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3-DPRINTING

2MOTIVATION

Third Industrial

Revolution!!!!

Futurologists such as Jeremy Rifkin believe that 3D printing signals the beginning of a Third Industrial Revolution.

3D printing moves us away from the Henry Ford era mass production line, and will bring us to a new reality of customizable, one-off production.

Need a part for your washing machine? o As it is now, you’d order from your repairman who gets it from a

distributor, who got it shipped from China, where they are mass-produced.o In the future, the beginning of which is already here now, you will simply

3D print the part right in your home.

Jeremy Rifkin

3OUTLINE

What Is 3-D Printing? General Principles Processes and Technologies VAT Photo Polymerisation Applications Future Scope & Conclusion References

4WHAT IS 3-D PRINTING?

3D printing, also known as Additive manufacturing (AM), refers to various processes used to synthesize a three-dimensional object from a digital file.

In 3D printing, successive layers of material are formed under computer control to create an object.

The creation of a 3D printed object is achieved using additive processes.

In an additive process an object is created by laying down successive layers of material until the entire object is created.

These objects can be of almost any shape or geometry.

A MakerBot 3D printer

5General Principles(or How does 3D printing work?)

1. Modelling 2. Printing 3. Finishing

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1. Modelling:-o It all starts with making a virtual design of the object you want to create. o This virtual design is made :

with a computer aided design (CAD) package, via a 3D scanner or by a plain digital camera and photogrammetry software

Examples of Virtual Design File:

CAD model used for 3D printing

Autodesk model used for 3D printing

General Principles (contd.)

72. Printing:-o Before printing a 3D model from an Virtual Design file, it must first be

examined for errors. o This step is called "repair", as the original model needs to be fixed. o Once completed, the Virtual Design file needs to be processed by a

piece of software called a "slicer," which converts the model into a series of thin layers and produces a G-code file containing instructions to instruct the 3D printer during the 3D printing process.

3. Finishing:-Though the printer-produced resolution is sufficient for many applications,

printing a slightly oversized version of the desired object in standard resolution and then removing material with a higher-resolution subtractive process can achieve greater precision.

3D printed ceramic pot

Flower model made with a 3D printer

General Principles (contd.)

8Processes and Technologies Not all 3D printers use the same technology. There are several ways to print and

all those available are additive, differing mainly in the way layers are build to create the final object.

Since 2010, the American Society for Testing and Materials (ASTM) group “ASTM F42 – Additive Manufacturing”, developed a set of standards that classify the Additive Manufacturing processes into 7 categories according to Standard Terminology for Additive Manufacturing Technologies. These seven processes are:

1. Vat Photo Polymerisation2. Material Jetting3. Binder Jetting4. Material Extrusion5. Powder Bed Fusion6. Sheet Lamination7. Directed Energy Deposition

The most common method used is “VAT Photo Polymerisation”

9VAT Photo Polymerisation

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

An ultraviolet (UV) light is used to cure or harden the resin where required, whilst a platform moves the object being made downwards after each new layer is cured.

The most commonly used technology in this process is Stereolithography (SLA).

10Applications1.Medical industry:-

The outlook for medical use of 3D printing is evolving at an extremely rapid pace as specialists are beginning to utilize 3D printing in more advanced ways.

Patients around the world are experiencing improved quality of care through 3D printed implants and prosthetics never before seen.

Various fields:i. Bio-Organ printingii. Skull and jaw implantsiii.Dental implants

CAD model of skull

Bio printing machine

Bio-printed model of Kidney

Installed 3D printed skull implant

11Applications (contd.)

3D printing as an advanced technology can compensate the individual’s disability or deficiency by manufacturing complex composite 3D objects using 3D scanned data.

It can help people regain mobility, improve their employment and social opportunities and possibly help self-reliance and alleviate self-confidence issues.

 Scanned and designed CAD model (left), Integration due to 3D printed part (right)

12Applications (contd.)2. Food:- 

3D printing of chocolate

A company called Choc Edge is currently marketing "the world's first commercial 3D chocolate printer", the Choc Creator. It uses a nozzle to dispense molten chocolate into any pattern and shape.

MIT’s Cornucopia program is also working on specialized 3D printers for the food industry and so far has designed four prototypes. 

Researches in university of Cornell have demonstrated new materials suitable for baking, broiling and frying for use with food 3D printers.

3D printing of food, before being fried (left), after frying

(right) 

One of the problem with food printing is the nature of the texture of a food. Example: foods that are not strong enough to be filed are not appropriate for 3D printing for now.

13Applications (contd.)3. Industrial printing:-

i. Rapid prototyping:• Manufacturers have long used 3D printers

in their design process to create prototypes for traditional manufacturing and research purposes.

• Using 3D printers for these purposes is called rapid prototyping.

ii. Rapid Manufacturing:• Rapid manufacturing is a new method of

manufacturing where companies are using 3D printers for short run custom manufacturing.

• In this way of manufacturing the printed objects are not prototypes but the actual end user product.

The Audi RSQ was made with rapid prototyping industrial

KUKA robots

3D Printed Shell Amplifier Prototype

14Applications (contd.)

A good example of a rapid prototyping machine is the Z310 3D printer from Z-Corporation

15Future & Conclusion

The worldwide 3D printing industry is expected to grow from $3.07B in revenue in 2013 to $12.8B by 2018, and exceed $21B in worldwide revenue by 2020.

As it evolves, 3D printing technology is destined to transform almost every major industry and change the way we live, work, and play in the future.

Technological development IN 3D Printing will change the nature of commerce, because end users will be able to do much of their own manufacturing rather than engaging in trade to buy products from other people and corporations.

But, since nearly anything can be printed by 3D Printers and this is a troubling prospect if criminals use 3D Printers to create illegal products.

Facial Replicas at 3D Systems. Animators have begun using the technology to create faces with multiple expressions.

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