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CHAPTER-1
INTRODUCTION
3D-Printing or Additive manufacturing is a process of making a three dimensional solid
objects 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 different 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 know as
Subtractive process.
3D printing is a rapidly developing technology in the last years. This technology has
applications in the fields like engineering, medical, industries and many more. These
include creation of mass-customized products, prototypes, replacement of parts and even
medical and dental implants. The speed and ease of designing and modifying products has
made them the number one rapid prototyping technique.
A 3D printer is a limited type of industrial robot that is capable of carrying out an additive
process under computer control
While 3D printing technology has been around since the 1980’s, it was not until the early
2010’s that the printers became widely available commercially.
The first working 3D printer was invented in1984 by Chuck Hull of 3D Systems Corp.
Since the start of the 21st century there has been a large growth in the sales of these
machines and their price has been dropped substantially.
Rapid prototyping in a general term describing technologies that can produce physical
objects form CAD data. It is often also called Solid Freeform Fabrication (SFF) and
Additive Manufacturing (AM). RP can be used in a wide range of industries and
technologies and in no of applications.
3D printing is generally classified as a powder based RP method and the 3D ink jet
printing process is one by Z Corporation, with basic materials being in the form of
powder and liquid binder. It is the only RP method that can produce physical models in
full color, by using subtractive color mixing and digital half toning, much like in
conventional color ink jet printing, realized through the applications of colored binders in
addition to the clear binder. This enables creation of various models that are useful in
solutions for e.g. visualization, concept modeling, Finite Element Analysis (FEA),
presentation models, etc
CHAPTER-2
HISTORY
The inception of 3D printing can be traced back to 1976, when the inkjet printer was
invented. In 1984, adaptations and advances on the inkjet concept morphed the
technology from printing with ink to printing with materials. In the decades since, a
variety of applications of 3D printing technology have been developed across several
industries.
The technology for printing physical 3D objects from digital data was first developed by
Charles Hull in 1984. He named the technique as Stereo lithography and obtained a patent
for the technique in 1986. While Stereolithography systems had become popular by the
end of 1980s, other similar technologies such as Fused Deposition Modeling (FDM) and
Selective Laser Sintering (SLS) were introduced.
In 1993, Massachusetts Institute of Technology (MIT) patented another technology,
named "3Dimensional Printing techniques", which is similar to the inkjet technology used
in 2D Printers.
In 1996, three major products, "Genisys" from Stratasys, "Actua 2100" from 3D Systems
and "Z402" from Z Corporation, were introduced.
In 2005, Z Corp. launched a breakthrough product, named Spectrum Z510, which was the
first high definition color 3D Printer in the market.
Another breakthrough in 3D Printing occurred in 2006 with the initiation of an open
source project, named Reprap, which was aimed at developing a self replicating 3D
printer.
CHAPTER-3
WORKING
Step 2: Conversion to STL - Convert the CAD drawing to the STL format. Standard
Tessellation Language (STL) is a file format developed for 3D Systems in 1987 for use
by Stereo lithography apparatus (SLA) machines. Most 3-D printers can use STL files in
addition to some proprietary file types such as ZPR by Z Corporation and ObjDF by
Objet Geometries.
Step 3: Transfer to AM Machine and STL File Manipulation - The user copies the
STL file to the computer that controls the 3-D printer. There, the user can designate the
size and orientation for printing. This is similar to the way you would set up a 2-D
printout to print 2-sided or in landscape versus portrait orientation.
Step 4: Machine Setup - Each machine has its own requirements for how to prepare for a
new print job. This includes refilling the polymers, binders and other consumables the
printer will use. It also covers adding a tray to serve as a foundation or adding the
material to build temporary water-soluble supports.
Step 5: Build - The build process is mostly automatic. Each layer is usually about 0.1
mm thick, though it can be much thinner or thicker. Depending on the object's size, the
machine and the materials used, this process could take hours or even days to complete.
Step 6: Removal - Remove the printed object (or multiple objects in some cases) from
the machine. We have to take safety precautions to avoid injury such as wearing gloves to
protect from hot surfaces or toxic chemicals.
Step 7: Post Processing - Many 3-D Printers will require some amount of post-
processing for the printed object. This could include brushing off any remaining powder
or bathing the printed object to remove water-soluble supports. The new print may be
weak during this step since some materials require time to cure, so caution might be
necessary to ensure that it doesn't break or fall apart.
Step 8: Application - The newly printed objects are for the desired application.
The FUBINI theorem named after the Italian mathematician Guido Fubini. The theorem
is a result which gives the conditions under which it is possible to compute double
integral using iterated integrals.
∫ (∫ ( ) ) ∫ (∫ ( ) ) ∫ ( ) ( ) ......(3.31)
∫ | ( )| ( ) ……………………. (3.32)
In order to analyze the theorem, we suppose A and B are complete measure spaces.
Suppose f(x,y) is A x B measurable if
∫ (∫ ( ) ) ∫ (∫ ( ) ) ∫ ( ) ( )
…………(3.33)
Where the integrals is taken with respect to a product measure on the space over A x B,
then
∫ ( ) ∫ ( ) ∫ ( ) ……(3.34)
The first two integrals being iterated integrals with respect to two measures respectively
and the third being an integral with respect to product of these two measures. If the above
integral of the absolute value is not finite, then the two iterated integrals may actually
have different values. Thus we have that if f(x,y)=g(x,y) for some functions g and h.
The integral on the right side with respect to a product measure. Fubini’s theorem proves
that 3D printers can print any real life solid object.
CHAPTER-4
The most popular material is plastic, and most of home desktop style printers print objects
using plastic, however some of the higher end printers are capable of printing using many
different materials. Currently some of the object range of printers support up to 107
materials.
4.1 PLASTICS
At the moment the majority of the 3D printers, especially the low cost system, print using
a technology called “Fused Filament Fabrication”(FFF) , these printers currently tend to
print using one of the following materials:
4.2 POWDERS
The higher end printers can use a various powder based materials. These materials
include
4.2.1 POLYAMIDE
This is a strong and flexible material that allows a high level of detail to be achieved.
Polyamide objects are constructed from a white, very fine, granular powder.
4.2.2 ALUMIDE
Is a Polyamide-like material with a distinctive sandy and granular look that is a rigid and
strong material. Alumide objects are constructed from a blend of gray aluminum powder
and polyamide, a very fine granular powder.
4.2.3 MULTICOLOR
A full color material with a sandy and granular appearance. Models made out of
multicolor are constructed from a fine granular powder.
4.3 RESINS
Resins are also a material sometimes used in a 3D printing. Although design freedom is
limited due to the structure necessary to support the objects during the printing process.
The following are the examples of some resins that can be used:
4.4.1 TITANIUM
Is very light and the strongest 3D printing material available. Objects made from titanium
are printed using titanium powder that is sintered together by a laser.
4.4.3 BRONZE
Objects produced in bronze are 3D printed in using a bronze powder that is infused with
bronze. Bronze is an affordable and strong material for printing models in metal.
4.4.5 CERAMICS
A 3D printing material that has a shiny appearance is heat resistant, recyclable and food
safe. Models made out of ceramics are constructed from alumina silica ceramic powder,
then sealed with porcelain and silica and glazed. A perfect material for home décor items
and tableware.
CHAPTER-5
TYPES OF 3D PRINTERS
There are 9 different types of 3D-Printer technologies.
SLA has been the oldest of the 3D printing technologies, first invented by Chuck Hull in
1984. SLA works by exposing a layer of photosensitive liquid resin to a UV-laser beam
so that the resin hardens and becomes solid. Once the laser has swept a layer of resin in
the desired pattern and it begins to harden, the model-building platform in the liquid tank
of the printer steps down the thickness of a single layer, and the laser begins to form the
next layer. Each layer is built on top of the preceding one. After printing has completed,
the object is rinsed with a solvent. Sometimes baked in a UV oven to finish processing.
DLP technology was invented in 1987 by Larry Hornbeck of Texas Instrument. DLP also
uses liquid photopolymers but instead of laser, it uses a special projector. It has a
computer-controlled, micro-mirror grid, laid out on a semiconductor chip. These tiny
mirrors tilt back and forth. When a mirror is tilted, it reflects light, creating a bright pixel.
When the mirror is tilted the other way, the pixel is dark. One of the benefits is its speed.
We can print layers in an instant with this type of 3D printer.
SLS is similar to SLA, but difference is that it uses powdered material in the build
area instead of liquid resin. A laser is used to selectively sinter a layer of granules,
which binds the material together to create a solid structure. When the object is fully
formed, it’s left to cool in the machine before being removed. This type of 3D printer
requires the use of expensive high-powered lasers. The materials used in SLS can range
from nylon, glass, and ceramics to aluminum, silver, and even steel.
The EBM technique uses a computer-controlled electron beam under high vacuum to
fully melt the metallic powder at high temperatures up to 1000 °C.
LOM uses layers of adhesive-coated paper, plastic or metal laminates, which are fused
under heat and pressure then shaped by cutting with a computer controlled laser or knife.
This is sometimes followed by machining and drilling. The 3D object is created layer-by-
layer and after the excess material is cut away, the object can be sanded or sealed with
paint. LOM is one of the most affordable and fastest 3D printing methods available to
create relatively large parts. It also allows for full-color 3D printed objects.
CHAPTER-6
6.1 ADVANTAGES
3D printing technology has various advantages. The 3D printing technology can now be
used in almost any field.
With 3D printing technology, manufacturing has become easier than before.3D printing
processes allow for mass customization the ability to personalize products according to
individual needs and requirements. Even within the same build chamber, the nature of 3D
printing means that numerous products can be manufactured at the same time according
to the end-users requirements at no additional process cost. By using this technology we
have unlimited possibilities of custom designing.
3D printing enables quick production of prototypes or small version of real life objects.
This also helps the researchers and engineers to plan the actual object and catch any
design flaws that may affect the quality and functionality of the object. Rapid prototyping
makes R&D cycles shorter while providing the flexibility of creating and testing multiple
design iterations 3D printing can be used to modify, rather than create, existing products.
Although the initial cost of setting up a 3D printer is high, the overall cost is reduced in
the form of labor cost, also time saved and mass manufacturing ensures that the cost of
production is relatively low.
6.1.4 SUSTAINABLE
Since 3D printers can print products as and when needed and does not cost more than the
manufacturing cost, no expenses on storage of good is required. Furthermore, 3D printing
is showing great promise in terms of fulfilling a local manufacturing model, whereby
6.2 LIMITATIONS
3D printing technology has some of the limitations too, which sometimes affect the
thinking of a person to take up this technology.
CHAPTER-7
APPLICATIONS
The 3D printing technology has played a major role in the manufacturing field. It has
helped in customizing, rapid manufacturing and also modifying the product.
The 3d printing technology has also found a prominent application in the field of medical.
7.2.1 BIO-PRINTING
It’s a process of creating spatially controlled cell patterns, in which the behavior of
biological tissues can be reproduced. This ideally extends to printing complete viable
organs for transplant. Bio printed organs could potentially decrease transplant organ
rejection and increase the availabity of organs for patients.
The 3D printing technology as the major use in the field of industry. It has changed the
way things are manufactured and produced. The four main industries are automotive
aerospace, construction and industrial art and jewelry.
Another general early adopter of Rapid Prototyping technologies the earliest incarnation
of 3D printing was the automotive sector.
They use this technology for prototyping applications, but developing and adapting their
manufacturing processes to incorporate the benefits of improved materials and end results
for automotive parts.
In 2014, Swedish supercar manufacturer Koenigsegg announced the One:1, a supercar
that utilizes many components that were 3D printed. In the limited run of vehicles
Koenigsegg produces, the One:1 has side-mirror internals, air ducts, titanium exhaust
components, and complete turbocharger assemblies that were 3D printed as part of the
manufacturing process.
The field of architecture and civil engineering has also found the use of 3D printing
technology. Using 3D printing technology they print the miniature structure of real life
objects and then look for the flaws present in it. Also many houses and other items are
printed using 3D printer. E.g Recent a company in Russia built an house using the parts
completely made out of 3D printers.
Artists and Sculptors are engaging with 3D printing in myriad of different ways to
explore form and function in ways previously impossible. There are numerous artists that
have now made a name for themselves by working specifically with 3D modeling, 3D
scanning and 3D printing technologies.
For the jewellery sector, 3D printing has proved to be particularly disruptive. There is a
great deal of interest and uptake based on how 3D printing can, and will, contribute to the
further development of this industry. From new design freedoms enabled by 3D CAD and
3D printing, through improving traditional processes for jewellery production all the way
to direct 3D printed production eliminating many of the traditional steps.
4
7.3.5 EDUCATION AND RESEARCH
Coming to the field of education and research, 3D printing technology can help in many
ways. 3D printing and open source 3D printers in particular, are the latest technology
making inroads into the classroom. It can help students in creating various models and
also they can use in field of research.
CHAPTER-8
CONCULSION
The developed, existing standardized method for color measurement ,monitoring and
control, used in graphic technology, printing and color science can, to some extent be
applied to issues arising in the field of color 3D printing. 3D printing provides various
capabilities, permanence and the appropriate research methodology.
The contribution of 3D printing in field like medical, aerospace and others have brought
lot of new possibilities and ways to explore new things.3D printing technology has
brought lot of change in manufacturing sector too, by reducing the cost of labor and
increasing the time of production.
We have also seen mathematically that 3D printing technology is justified and there are
numerous methods of implementing the same. Still lots of research is required in this
technology to bring the its cost and also to make it feasible and robust.
REFRENCES
[2] Vivek Srinivasan ,Jarrod Bassan .”3D-Printing” CSE Leading Edge Forum 2012.
[3] Howard Smith, “3D Printing News and Trends”, CSC Forum ,
http://3dprintingreviews.blogspot.com
[6] Market, M.S, Jiang Z., James T, Kong “A 3D printed model”, ConfProc IEEE Eng
Med BiolSoc,5,2007 pp. 4472-4475.