscous material. However, the resolution of the final printing

slow because the residual materials can remain during the continuous processing.

Table 1 Comparison of 2D printing technology

Advanced technology and market trend of printed electronic, the gravure offset

printing is similar to gravure printing, but the printing technology uses an intaglio plate

and an independent roll to remedy the gravur e printing’s shortcomings. The ink is coatedon an intaglio plate and the roll takes the ink from the plate. Finally, the ink is print on

final substrate from the roll. The gravure offset printing has higher resolution of final

printing. However, the investment cost of the machine is more expensive than the other

printing technologies (KOSEN, 2011, p.86).

2013, Dr.Nam-soo Peter Kim, who is associate professor in department of

metallurgical and material engineering in UTEP and faculty in W.M. KECK center





of UTEP, said that 3D printing technology print 3D object of virtually any shape, and the

3D printing is classified into three methods - Fused Deposition modelling (FDM), Stereo

Lithography (SLA), and Selective laser sintering (SLS) - during interview. He said that

the Fused Deposition modelling (FDM) method extrudes thermoplastic material by

melting the material at the high temperature (≥150°C). The material hardens at the room

temperature, and the extruded material builds up on the harden material again. These

steps repeat on every layer of the whole 3D structure.

The FDM method is easy to operate and quickly produces a 3D object. Also, the

final 3D object has high strength because the method uses plastic. However, because of

its fast processing, the degree of precision is lower than other 3D printing technology.

The representative 3D printer company is 3DCubify and 3Doodler (Kim, personal

communication, July 8, 2013).According to the interview, the Stereo Lithography (SLA)

method builds each part’s layer using photo-curable material, and it radiates the

ultraviolet light to make the material harden after deposing the material. These steps

repeat on every layers of whole 3D structure, as with the FDM method. The SLA method

has a high degree of precision, compared to the FDM method. However, the SLA method

takes a long time to produce and has a high manufacturing cost, since each step takes a

longer time than the FDM method. There presentative 3D printer company is Stratasys

(Kim, personal communication, July 8, 2013).According to the interview, the Selective

laser sintering (SLS) method builds each layer of 3D structure using a powder typed

material. The powder typed material is deposed with uniform thickness on stage, and the

laser hardens the powder selectively to produce the certain 3D structure. The SLS method

has the highest degree of precision when compared to the FDM method and the SLA

method. However, the manufacturing cost is too expensive because it uses laser. The

representative company is Solid concept Inc. (Kim, personal communication, July 8,2013).





Table 2 Comparison of 3D printing

3D Cubify, 3DoodlerStratasysSolid concept Inc. The biggest difference of 2D and

3D printing technology is final application. The main application of 2D printing

technology is electronic device, such as solar cell, display, smart phone, and so on. On the

other hand, the final application of 3D printing technology is infinite, such as field of

medical, fashion, cooking, and so on.

According to the interview, the most important factor of the printing material for

2D printing technology is electrical conductivity. Because the materials are used mainlyfor electronic device, high electrical conductive materials help to give high power of

electricity in a short time, which is high performance of electronic device. Also, Nano

size of materials gives higher conductivity than regular sized material, even though it is

same material. Thus, the printing materials are composed to Nano (nm) sized metal,

which has higher conductivity than other materials, and the representative metals are

copper and silver (Kim, personal communication, July 8, 2013).The scholarly article,

Challenges and Opportunities in Direct Technology Using Nano-metal Particles,

said that Nano sized copper is cheaper than any other noble metal, such as gold and silver,

and it has high electrical conductivity, as like the metals (copper: 0.596×10

,silver:

0.63×106ohm-1cm-1, and gold: 0.452×106ohm-1cm-1)(Han & Kim, 2009,

p.75).However, Dr.Kim said, “the Nano sized of copper is easy to from copper oxide,

which has non-conductive material” (Kim, personal communication, July 8, 2013).

Therefore, lots of researches have been conducted to solve this problem.Dr. Kim also said





the following: “Nano sized silver is widely used on the printing engineering applications

because itis stable material, which has no problem to change non-conductive material

rather than copper; it has high electrical conductivity to use as printing materials.

However, the silver has problem on its expensive” (Kim, personal communication, July 8,

2013).”The main materials for 3D printing technology are thermoplastic, photo-curable

materials, and powdered typed materials, as mentioned above. However, this review

paper focused on thermoplastic material, which is material for the FDM method, because

the mass of people prefer this method, due to its cheap manufacturing price.

According to a blog’s posting, the difference between ABS and PLA for 3D

printing, the thermoplastic is composed of two main materials: acrylonitrile butadiene

styrene (ABS) and polymathic acid (PLA). Both ABS and PLA melt at the high

temperature and harden at room temperature. However, the general material properties of

ABS and PLA are different (Chilton, 2013).According to the Chilton’s posting, the final

3D structure composing the ABS has high durability and a cheaper price than the PLA. Its

strength, flexibility, machinability, and higher temperature resistance are useful in

professional application and in the field of engineering. However, it requires a higher

temperature than PLA for extruding from 3D printer nozzle. Also it has problem on

shrinking and crack during the hardening in short time (Chilton, 2013).According to the

posting of Chilson’s blog, the PLA is easy to extrude, so the surface of final structure

composing the PLA is smooth. The wide ranges of colours are available for PLA. Also

this material is environment friendly because the PLA is made with plant based origin.

Thus, the shapes and colours are useful for the field of design and art. However, the price

of PLA is more expensive than the ABS, and the durability of final 3D product is low

(Chilson, 2013).Since the each advantage and disadvantage of ABS and PLA are

different, the market of 3D printer uses mixture of ABS and PLA to supplement itsdisadvantage.

2.2Need and Scope of Project

According to a report, Printed electronics technology and its prospect of future

written by Research and Policy Center for Chemical Technology, 2D printing technology

can produce circuit of electronic device on any substrate (Research and Policy Center





for Chemical Technology [RPCCT], 2011). The report said that 2D printing engineering

can produce the electrical conductive pattern on thin plastic substrate or paper for the

circuit of electronic devices, and it means that consumer can use bended and light

electronic devices, such as flexible smart phone or display, in near future. Also, 2D

printing technology produce lots of products in a short time, and it produce a high

performance of electronic device, since the printing technology can produce certain shape

of circuit on any spot, saving materials (RPCCT, 2011).3D printing contributes to

improve the medical field and architecture field. 3D printer can produce the physical parts

of human and animals for the medical field. On June 28th, 2013, the owner of a duck and

soft engineer, Mike Garey, produced an artificial leg for the duck, Buttercup (Kearney,

2013). He found the answer to fix his leg through 3D printer, Nova Copy. Finally, the

duck’s leg was fixed thanks to 3D printing technology. Also, according to a article, 3D

printer, the Medical College in the University of California produces Siamese twins’

attached internal organs in 2002. The 3D printer produced detailed physical parts, and a

operating surgeon did practice using the 3D structure of physical part before the operation

for the Siamese twins. Likewise, the 3D printing technology gives big contribution in

medical field (Jung, 2012).According to a blog posting, The College of design in West

Virginia University Tech.made construction model of the State’s assembly hall using 3D

printer. Professor Javins said,“The 3D printing technology saved hundred hours to

produce the same structure in handwork system” (Kim, 2011).Likewise, the 3D printing

technology saves time and material in the field of architecture. Not only for medical and

architecture field, but also the 3D printingtechnology also helps the other fields, such as

aerospace, automotive, and so on. For thesereasons, the 3D printing brings technical and

industrial advantages in all application.

According to another report, Printed electronics technology and its prospect offuture (RPCCT, 2011), $1 cheaper of a blister pack, which is a recorder whenever eating

medicine, can be manufactured using 2D printing technology. Also, the report said that

Radiofrequency Identification (RFID) tag, which is used for prevention of thefts, can be

producedin $0.01 with 2D printing technology. Finally, all products will be used the tag

in near future.Another report,advanced technology and market trend of printed electronic,

anticipated,“The market trend based on 2D printing technology will be $ 300 billion in





2028” (KOSEN,2011). Therefore, the 2D printing technology will helps to new market

creation anddevelopment.3D printing technology is selected as main item for national

strategycommercialization in the U.S. federal government, and he announced the National

AdditiveManufacturing Innovation Institute (NAMII) project through the form of a Broad

AreaAnnouncement by the Department of Defenses on May 9th, 2012 (2012). The main

purpose of the NAMI project is the establishment of the institutes, combining with

universities, researchinstitutes, company, and government in the U.S., and the institute

increases the market of 3D printing and discovers the creating business tragedy using the

3D printing technology.For this reasons, global research firm, McKinsey, expected that

sized application of 3D printingcould have direct economic impact of $230 billion to

$550 billion per year in 2025.According to article, they said that “Even in 2025,

traditional manufacturing will almostcertainly have a large cost advantage over additive

manufacturing for most high volume products.” (Maxey, 2013) Ministry of Science and

Technology in China invested $650million on companies and business that are related to

3D printing technology. Europe startedto combine the 3D printing technology in

education. Therefore, not only for the world marketof 3D printing is increasing gradually,

but also the world society, in field of life, education, and so on, is investing their money

to 3D printing technology.





3. Design Methodology

3.1 Block Diagram

The picture shows the structure of a typical 3D printer. The print table is the

platform where the objects for printing has been situated. It provides the basic support for

manufacturing objects layer by layer.





The extruder is the most important part of a 3D-Printer. As the extruders in the

normal paper printers, this extruder is also used to pour ink for printing. The movement of

extruder in various dimensions create the 3D print. For printing a 3d object, the extruder

has to access X, Y and Z coordinates. For achieving this, many techniques are used

according to the printer specification required for various applications.

If the 3D-Printer is a desktop printer, the Z axis movement of the extruder can be

avoided and that function can be transferred to the print table. This will avoid complexity

in 3D printing as well as time consumption.

When the STL file is input to the printer, the microcontroller extracts each layer

from it and also extracts each line segment from each layer. Then it gives controls to the

movement of the extruder at required rate. The X-direction movement of extruder is made

possible by the X-motor. When the X motor rotates, the shaft also rotates and the extruder

moves in X direction. The Y-direction movement of extruder is made possible by the Y-

motor. When the Y motor rotates, the shaft also rotates and the extruder moves in Y

direction. The X direction movement is made by the print table.

In the case of desktop printers, the printing ink is usually plastic wire that has been

melted by the extruder at the time of printing. While printing, the plastic wire will melt

and when it fall down to the printing table.





Consider printing larger objects like house using 3D printer. There will not be any

X motor or Y motor in that case. An extruder which can pour concrete mix is fixed on the

tip of a crane. The crane is programmed for the movement of extruder in X, Y and Z axis.

The concept and structure of 3d printer changes according to the type, size, accuracy and

material of the object that has to be printed.Generalizing the facts, the extruder need to

access all the 3 coordinates in space to print and object. The method used for that doesn’t

matters much.Several different 3D printing processes have been invented since the late

1970s. The printers were originally large, expensive, and highly limited in what they

could produce.

A large number of additive processes are now available. The main differences between processes are in the way layers are deposited to create parts and in the materials

that are used. Some methods melt or soften material to produce the layers, e.g. selective

laser melting(SLM) or direct metal laser sintering (DMLS), selective laser sintering

(SLS), fused deposition modelling (FDM), while others cure liquid materials using

different sophisticated technologies, e.g. stereo lithography (SLA). With laminated

object manufacturing (LOM), thin layers are cut to shape and joined together (e.g. Paper,





polymer, metal). Each method has its own advantages and drawbacks, which is why

some companies consequently offer a choice between powder and polymer for the

material used to build the object. Other companies sometimes use standard, off- the-shelf

business paper as the build material to produce a durable prototype. The main

considerations in choosing a machine are generally speed, cost of the 3D printer, cost of

the printed prototype, cost and choice of materials, and colour capabilities.

Printers that work directly with metals are expensive. In some cases, however, lessexpensive printers can be used to make a mould, which is then used to make metal parts.





3.1.2 Extrusion Deposition

In extrusion deposition, Fused Deposition technique is used. Fused Deposition

Modelling (FDM) was developed by Stratasys in Eden Prairie, Minnesota. In this process,

a plastic or wax material is extruded through a nozzle that traces the parts cross sectional

geometry layer by layer. The build material is usually supplied in filament form, but some

setups utilize plastic pellets fed from a hopper instead. The nozzle contains resistive

heaters that keep the plastic at a temperature just above its melting point so that it flows

easily through the nozzle and forms the layer. The plastic hardens immediately after

flowing from the nozzle and bonds to the layer below. Once a layer is built, the platform

lowers, and the extrusion nozzle deposits another layer. The layer thickness and vertical

dimensional accuracy is determined by the extruder die diameter, which ranges from

0.013 to 0.005 inches. In the X-Y plane, 0.001 inch resolution is achievable. A range of

materials are available including ABS, polyamide, polycarbonate, polyethylene,

polypropylene, and investment casting wax.





3.2 Description of the System

The Prusa Mendel i3 is the third version of the open source 3D printer Prusa

Mendel. Our version is based on an acrylic frame cut by water jet cutter and threaded

rods. Axis motion is made on linear bearings, belts and pulleys or threaded rods and

NEMA 17 motors.

The machine's design files and the assembly instructions are licensed under the

GPL.This design was inspired by older designs: Prusa Mendel i3 EiNSTeiN VARIANT

on Reprap.org, Modified extruder designed by ch1t0 on Thingiverse. The release of the

Prusa i3 under the GPL license and numerous other factors (its low cost, minimal BOM,

simple assembly and calibration procedures, more than adequate documentation, etc)

have encouraged the further development of a growing number of Prusa i3 "variants"

worldwide, with different parts, different materials and different assembly processes, but

which altogether adhere to the general looks, component assembly, dimensions and

functionality of the original Prusa i3.

Following are the development of our design which changes several features from

its parents.

Extruder upgrade: Magma Hotend (by Trinity Lab) support.

New cooling fan duct for Magma Hotend.

Y Idler with a tensioner system.

X End Idler with endstop holder

.Upgrade X End Idler in order to support 624 bearing.

Y Motor with endstop holder.

Addition of Z endstop Holder in situ.

Addition of a Dremel FlexShaft Attachment for 3 Axis CNC Milling.

Enhanced frame rigidity (prevents x-axis backlash)





Easy assembly

Parametric files for multiple sizes/bearings or bushings





4. Component list

4.1 Printed Parts





4.2 Extruder

Some data about the springs

Height 20mm, Outer diameter 7.5mm, Inner diameter 5mm

4.3 Smooth and threaded rods

2x Smooth rod Ø8x320 mm







2x Threaded rod M5x300 mm



4.4 Electronics





5. Mechanical parts (Hardware)





5.1 Screws, nuts and washers

5.2Aluminium or acrylic frame

1x Single frame





5.3 Heated Bed





6. Software Details





7. Application

Three-dimensional printing makes it as cheap to create single items as it is to

produce thousands and thus undermines economies of scale. It may have as profound an

impact on the world as the coming of the factory did....Just as nobody could have

predicted the impact of the steam engine in 1750 or the printing press in 1450, or the

transistor in 1950 . It is impossible to foresee the long-term impact of 3D printing. But the

technology is coming, and it is likely to disrupt every field it touches.

Additive manufacturing's earliest applications have been on the tool room end of

the manufacturing spectrum. For example, rapid prototyping was one of the earliest

additive variants, and its mission was to reduce the lead time and cost of developing

prototypes of new parts and devices, which was earlier only done with subtractive tool

room methods (typically slowly and expensively). With technological advances in

additive manufacturing, however, and the dissemination of those advances into the

business world, additive methods are moving ever further into the production end of

manufacturing in creative and sometimes unexpected ways. Parts that were formerly the

sole province of subtractive methods can now in some cases be made more profitably via

additive ones.

Standard applications include design visualization, prototyping/CAD, metal

casting, architecture, education, geospatial, healthcare, and entertainment/retail.

3D printer came with immense number of applications. All the traditional methods

of printing causes wastage of resources. But 3D printer only uses the exact amount of

material for printing. This enhances the efficiency. If the material is very costly, 3d

printing techniques can be used to reduce the wastage of material.

Consider printing of a complex geometry like combustion chamber of a rocket

engine. The 3D printing will enhances the strength and accuracy of the object.

Conventional methods uses parts by parts alignment. This will cause weak points in

structures. But in the case of 3D printed object, the whole structure is a single piece.





3D printer has numerous application in every field it touches. Since it is a product

development device, rate of production, customization and prototyping capabilities need

to be considered.

7.1 Rapid Prototyping

Rapid prototyping is a group of techniques used to quickly fabricate a scale

model of a physical part or assembly using three-dimensional computer aided design

(CAD) data. Construction of the part or assembly is usually done using 3D printing or

"additive layer manufacturing" technology.

The first methods for rapid prototyping became available in the late 1980s and

were used to produce models and prototype parts. Today, they are used for a wide range

of applications and are used to manufacture

Production-quality parts in relatively small numbers if desired without the typical

unfavourable short-run economics. This economy has encouraged service bureaus.

Historical surveys of RP tart with discussions of simulacra used by 19th-century

sculptors. Some use the progeny technology . The ability to reproduce designs

from a dataset has given rise to issues of rights, as it is now possible to interpolate

volumetric data from one-dimensional images. As with CNC subtractive methods, the

computer-aided-design computer-aided manufacturing CAD-CAM workflow in the

traditional Rapid Prototyping process starts with the creation of geometric data, either as a

3D solid using a CAD workstation, or 2D slices using a scanning device. For RP this data

must represent a valid geometric model; namely, one whose boundary surfaces enclose a

finite volume, contain no holes exposing the interior, and do not fold back on themselves.

In other words, the object must have an “inside.” The model is valid if for each point in3D space the computer can determine uniquely whether that point lies inside, on, or

outside the boundary surface of the model. CAD post-processors will approximate the

application vendors’ internal CAD geometric forms (e.g., B-splines) with a simplified

mathematical form, which in turn is expressed in a specified data format which is a

common feature in Additive Manufacturing: STL (stereo lithography) a de facto standard

for transferring solid geometric models to SFF machines. To obtain the necessary motion





control trajectories to drive the actual SFF, Rapid Prototyping, 3D Printing or Additive

Manufacturing mechanism.

7.2 Mass customization

Mass customization, in marketing, manufacturing, call centres and management,

is the use of flexible computer-aided manufacturing systems to produce custom output.

Those systems combine the low unit costs of mass production processes with the

flexibility of individual customization advantage and economic value.

Mass customization is the method of "effectively postponing the task of

differentiating a product for a specific customer until the latest possible point in the

supply network." (Chase, Jacobs & Aquilano 2006, p. 419). Kamis, Koufaris and Stern

(2008) conducted experiments to test the impacts of mass customization when postponed

to the stage of retail, online shopping. They found that users perceive greater usefulness

and enjoyment with a mass customization interface vs. a more typical shopping interface,





particularly in a task of moderate complexity. From collaborative engineering

perspective, mass customization can be viewed as collaborative efforts between

customers and manufacturers, who have different sets of priorities and need to jointly

search for solutions that best match customers’ individual specific needs with

manufacturers’ customization capabilities (Chen, Wang & Tseng (2009)).

With the arrival of 3D printer, we are able to customize any products we want.

Consider you are in a shop to buy a spectacle. The only choice you have is to select a

model from the shop. If you didn’t like any model, you will probably go to another shop.

By the implementation of 3d printed spectacles, you are provided with power for creating

any spectacle in the world with just the CAD model. Many implementations of mass

customization are operational today, such as software-based product configurators that

make it possible to add and/or change functionalities of a core product or to build fully

custom enclosures from scratch.

7.3 Automobiles

In early 2014, the Swedish supercar manufacturer, Koenig egg, announced the

‘One:1’, a supercar that utilises many components that were 3D printed. In the limited run

of vehicles Koenig egg produces, the ‘One:1’ has side-mirror internals, air ducts, titanium

exhaust components, and even complete turbocharger assembles that have been 3D

printed as part of the manufacturing process

An American company, Local Motors is working with Oak Ridge National

Laboratory and Cincinnati Incorporated to develop large scale additive

manufacturing processes suitable for printing an entire car body. The company plans to print the vehicle live in front of an audience in September 2014 at the International

Manufacturing Technology Show. Produced from a new fibre-reinforced thermoplastic

strong enough for use in an automotive application, the chassis and body without

drivetrain, wheels and brakes weighs a scant 450 pounds and the completed car is

comprised of just 40 components, a number that gets smaller with every revision.





Figure down, shows the 3D CAD model of a bike, actually of a 3D printed scale

replica created by designer Jacky Wan from Redicubricks. The 3D printed bike is

made of over 40 individual pieces and Wan details his print and build process over on

Ultimakers blog. He even includes a link to his 3D files so you can build one yourself if

you think you’re up to it. The project is certainly not for beginners. When designing the

bike replica, Wan imposed several goals on himself; He wanted to maintain the external

looks of the bike, all parts needed to snap fit together to make gluing easier, keep seams

and striation to a minimum and everything needed to print on his Ultimaker: Original. Of

course 3D printing a realistic motorcycle replica wasn’t going to mak e it easy for him to

meet to those goals.





7.4 Wearables

San Francisco-based clothing company, Continuum is among the first to create

wearable, 3D printed pieces. Customers design bikinis on Continuum’s website,

specifying their body shapes and measurements. The company then uses nylon to print

out each unique order. Founder Mary Huang believes that this intersection of fashion and

technology will be the future because it “gives everyone access to creativity.”This year,

architect Francis Bitonti and fashion designer Michael Schmidt collaborated to make a

dress for burlesque diva Dita Von Teese. She wore the garment to the Ace Hotel in March

for a convention hosted byonline 3D printing marketplace, Shapeways. The dress consists

of 2,500 intersecting joint pieces that were linked together by hand. The finishing touches

a black lacquer coating and 12,000 hand-placed Swarovski crystals reflect Schmidt’s

iconic glam that attracts a clientele of Madonna, Rihanna, Lady Gaga, and the like.

British designer Catherine Wales is making moves too. She is best known for her Project

DNA collection, which includes avant-garde 3D printed masks, accessories, and apparel,

all printed with white nylon.

The eccentric shapes of her garments reflect that 3D printed clothing is still in its

early stages. Today, the materials and technologies used for 3D printing still dictate and

affect garment design.

Dutch designer Iris Van Herpen has already put this new material to the test in her

Voltage Haute Couture collection, which raised eyebrows at Paris Fashion Week

in January 2013. A frontrunner in the realm of futuristic fashion design, Van Herpen has

been taking her 3D printed dresses and shoes to the runways since 2010. Still, she admits

that there are challenges associated with incorporating a new medium into the

manufacturing process. “I always work together with an architect because I am not good

with the 3D programs myself,” she said.

The idea of custom design has mass appeal and marketability. Who doesn’t want to wear

a one-of-a-kind, perfectly tailored piece? Perhaps the teenage girl of the future won’t have

to suffer the social agony of showing up to a school dance wearing the same dress as her

archenemy.





7.5 Bio-Medical

Scientists, including an Indian-origin researcher, have created a 3D-printed bionicear that can "hear" radio frequencies far beyond the range of normal human capability.Using off-the-shelf printing tools, the scientists at Princeton University explored 3D

printing of cells and Nano particles, creating the bionic ear.

Surgeon Dr. Anthony Atala demonstrated during TED an early-stage experimentthat could someday solve the organ-donor problem: a 3D printer that uses living cells to

print out a transplantable kidney

In the near future, having a broken arm could look way cooler thanks toa new, black, lightweight 3-D printed cast that's patterned like latticework andwhich uses an ultrasound device to make bones heal more quickly.




6. References

1) Korean Scientist and Engineers Network. (2011).Advanced technology and markettrend of printed electronic (1sted.). South Korea

2)

Kim, S. H.Korea Environmental Nano Research Center. (2010). Printable Materialsand Printing Technology Road Map (1st Ed.). South Korea: Kim, N. S., Oh, D. H.,Lee, Y. J., Lee, J.H., Jo, Y. K., Hwang, J. H., and Hong, S. I.

3)

Han, K. N., and Kim, N. S. (2009). Challenges and Opportunities in Direct WriteTechnology Using Nano-metal Particles, Journal of KONA Powder and Particles,

No. 27, pp. 73-83

4) The Book on 3D Printing Paperback – August 31, 2013, By Isaac Budmen

5)

3D Printing: The Next Industrial Revolution Paperback – May 4, 2013, ByChristopher Barnatt

6)

Fabricated: The New World of 3D Printing Paperback – February 11, 2013,By HodLipson

7) Gargiulo, E.P., 1992, Stereolithography process accuracy: user experience, Proc. 1stEuropean Conf. Rapid Prototyping, 187 – 201.

8)

Lee, K.W., Wang, S., Fox, B.C., Ritman, E.L., Yaszemski, M.J., Lu, L., 2007. Poly

bone tissue engineering scaffold fabrication using stereo lithography: effects of resinformulations and laser parameters. Bio macromolecules 8, 1077 – 1084.

9) C.L., Leong, K.F., Chua, C.K., Du, Z., 2001. Dual material rapid prototypingtechniques for the development of biomedical devices. Part I. Space creation. Int. J.Adv. Manuf. Technol. 18 (10), 717 – 723.

10) Avi Reichental what next in 3d printing

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