3D Printing

P. Sujan KumarPhD Scholar,

AcSIR-RE

1984 - 86Charles Deckard Hull invents 3D printing and coins

the term “Stereo Lithography”

1992First 3D printer built by 3D Systems

1999First application of 3D printing in the medical field -

creating the human bladder

HISTORY OF 3D PRINTING

2000Miniature human kidney created through 3D printing

2006The Selective Laser Sintering machine – printing

multiple materials & fields

2009First usable prosthetic leg – this opens the door for

customized products using 3D printing

20113D printers start offering 14k gold as printable

material

• It is a method of converting a virtual 3D model into a physical object.

• 3D object is created by laying down successive layers of material

3D Printing or “Additive Manufacturing”

Additive Manufacturing technologies

• Vat Photopolymerisation (Stereolithography)• Material Jetting • Binder Jetting • Material Extrusion • Powder Bed Fusion • Sheet Lamination • Directed Energy Deposition

• Stereolithography• Selective laser sintering (SLS)• Fused deposition modeling (FDM)• Laminated object manufacturing• Ink-Jet 3D printing

Different Methods/Technologies of 3D printing

Stereolithography

Stereo lithography is an additive manufacturing process using a liquid UV-curable photopolymer ”resin” and a UV laser to build parts a layer at a time.

Material Jetting

In this process, material is applied in droplets through a small diameter nozzle, similar to the way a common inkjet paper printer works, but it is applied layer-by-layer to a build platform making a 3D object and then hardened by UV light.

Binder Jetting

In this process, powder base material and a liquid binder are used. In the build chamber, powder is spread in equal layers and binder is applied through jet nozzles that “glue” the powder particles in the shape of a programmed 3D object.

Powder bed fusion/ SLS method

Selective laser sintering (SLS) is an additive manufacturing technique that uses a high power laser (for example, a carbon dioxide laser) to fuse small particles of plastic, metal (direct metal laser sintering),ceramic or glass powders into a mass that has a desired 3-dimensional shape).

Fused deposition modeling (FDM)

Fused deposition modeling (FDM) is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. Basic materials used are either ABS (Acrylonitrile Butadiene Styrene) and PLA (Polylactic acid)

Sheet Lamination/ Laminated Object Manufacturing method

In this method, layers of adhesive-coated paper, plastic or metal laminates are successively glued together and cut to shape with a knife or laser cutter.

Directed Energy Deposition

The 3D printing apparatus is usually attached to a multi-axis robotic arm and consists of a nozzle that deposits metal powder or wire on a surface and an energy source (laser, electron beam or plasma arc) that melts it, forming a solid object.

You only need a printer, raw material, and software to tell the printer what to print.

Working of a 3D printer

STEP 1: Create CAD file using a softwareSTEP 2: CAD file is exported to a 3D printing machineSTEP 3: Load the material and the object is printed

Application areas• Industrial design• Automotive and aviation industries• Architecture• Food preparation• Medical industry• Toys• Complex Structure and many more……

Examples:

Rep RapModel:

RepRapPro Huxley

Eventorbot

Model: Delta

Micro Up Afinia H-Series

PrintrbotModel: Printrbot

GO

MakerbotModel:

Replicator 2x

The Future is

3DModel: Glacier Steel

3D SystemsModel: CubeX

FormlabsModel: Form 1

StratasysModel: U print SE Plus

Some of the 3D Printers available in market

• RAPID PROTOTYPING: 3D printing gives designers the ability to quickly turn concepts into 3D models or prototypes (rapid prototyping).

• Clean process. Wastage of material is negligible.• Complex shape can be produced .• EASY TO USE No skilled person needed.• REDUCE DESIGN COMPLEXITY• CHEAP Cheaper process than any other process.• People in remote locations can fabricate objects that would

otherwise be inaccessible to them.

ADVANTAGES

• Process is slow• Components do not have enough strength. • COST OF RAW MATERIALS• 3-D printers are still expensive.• Misuse of technology• Although 3-D printers have the potential of creating many jobs

and opportunities, they might also put certain jobs at risk .

DISADVANTAGES

• With today's 3D printers, if you lose your TV remote's battery cover you can print a replacement battery cover. With tomorrow's, if you lose your remote, you'll be able to print a new remote.

• 3D printers are always getting cheaper and better.• There is currently research going on to create 3D printers that

could print out organs for people in need of a transplant.• Within a decade, 3D printers will become commonplace in

houses.

FUTURE of 3D printing

3D printer at CSIR

Stratasys Fortus-250mc

Material: ABSplus-P430

Build envelope (XYZ): 254 x 254 x 305 mm (10 x 10 x 12 in.)

Achievable accuracy ± .241 mm (± .0095 in.)http://www.stratasys.com/3d-printers/design-series/fortus-250mc

Some examples of printed products

Rapid Prototyping/ 3D Printing

How To Prototype

• Step 1: Idea Generation.• Step 2: Free Hand Sketch• Step 3: Dimensioning the sketched model• Step 4: Replicate in a CAD Software.• Step 5: Analyse the model in the software.• Step 6: Print it.• Step 7: Iterate the model with required

modifications

“The future can not be predicted, but it can be made !”