1.

Introduction

3Dimensions printing is a method of converting a virtual 3D model into a physical object.

3D printing is a category of rapid prototyping technology. 3D printers typically work by printing
successive layers on top of the previous to build up a three dimensional object.

The past decade has witnessed the emergence of new manufacturing technologies that
build parts on a layer-by-layer basis. Using these technologies, manufacturing time for parts of
virtually any complexity is reduced considerably. In other words, it is rapid. Rapid Prototyping
Technologies and Rapid Manufacturing offer great potential for producing models and unique
parts for manufacturing industry.

A few years ago, to get some prototyping work done for a product or design you are
working on, you are required to spend a lot of man-hours just to come up with the model. Those
hours will be spent creating miniature parts of your design using wood and then gluing all those
parts together painstakingly. Prototyping is, at the very least, time-consuming and extremely
tedious.
These days, however, you can take the tediousness and the time investment out of your
prototyping tasks through rapid prototyping or 3d printing. 3D printing is a revolutionary method
for creating 3D models with the use of inkjet technology. Many engineers have even dubbed 3D
printing as the process of creating something out of nothing. Thus, the reliability of products can
be increased; investment of time and money is less risky. Not everything that is thinkable today
is already workable or available at a reasonable price, but this technology is fast evolving and the
better the challenges, the better for this developing process.

The term Rapid prototyping (RP) refers to a class of technologies that can automatically
construct physical models from Computer-Aided Design (CAD) data.

It is a free form fabrication technique by which a total object of prescribed shape, dimension and
finish can be directly generated from the CAD based geometrical model stored in a computer,
with little human intervention. Rapid prototyping is an "additive" process, combining layers of
paper, wax, or plastic to create a solid object. In contrast, most machining processes (milling,
drilling, grinding, etc.) are "subtractive" processes that remove material from a solid block. RP’s
additive nature allows it to create objects with complicated internal features that cannot be
manufactured by other means.

In addition to prototypes, RP techniques can also be used to make tooling (referred to as rapid
tooling) and even production-quality parts (rapid manufacturing). For small production runs and
complicated objects, rapid prototyping is often the best manufacturing process available. Of
course, "rapid" is a relative term. Most prototypes require from three to seventy-two hours to
build, depending on the size and complexity of the object. This may seem slow, but it is much
faster than the weeks or months required to make a prototype by traditional means such as
machining. These dramatic time savings allow manufacturers to bring products to market faster
and more cheaply.

3D PRINTING: MAKING THE DIGITAL REAL

Imagine a future in which a device connected to a computer can print a solid object. A future in
which we can have tangible goods as well as intangible services delivered to our desktops or
highstreet shops over the Internet. And a future in which the everyday "atomization" of virtual
objects into hard reality has turned the mass pre-production and stock-holding of a wide range of
goods and spare parts into no more than an historical legacy.

Such a future may sound like it is being plucked from the worlds of Star Trek. However, whilst
transporter devices that can instantaneously deliver us to remote locations may remain a fantasy,
3D printers capable of outputting physical objects have been in development for over two
decades. What's more, several 3D printers are already on the market. Available from companies
including Fortus, 3D Systems, Solid Scape, ZCorp, and Desktop Factory, these amazing devices
produce solid, 3D objects from computer data in roughly the same way that 2D printers take our
digital images and output hardcopy photos.
The Desktop Factory currently sells a 3D printer for $4995. This can print models up to a five-
inch cube in size with consumables costing around $1 per cubic inch. However, prices for most
3D printers tend to start in the ten-to-twenty thousand pound bracket and spiral upwards.
Although some desktop models are on the market, most 3D printers are usually fairly bulky and
often floor-standing.
2. Rapid Prototyping Techniques

Rapid prototyping is the fabrication of parts from CAD data sources. Several rapid
prototyping methods have been created to produce objects of complex geometries in a relatively
short amount of time. These systems are beneficial to engineers by allowing them to better
understand the products that they are designing and by providing them with a way to create a
visual aid to communicate with others. Rapid prototyping allows design challenges to be
determined earlier in the design process, saving time and money. The technology of rapid
prototyping is easy to access and simple to understand.

2.1 Stereo lithography

Patented in 1986, stereolithography started the rapid prototyping revolution. The

technique builds three-dimensional models from liquid photosensitive polymers that solidify
when exposed to ultraviolet light. As shown in the figure below, the model is built upon a
platform situated just below the surface in a vat of liquid epoxy or acrylate resin. A low-power
highly focused UV laser traces out the first layer, solidifying the model’s cross section while
leaving excess areas liquid. Next, an elevator incrementally lowers the platform into the liquid
polymer. A sweeper re-coats the solidified layer with liquid, and the laser traces the second layer
atop the first. This process is repeated until the prototype is complete. Afterwards, the solid part
is removed from the vat and rinsed clean of excess liquid. Supports are broken off and the model
is then placed in an ultraviolet oven for complete curing. Because it was the first technique,
stereolithography is regarded as a benchmark by which other technologies are judged. Early
stereolithography prototypes were fairly brittle and prone to curing-induced warpage and
distortion, but recent modifications have largely corrected these problems.
 Fig 2.1:Stereo lithography

2.2 Laminated Object Manufacturing

In this technique, developed by Helisys of Torrance, CA, layers of adhesive-coated sheet

material are bonded together to form a prototype.. As shown in the figure below.

Fig2.2: Schematic diagram of laminated object manufacturing.

A feeder/collector mechanism advances the sheet over the build platform, where a base
has been constructed from paper and double-sided foam tape. Next, a heated roller applies
pressure to bond the paper to the base. A focused laser cuts the outline of the first layer into the
paper and then cross-hatches the excess area (the negative space in the prototype). Cross-
hatching breaks up the extra material, making it easier to remove during post-processing. During
the build, the excess material provides excellent support for overhangs and thin-walled sections.
After the first layer is cut, the platform lowers out of the way and fresh material is advanced. The
platform rises to slightly below the previous height, the roller bonds the second layer to the first,
and the laser cuts the second layer. This process is repeated as needed to build the part, which
will have a wood-like texture. Because the models are made of paper, they must be sealed and
finished with paint or varnish to prevent moisture damage.

Helisys developed several new sheet materials, including plastic, water-repellent paper,
and ceramic and metal powder tapes. The powder tapes produce a "green" part that must be
sintered for maximum strength. As of 2001, Helisys is no longer in business.

2.3 Selective Laser Sintering

Developed by Carl Deckard for his master’s thesis at the University of Texas, selective laser
sintering was patented in 1989. The technique, shown in Fig, uses a laser beam to selectively
fuse powdered materials, such as nylon, elastomer, and metal, into a solid object. Parts are built
upon a platform which sits just below the surface in a bin of the heat-fusable powder. A laser
traces the pattern of the first layer, sintering it together. The platform is lowered by the height of
the next layer and powder is reapplied. This process continues until the part is complete. Excess
powder in each layer helps to support the part during the build. SLS machines are produced by
DTM of Austin, TX.
 Fig 2.3: Schematic diagram of selective laser sintering.

2.4 Fused Deposition Modeling

In this technique, filaments of heated thermoplastic are extruded from a tip that moves in
the x-y plane. Like a baker decorating a cake, the controlled extrusion head deposits very thin
beads of material onto the build platform to form the first layer.
 Fig2.4: schematic diagram of fused deposition modeling.

The platform is maintained at a lower temperature, so that the thermoplastic quickly

hardens. After the platform lowers, the extrusion head deposits a second layer upon the first.
Supports are built along the way, fastened to the part either with a second, weaker material or
with a perforated junction.

2.5 Electron beam melting (EBM)

It is a type of additive manufacturing for metal parts. It is often classified as a rapid

manufacturing method. The technology manufactures parts by melting metal powder layer per
layer with an electron beam in a high vacuum. Unlike some metal sintering techniques, the parts
are fully dense, void-free, and extremely strong.
 This solid freeform fabrication method produces fully dense metal parts directly from
metal powder with characteristics of the target material. The EBM machine reads data from a 3D
CAD model and lays down successive layers of powdered material. These layers are melted
together utilizing a computer controlled electron beam. In this way it builds up the parts. The
process takes place under vacuum, which makes it suited to manufacture parts in reactive
materials with a high affinity for oxygen.

Fig2.4: Electron beam melting

The melted material is from a pure alloy in powder form of the final material to be
fabricated (no filler). For that reason the electron beam technology doesn't require additional
thermal treatment to obtain the full mechanical properties of the parts. That aspect allows
classification of EBM with LSM where competing technologies like SLS and DMLS require
thermal treatment after fabrication. Comparatively to SLS and DMLS, EBM has a generally
superior build rate because of its higher energy density and scanning method. Minimum layer
thickness: 0.05 mm. Tolerance capability: +/- 0.4 mm.

2.6 3D Printing

Ink-Jet Printing refers to an entire class of machines that employ ink-jet technology. The
first was 3D Printing (3DP), developed at MIT and licensed to Soligen Corporation, Extrude
Hone, and others. The ZCorp 3D printer, produced by Z Corporation of Burlington, MA is an
example of this technology. As shown in Figure 6a, parts are built upon a platform situated in a
bin full of powder material. An ink-jet printing head selectively deposits or "prints" a binder
fluid to fuse the powder together in the desired areas. Unbound powder remains to support the
part. The platform is lowered, more powder added and leveled, and the process repeated. When
finished, the part is then removed from the unbound powder, and excess unbound powder is
blown off. Finished parts can be infiltrated with wax, CA glue, or other sealants to improve
durability and surface finish. Typical layer thicknesses are on the order of 0.1 mm. This process
is very fast, and produces parts with a slightly grainy surface. ZCorp uses two different materials,
a starch based powder (not as strong, but can be burned out, for investment casting applications)
and a ceramic powder. Machines with 4 color printing capability are available.

3D Systems’ version of the ink-jet based system is called the Thermo-Jet or Multi-Jet
Printer. It uses a linear array of print heads to rapidly produce thermoplastic models (Figure 6d).
If the part is narrow enough, the print head can deposit an entire layer in one pass. Otherwise, the
head makes several passes.

Fig 2.6: 3D Printing

3. The Basic Process of 3D Printing

Although several rapid prototyping techniques exist, all employ the same basic five-step process.
The steps are:

1. Create a CAD model of the design

2. Convert the CAD model to STL format
3. Slice the STL file into thin cross-sectional layers
4. Construct the model one layer atop another
5. Clean and finish the model

CAD Model Creation:

First, the object to be built is modeled using a Computer-Aided Design (CAD) software package.
Solid modelers, such as Pro/ENGINEER, tend to represent 3-D objects more accurately than
wire-frame modelers such as AutoCAD, and will therefore yield better results. The designer can
use a pre-existing CAD file or may wish to create one expressly for prototyping purposes. This
process is identical for all of the RP build techniques.

Conversion to STL Format:

The various CAD packages use a number of different algorithms to represent solid objects. To
establish consistency, the STL (stereolithography, the first RP technique) format has been
adopted as the standard of the rapid prototyping industry. The second step, therefore, is to
convert the CAD file into STL format. This format represents a three-dimensional surface as an
assembly of planar triangles, "like the facets of a cut jewel." 6 The file contains the coordinates of
the vertices and the direction of the outward normal of each triangle. Because STL files use
planar elements, they cannot represent curved surfaces exactly. Increasing the number of
triangles improves the approximation, but at the cost of bigger file size. Large, complicated files
require more time to pre-process and build, so the designer must balance accuracy with
manageability to produce a useful STL file. Since the STL format is universal, this process is
identical for all of the RP build techniques.

Slice the STL File:

In the third step, a pre-processing program prepares the STL file to be built. Several programs
are available, and most allow the user to adjust the size, location and orientation of the model.
Build orientation is important for several reasons. First, properties of rapid prototypes vary from
one coordinate direction to another. For example, prototypes are usually weaker and less
accurate in the z (vertical) direction than in the x-y plane. In addition, part orientation partially
determines the amount of time required to build the model. Placing the shortest dimension in the
z direction reduces the number of layers, thereby shortening build time. The pre-processing
software slices the STL model into a number of layers from 0.01 mm to 0.7 mm thick, depending
on the build technique. The program may also generate an auxiliary structure to support the
model during the build. Supports are useful for delicate features such as overhangs, internal
cavities, and thin-walled sections. Each RP machine manufacturer supplies their own proprietary
pre-processing software.

Fig 3.1:- Slice the STL File

Layer by Layer Construction:

The fourth step is the actual construction of the part. Using one of several techniques (described
in the next section) RP machines build one layer at a time from polymers, paper, or powdered
metal. Most machines are fairly autonomous, needing little human intervention.

Fig 3.2 Layer by Layer Construction

Clean and Finish:

The final step is post-processing. This involves removing the prototype from the machine and
detaching any supports. Some photosensitive materials need to be fully cured before use.
Prototypes may also require minor cleaning and surface treatment. Sanding, sealing, and/or
painting the model will improve its appearance and durability.
3D printing Vs conventional technologies

3DP does not—and will not—replace completely conventional technologies such NC and
high-speed milling, or even hand-made parts. Rather, one should regard 3DP as one more option
in the toolkit for manufacturing parts. Figure depicts a rough comparison between 3DP and
milling regarding the costs and time of manufacturing one part as a function of part
complexity10. It is assumed, evidently, that the part can be manufactured by either technology
such that the material and tolerance requirements are met.

Fig5.1: 3DP vs. conventional machining

Application of 3D printers

The concept of custom manufacturing is exciting to nearly everyone, but it always seems
to be something that will happen in the “future”. Gibson was right and the following list of
applications for 3D printers show the truth in the saying “The future is here. It’s just not evenly
distributed yet.” The following items are all available for purchase or are being used in industry
now. We are still a long way from Replicators like the ones from Star Trek: The Next
Generation, but we probably won’t have to wait till the 24th century either.

1. Art

3D printing allows artists to create objects that would be incredibly difficult, costly, or
time intensive using traditional processes. These sculptures by Bathsheba Grossman are
exquisitely complex and manufactured using a laser sintering process.

2. Action Figures

Blood Elves and band mates can both be brought to life using 3D printers. These two
were created using Zcorp. machines which apply glue ink and powder in fine layers slowly
creating a replica of one of your characters. Figure Prints allows you to create characters from
Warcraft, Rock band and Spore printing services are coming soon. A number of other sites allow
you to pull data from Second Life and your own 3D programs.

3. Jewelry

Jewelry makers were some of the first to use 3D printing in their manufacturing process,
however they do not use metal printers, but rather ones that use wax. In a process called
“investment casting” a piece of jewelry is sculpted or printed out of wax. Plaster is then poured
on either side. Molten metal is poured onto the wax which melts out leaving a metal version of
your wax sculpt in its place in the plaster. This piece is then finished and polished by a jeweler.
Many independent jewelers have been using high tech printers in their businesses and an
innovative company called Paragon Lake has combined this process with web based design tools
to offer an infinite inventory to the masses of jewelry stores.

4. Prototypes

Prototyping in product development is currently the biggest use of 3D printing technology.

These machines allow designers and engineers to test out ideas for dimensional products cheaply
before committing to expensive tooling and manufacturing processes.
5. Models

Sales folks lives get much easier when you can have models like this of your product printed up
for show and tell.

6. Medicine

3D World of Warcraft characters are cool, but these tools have the power to help save lives.
Surgeons are using 3d printers to print body parts for reference before complicated surgeries.
Other 3D printers are used to create bone grafts for patients who have suffered traumatic injuries.
Looking further in the future scientist are working on PRINTING replacement organs. Personal
Fabrication indeed!

7. Crime Scene Reconstruction

3D printing can save lives, bring Orcs to life, and solve crimes. 3D printing/scanning is used in
forensics in real life and as a prop for dramatic effect in this clip from CSI.
Advantages of 3D Printing

The most successful companies have adopted 3D printing as a critical part of the iterative design
process to:

Increase Innovation
• Print prototypes in hours, obtain feedback, refine designs and repeat the cycle until
designs are perfect.

Improve Communication
• Hold a full color, realistic 3D model in your hands to impart infinitely more information
than a computer image.
• Create physical 3D models quickly, easily and affordably for a wide variety of
applications.

Speed Time to Market

• Compress design cycles by 3D printing multiple prototypes on demand, right in your
office.

Reduce Development Costs

• Cut traditional prototyping and tooling costs.
• Identify design errors earlier.
• Reduce travel to production facilities.
Disadvantages of 3D Printing

Although three-dimensional printing has many advantages, it also has a few disadvantages that
come with it:

• Current 3D printing materials for investment casting tend to yield sporadically rough
surfaces.
• Sometimes encourages informal design methods which may cause more problems to fix.
• It may not be suitable for large sized applications.
• The user may have very high expectations about the prototype’s performance and it
might fail in the exact replication of the real product or systems.
• 3-D printers are still expensive.
• Although 3-D printers have the potential of creating many jobs and opportunities, they
might also put certain jobs at risk (for example, you can make your toys at home so toy
stores and toy makers might go out of business).
• 3DP parts have a ribbed and little rough appearance due to layering beads of plastic.
• Could be a slow process for large build volume parts.

The Future of 3D Printing

Firstly lets clarify what is meant by 3D printing, well in a nut shell it is a way of fabricating
objects designed on computer

, for example if you designed a mug using computer aided design

, within a few hours you could have the real thing sitting in front of you.

It is possible to watch your very creations come to life in true Star Trek fashion, before your
very eyes. To go into more detail, currently printers are fairly slow, limited and not tremendously
precise. A home 3D printer will typically set up back about ten thousand pounds, but this is
cheap considering the first commercially available printers cost at least ten times that amount.
3D printers presently are capable of fabricating objects using silicon and certain types of metal,
other substances that have been tested are plaster, play-doh and even chocolate!

A home 3D printer is about the size of a Microwave and connects directly to a desktop
computer running software that controls its operation. It then creates objects layer-by-layer by
squeezing material from a mechanically-controlled syringe. Unfortunately printers are somewhat
limited in the sense they still produce a fairly rough end product and the time scale it takes to
print an object is considerable.

Despite all the technical implications, there are huge possibilities for the future of 3D printing.
All ground breaking technology starts somewhere, for example in the case of the PC, mainframes
had existed for years, but personal computing only took off in the late seventies. A cheap self-
assembly computer called the Altair 8800, launched in 1975, sparked the rapid development of
personal computing. In similar circumstances self assembly 3D printers hope to spark the same
rapid development in rapid prototyping.

There are a number of different 3D printers available on the market today, all with slightly
different advantages, disadvantages, quirks and features. Some interesting projects include an
open source 3D printer which has successfully been used to fabricate better parts to replace
existing parts on the printer itself. The ultimate goal of 3d printers is to perfectly replicate
themselves, allowing much more cost effective manufacturing.

The future for 3D printing seems very promising, it is the fastest growing part of the rapid-
prototyping industry with revenues this year expected to be approximately a billion US dollars.
Many industries are showing huge amounts of interest and are seem great potential in different
applications where they could utilize three dimensional printing. The US army have
experimented using rapid prototyping to create parts for broken tanks, guns and other hardware
in combat situations. Businesses believe a rapid prototyping machine could prove invaluable in
showing factories how to assemble parts remotely, for example in China. Even NASA has
requested a high resolution machine to manufacture crucial parts in space.

In conclusion what is stopping you being part of a truly revolutionary technology, which could
become one of the major breakthroughs of the twenty first century? 3D printing has merely been
science fiction until recently, where it is now most certainly science fact. What can we expect to
see in the not so far away future? Well one ultimate goal is printable organic parts, for example
replacement organs, identical skin grafts and even limbs, to combat victims of illness, disease
and war.