3D Printing Technology

Seminar Report 2007-08 3D Printing Technology

ACKNOWLEDGEMENT

I would like to thank everyone who helped to see this seminar to completion. In

particular, I would like to thank my seminar coordinator, Prof. T Valsalan for the moral

support and guidance to complete my seminar on time. Also I would like to thank

Mr. T. Anil Kumar (Lecturer in EEE) for his valuable help and support.

I express my gratitude to all my friends and classmates for their support and help in

this seminar.

Last, but not the least I wish to express my gratitude to God almighty for his

abundant blessings, without which this seminar would not have been successful.

Dept. of Electrical & Electronics Engg. Govt. College of Engg., Kannur


ABSTRACT

The last two decades ended in the midst of revolution caused by a technology that

was barely noticeable at the beginning of the decade. In 1980 few would have guessed

that personal computer along with desktop publishing software would fundamentally

change the way of our industry did business. In 1990 again internet was known and used

by a relatively small set of people. Yet by the end of the decade it was a major force in

our industry and in society and in economy.

Once again we are facing anew decade and we have to wonder what the next

dominant technology likely to change our way of life is. While there is a number of

candidates for the ”next big technology” including perennial favorite, the free energy

device, our best is the technology called 3D printing which as the name implies is a

technology that literally prints real 3D objects. It is used by the marketing industry to

create models for marketing focus groups and pre-production sales demonstration.



CONTENTS

CHAPTER 1 INTRODUCTION 1

1.1 HISTORY 2

1.2 SOURCE DATA 2

CHAPTER 2 AN OVERVIEW OF 3D PRINTING TECHNOLOGY 4

2.1 BLOCK DIAGRAM 4

2.2 WORKING 6

2.3 COLOUR MODELLING 8

CHAPTER 3 APPLICATIONS AND SPECIFICATIONS 9

3.1 ADVANTAGES 9

3.2 BUILDING MATERIALS 11

3.3 SPECIFICATIONS 14

3.4 APPLICATIONS 15

CHAPTER 4 CONCLUSION 16

REFERENCE 17



CHAPTER 1

INTRODUCTION

Originally developed at the Massachusetts Institute of Technology (MIT) in

1993, .3DP technology creates 3D physical prototypes by solidifying layers of deposited

powder using a liquid binder. By definition 3DP is an extremely versatile and rapid

process accommodating geometry of varying complexity in hundreds of different

applications, and supporting many types of materials. Utilizing 3DP technology, Z Corp.

has developed 3D printers that operate at unprecedented speeds, extremely low costs, and

within a broad range of applications. 3D printers are used by leading manufacturers to

produce early concept models and product prototypes .This paper describes the core

technology and its related applications.

Dept. of Electrical & Electronics Engg. Govt. College of Engg., Kannur1


1.1 HISTORY

3d printing technology was originally developed in Massachusetts Institute of

Technology. First 3 D Printer was launched in 1998. First 3D color printer was launched in

2000. Introduced High definition 3D Printing in 2005. HD3DP concept is the result of a

combination of print-head technology, materials advancement, firmware, and mechanical

design.

1.2 SOURCE DATA

3D printing technology leverages 3D source data, which often takes the form of

computer-aided design (CAD) models. Mechanical CAD software packages, the first

applications to create 3D data, have quickly become the standard for nearly all product

development processes. Other industries such as architectural design have also embraced

3D technologies because of the overwhelming advantages they provide, including improved

visualization, greater automation, and more cost-effective reuse of 3D data for a variety of

critically important applications. Due to the widespread adoption of 3D-based design

technologies, most industries today already create 3D design data and are capable of

producing physical models with 3D printers. The software that drives the 3D printers

accepts all major 3D file formats, including .stl, .wrl, .ply, and .sfx files, which leading 3D

software packages can export. In addition to mainstream applications in mechanical and

architectural design, 3D printing has expanded into new markets including medical,

molecular, and geospatial modeling. Additional sources of data include CT/MRI diagnostic

data, protein molecule modeling database data, and digitized 3D-scan data. As designing

and modeling with 3D technologies has become more pervasive, developers have created a

large number of software packages tailored for use in specific industries. A small sampling

of 3D software packages that are directly compatible with the 3D printers appear in the

table below.



SolidWorks® Maya® RapidForm™ 3D Studio Viz®

Pro/ENGINEER® SketchUp® Alias® Form Z®

CATIA® RasMol Raindrop GeoMagic® VectorWorks

3D Studio Max® Rhino® Inventor® Mimics

After exporting a solid file from a 3D modeling package, users can open the file in

ZPrint™, the desktop interface for Z Corp.’s 3D printers. The primary function ofZPrint

is to cut the solid object into digital cross sections, or layers, creating a 2D image for each

0.1016mm (0.004”) slice along the z axis. In addition to sectioning the model, users can

utilize ZPrint to address other production options, such as viewing, orienting, scaling,

coloring, and labeling multiple parts. When a user decides to print the job, ZPrint

software sends 2D images of the cross sections to the 3D Printer via a standard network,

just as other software sends images or documents to a standard 2D printer. Setup takes

approximately 10 minutes.



CHAPTER 2

AN OVERVIEW OF 3D PRINTING TECHNOLOGY

2.1BLOCK DIAGRAM

The microcomputer is used to create a 3 Dimensional model of the

component to be made using well-known CAD techniques. A slicing

algorithm is used to identify selected successive slices, i.e., to provide data

with respect to selected 2-D layers, of the 3-D model.

Once a particular 2–D slice has been selected, the slice is then reduced

to a series of one dimensional scan lines. Each of the scan line may comprise

of single line segments or two or more shorter line segments. Each line

segment having a defined starting point on a scan line and a defined line

segment length.

The microcomputer actuates the powder distribution operation when a

particular 2-D slice of the 3-D model which has been created has been

selected by supplying a powder “START” signal to a powder distribution

controller circuit which is used to actuate a powder distribution system to

permit a layer of powder for the selected slice to be deposited as by a powder

head device. The powder is deposited over the entire confined region within

which the selected slice is located.

Once the powder is distributed, the operation of powder distribution

controller is stopped when the microcomputer issues a powder “STOP”

signal signifying that powder distribution over such region has been

completed.

Microcomputer then select a scan line i.e., the first scan line of the

selected 2-D slice and then select a line segment, e.g., the first 1-D line

segment of the selected scan line and supplies data defining the starting point

thereof and the length thereof to a binder jet nozzle control circuit. For



simplicity in describing the operation it is assumed that a single binder jet

nozzle is used and that such nozzle scans the line segment of a slice in a

manner such that the overall 2-D slice is scanned in a conventional raster

scan operation. When the real time position of the nozzle is at starting point

of the selected line segment. Nozzle is turned on at the start of the line

segment and turned off at the end of line segment in accordance with the

defined starting point and length data supplied from the computer for that

line segment. Each successive line segment is similarly scanned for the

selected scan line and for each successive scan line of the selected slice in

the same manner. For such purpose nozzle carrier system starts its motion

with a scan “BEGIN” signal from microcomputer. So that it is moved in both

x-axis direction and in the Y-axis direction. Data as to the real time position

of the nozzle carrier is supplied to the nozzle control circuit. When the

complete slice has been scanned, a scan “STOP” signal signifies an end of

the slice scan condition.



2.2 3D PRINTING WORKING

3D printers use standard inkjet printing technology to create parts layer-

by-layer by depositing a liquid binder onto thin layers of powder. Instead of

feeding paper under the print heads like a 2D printer, a 3D printer moves the

print heads over a bed of powder upon which it prints the cross-sectional data

sent from the ZPrint software. The system requires powder to be distributed

accurately and evenly across the build platform. 3D Printers accomplish this task

by using a feed piston and platform, which rises incrementally for each layer. A

roller mechanism spreads powder fed from the feed piston onto the build

platform; intentionally spreading approximately 30 percent of extra powder per

layer to ensure a full layer of densely packed powder on the build platform. The

excess powder falls down an overflow chute, into a container for reuse in the

next build.

Once the layer of powder is spread, the inkjet print heads print the cross-

sectional area for the first, or bottom slice of the part onto the smooth layer of

powder, binding the powder together. A piston then lowers the build platform

0.1016mm (0.004”), and a new layer of powder is spread on top. The print heads

apply the data for the next cross section onto the new layer, which binds itself to

the previous layer. ZPrint repeats this process for all of the layers of the part. The

3D printing process creates an exact physical model of the geometry represented

by 3D data. Process time depends on the height of the part or parts being built.

Typically, 3D printers build at a vertical rate of 25mm – 50mm (1” – 2”) per

hour.

When the 3D printing process completes, loose powder surrounds and

supports the part in the build chamber. Users can remove the part from the build

chamber after the materials have had time to set, and return unprinted, loose

powder back to the feed platform for reuse. Users then use forced air to blow the

excess powder off the printed part, a short process which takes less than 10

minutes. Z Corp. technology does not require the use of solid or attached

supports during the printing process, and all unused material is reusable.



3D printing is fast

3D printing is the fastest additive technology commercially available on

the market. Other companies often refer to their equipment as 3D printers,

however these systems rely on processes using a vector approach or single-jet

technology to deposit all build material. Z Corp. uses inkjet print heads with a

resolution of 600 dpi (dots per inch), focuses on a drop-on-demand approach,

and manufactures the only true 3D inkjet printers available. The technology

allows printing of multiple parts simultaneously, while only adding a negligible

amount of time to the print time for one part.

The fundamental inkjet approach is the primary contributor to greater

speed, although there are several other reasons why this system is the fastest.

ZPrint software processes data in parallel with the printing of the part. While the

3D printer deposits the first layer, the software slices and processes the fifth

layer. Some additive technologies process all tool paths before the job begins.



Although the processing time may seem to be fast, it is often only a fraction of

the total time it takes to build the part. It can actually take up to an hour to

prepare a job with multiple parts using some additive technologies.

3D printers enable the stacking of parts vertically because they do not require

rigid support structures. Producing parts with other types of additive

technologies requires structural supports along the vertical axis, limiting the

ability to stack or nest parts. With this 3D printers, users can utilize the entire

build area and produce multiple parts with only one set-up procedure, further

reducing the total number of builds and processing time.

2.3 COLOUR MODELLING

When printing 2D images from digital files, computers convert the RGB

values (Red, Green, and Blue colors displayed on the monitor) to CMYK colors

(Cyan, Magenta, Yellow, and Black). Typically, a 2D color desktop printer will

have a print head with three of the color channels, CMY, and another for black,

K. Using these four inks, the printer combines several dots in each printed pixel

though the use of ordered dither patterns to create the appearance of thousands of

colors. The same principle applies to 3D printing. 3D printers use four colored

binders: cyan, magenta, yellow and clear, to print colors onto the shell of the

part. ZPrint software communicates color information to the printer within the

slice data. Full-color 3D printing produces prototypes with the same coloring as

the actual product. Users also use color to represent analysis results directly on

the model or to annotate and label design changes to further enhance the

communication value of the model.

While color can be an essential communications tool, many 3D software

packages do not provide a simple way to produce 3D files that include color

data. To address this challenge developed ZEdit™ software, a Microsoft®

Windows® based program that facilitates the addition of color data to 3D part

files. ZEdit is a tool for part coloring, markup, labeling, and texture mapping.

Users also utilize it to map .jpeg files onto 3D part geometries. ZEdit software

works with files from any of the leading 3D software packages.



Z Corp.’s 3D printers produce high-resolution models

Z Corp. first introduced high-resolution 3D Printing (HD3DP™) in 2005.

The HD3DP concept is the result of a combination of print-head technology,

materials advancement, firmware, and mechanical design. Highly engineered

inkjet print heads, with 600-dpi, high-resolution capabilities, are the product of

years of research. Z Corp. leverages the engineered print heads in combination

with proprietary firmware to control the print head during the printing process,

accurately and precisely depositing colored binder in the areas indicated by the

ZPrint software. Additionally, this 3D printers control the print head movement

while positioned extremely close to the powder, reducing inaccuracies related to

fanning of the binder spray.

CHAPTER 3

APPLICATIONS AND SPECIFICATIONS

3.1 ADVANTAGES

1) 3D printing is Affordable

3D printers produce very little waste. The unprinted powder surrounds

and supports complex parts during printing. Users can reuse all unused support

powder. Thus, printed-part volume becomes the basis for all part-creation costs.

Other additive processes require the building of solid support structures to

support complex geometries during the printing process. Users have to discard

these support structures after use, and the wasted material contributes

significantly to the cost of additive technologies.

3D printers are dependable and easy-to-use, resulting in low operating

costs. Modular design and standard inkjet printing technology combine to

produce a reliable system that is straightforward to operate and easy to maintain.

The use of an “off-the-shelf” print head allows for inexpensive, quick

replacement of the system’s primary consumable component. The application of

modular design techniques to the printer’s electronics, printing, and maintenance



components makes the printers efficient to maintain with minimum downtime,

further reducing costs.

2) 3D printers are easy to use

The straightforward user interface and simple part-making process

make 3D printers accessible to everyone involved in product design. The

materials used are non-toxic, completely safe, and do not require specialized

operating environments such as a lab or a shop. Users can operate 3D printers

right in an office rather than in a designated space with specialized requirements.

Because of the intuitive ZPrint software interface and simple set-up procedures,

anyone can efficiently operate one of 3D printers, eliminating the need for a

dedicated machine operator. The reliable technology allows its 3D printers to

run unattended during the printing process, reducing user interaction to the

simple setup and part removal steps, which generally take less than one hour.

The process of bonding loose powder to solidify into parts is compatible

with many types of materials. While the 3D printer remains exactly the same,

users can change the build material to produce parts with a wide range of

material properties to meet various application requirements. Z Corp. offers five

materials and continues to develop other materials to provide performance

enhancements for additional applications. Users can select the best material to

support the needs of a specific application.

3) Speed

3D Printers are the fastest.5-10x faster than other RP technology.A part

can be printed at rate of 25mm vertical per hour. In todays competitive global

market speed in product development has become a critical factor for success.

4) Affordability

Z Corporation® sets the standard for affordability in 3D printing.

Because Z Corporation printers leverage standard inkjet printing technology,

they are more reliable and affordable. The approach results in material usage

costs that are a fraction of other rapid prototyping technologies; finished parts

cost $.10 USD per cubic centimeter in materials. A handheld part can be

produced for about $10 USD in material costs. Z Corporation 3D printers recycle



all unused material, so you only pay for the actual materials used to produce a

part.

5) High-Quality Color

Z Corporation 3D Printers operate like a 2D desktop inkjet printer,

allowing for the use of multiple print-heads to support full-color printing with

dramatic increases in speed. Full,24-bit color capabilities use colored binder

materials (cyan, magenta, and yellow, just like a 2D printer) to produce millions

of distinct colors. Full-color printing allows the addition of annotations,

engineering labels and texture maps. Z Corporation’s introduction ofHD3DP

(High-Definition 3D Printing) capabilities also supports the production of

models having complex geometries and small, detailed features.

6) Versatile

The process of bonding loose powder to solidify into parts is compatible

with many types of materials.While the 3D printer remains exactly the

same.users can change the build material to produce part with wide range of

material property to meet various application requirement.

3.2 BUILDING MATERIALS

1) High-Performance Composite Material makes strong, high-definition

parts and is the material of choice for printing color parts. The most widely

used material, high-performance composite material enables color HD3DP on

the 600-dpi platform 3D printer. Fine resolution on small features and excellent

strength make this material suitable for applications ranging from concept

modeling to sand-casting patterns. It consists of a heavily engineered plaster

material with numerous additives that maximize surface finish, feature

resolution, and part strength. This material is ideal for:

• High-strength requirements

• Delicate or thin-walled parts

• Color printing

• Accurate representation of design details



2) Direct Casting Metal Material creates sand-casting molds for non-ferrous

metals. This material is a blend of foundry sand, plaster, and other additives that

when combined produce strong molds with good surface finishes. Direct casting

metal material can withstand the heat required to cast non-ferrous metals. Users

of this “ZCast®” process can create prototype castings without incurring the costs

and lead-time delays of tooling.



3) Investment Casting Material fabricates parts that users dip in wax to

produce investment casting patterns without molds or geometric constraints.

The material consists of a mix of cellulose, specialty fibers, and other

additives that combine to provide an accurate part while maximizing wax

absorption and minimizing residue during the burn-out process. Users

utilize investment casting material to create high quality castings with

excellent surface finishes in a number of industries.

4) Snap-fit material creates Snap- parts with plastic-like, flexural

properties, Which are ideal for snap-fit applications. Z Corp. has optimized

this material for infiltration with the Z-Snap™ epoxy. Users utilize snap-fit

material to create plastic-like parts that snap into other components and

assemblies.

5) Elastomeric Material creates parts with rubber-like properties.

Optimized for infiltration with an elastomer, this material system consists of

a mix of cellulose, specialty fibers, and other additives. Users utilize

elastomeric material to produce accurate parts that are capable of absorbing

the elastomer, which gives the parts their rubber-like properties.

The microcomputer is used to create a 3 Dimensional model of the

component to be made using well-known CAD techniques.A slicing

algorithm is used to identify selected successive slices, i.e., to provide data

with respect to selected 2-D layers, of the 3-D model.

Once a particular 2–D slice has been selected, the slice is then

reduced to a series of one dimensional scan lines. Each of the scan line may

comprise of single line segments or two or more shorter line segments.Each

line segment having a defined starting point on a scan line and a defined line

segment length.

The microcomputer actuates the powder distribution operation when a

particular 2-D slice of the 3-D model which has been created has been



selected by supplying a powder “START” signal to a powder distribution

controller circuit which is used to actuate a powder distribution system to

permit a layer of powder for the selected slice to be deposited as by a powder

head device. The powder is deposited over the entire confined region within

which the selected slice is located.

Once the powder is distributed, the operation of powder distribution

controller is stopped when the microcomputer issues a powder “STOP”

signal signifying that powder distribution over such region has been

completed.

Microcomputer then select a scan line i.e., the first scan line of the

selected 2-D slice and then select a line segment, e.g., the first 1-D line

segment of the selected scan line and supplies data defining the starting point

thereof and the length thereof to a binder jet nozzle control circuit. For

simplicity in describing the operation it is assumed that a single binder jet

nozzle is used and that such nozzle scans the line segment of a slice in a

manner such that the overall 2-D slice is scanned in a conventional raster

scan operation.



3.3 SPECIFICATION

Some of 3D printers available in the market are 1) Z printer 310

2) Spectrum Z 510 3) Z printer 45

1) Z printer 310 [Industrial strandate Monochrome

3D printing system]

Equipment Dimension

74 * 86 * 109cm

Equipment weight

115 Kg

Power Requirement

115 V, 4.3 A or 230 V / 2.4 A

Resolution; 300 * 450 dpi

Build speed; 2 – 4 layers per minute

2) Spectrum Z-510 [next generation H D colour 3DP]

Equipment Dimension: 107 * 79 * 127cm

Equipment weight - 204 Kg

Resolution-600*540dpi

Power-100V, 7.8A or 115V, 6.8A or 230V, 3.4A



3.4 APPLICATION

1. Concept modeling

2. Finite Element Analysis

3. Functional Testing

4. Metal Casting

5. Presantation Models



CHAPTER 4

CONCLUSION

3D Printing is the method of converting virtual 3D models into physical

model. After the arrival of 3D Printing futurist predicted that we’d soon see them

in every home. In future consumers will probably make what they want at home

with their own 3D Printers. If some want a latest fashion toy. They will buy the

3D file instead of the product. One day we may have 3D Printer that use

nanotechnology to create products by depositing them atom by atom. Simple

machinery has been created at the atomic scale such as small wheels, transistors

and “walking DNA”. These could be the precursors to more advanced custom

manufacturing system.



REFERENCE

1. http://www.emco.co.uk/rapid.htm

2,http://www.hawkridgesis.com/products/p.add.z corps.htm/

3. http://www.sldtech.com/PDFs/3D printers Brochure overviews.pdf

4. www.architecture.mit .edu.

5. www.realizationgroup.com


http://www.realizationgroup.com/

3D Printing Technology

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