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 . . . . . . . . . . . . . . . . . . . . . 4
1.2 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 or 3D 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 dierent 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. The
printer 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 stereolithographydened 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 dierenti-
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
elds. It has been speculated that 3D printing may become a mass mar-
ket item because open source 3D printing can easily oset 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 nal 3D model
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has been printed.
A standard data interface between CAD software and the machines is the
STL le format. An STL le approximates the shape of a part or assembly
using triangular facets. Smaller facets produce a higher quality surface. PLY
is a scanner generated input le format, and VRML (or WRL) les 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 le 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 nal 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 sucient 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 rst 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 lled 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 nd 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 Methods
There 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 dierent 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 dierent materials can be used for 3D printing, such as ABS plastic,
PLA, polyamide (nylon), glass lled 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 les, and Shapeways
prints the objects for them or others. Users can have objects printed from a
variety of materials, including food-safe ceramics.
They oer 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 nish.
Figure 2.2: Strong & Flexible Plastic
Alumide
Brittle Nylon Plastic thats lled with Aluminum dust.
Figure 2.3: Alumide
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Detail Plastic
Acrylic based polymer that can print ne details. Smooth and slightly shiny.
Figure 2.4: Detail Plastic
Frosted Detail Plastic
UV-cured acrylic plastic that prints ne details and walls. Smooth and
translucent.
Figure 2.5: Frosted Detail Plastic
Steel
Great for jewelry and durable pieces. The shiny surface is slightly pitted &
rough.
Figure 2.6: Steel
Sterling Steel
Real Sterling Silver is available in 3 levels of polish from rough Raw Silver
to pristine Premium Silver.
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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 eorts to develop aord-
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 specications 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 used
their 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 nished 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 assist
initiatives 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-assembled
form since 2012 at prices in the
US$2000 range. The Kickstarter 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 nancially 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 rst 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 be
using 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 rst
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 ecient food storage for long-haul space ights, 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-modied RepRap printer will be tted 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 rst 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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