OPTIMIZATION OF ADDITIVE MANUFACTURING

PROCESSES FOCUSED ON 3D PRINTING

B. PRANAY DISHAN
M.Tech. (AMS)
H.T.No.: 16071D3301
Mobile No.: 8885663839
Email ID: pranaydishan11@gmail.com

Under the guidance of,

Dr. G. RAGHU BABU
Professor
Mechanical Engineering
Email ID: raghubabu_g@vnrvjiet.in

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 OUTLINE OF PRESENTATION

 Abstract

 Introduction

 Literature Review

 About the Project

 Conclusion

 References

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 ABSTRACT

3D printing or additive manufacturing technologies is most

widely used for various engineering applications. One of the
most commonly adopted methods in additive manufacturing is
Fused Deposition Modelling . The quality of 3D printed parts
mainly depends on careful selection of process variables. Thus,
identification of the 3D printing process parameters that
significantly affect the quality of parts built is very essential. The
present work aims to review the research carried out so far in
determining and optimizing the process parameters of the 3D
printing technology with respect to FDM process.

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 INTRODUCTION

3D PRINTING

3D printing or Additive Manufacturing (AM) is any of various

processes for making a three-dimensional object of almost any
shape from a CAD model primarily through additive processes
in which successive layers of material are laid down under
computer control.

Main material utilized in the development of 3D objects is

plastic, however, there has additionally been innovation toward
using alternative materials like metals of various sorts and
additionally organic matter and its varied derivatives.
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 HISTORY OF 3D PRINTING

HISTORY OF 3D PRINTING

The earliest 3D printing technologies first became visible in the

1980’s. the very first patent application for RP technology was
filed by a Dr. Kodama, in Japan, in May 1980. Unfortunately
for Dr. Kodama, the full patent specification was subsequently
not filed before the one year deadline after the application.

In real terms, the origins of 3D printing can be traced back to

1986, when the first patent was issued for stereolithography
apparatus (SLA). This patent belonged to Charles (Chuck) Hull,
who first invented his SLA machine in 1983.
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 TYPES OF 3D PRINTING

TYPES OF 3D PRINTING PROCESSES

 Stereo Lithography (SL).

 Fused Deposition Modelling (FDM).

 Selective Laser Sintering (SLS)

 Laminated Object Manufacturing (LOM).

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 STEREOLITHOGRAPHY (SLA)

SLA works by exposing a layer of photosensitive liquid resin to a

UV-laser beam. Laser moves in the desired pattern and material
begins to harden. Then 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.
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 FUSED DEPOSITION MODELLING
(FDM)

Thermoplastic filament is heated and extruded through an

extrusion head that deposits the molten plastic in X and Y
coordinates, while the build table lowers the object layer by
layer in the Z direction
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 SELECTIVE LASER SINTERING (SLS)

SLS is similar to SLA, but the key difference is that this type of
3D printer 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.
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 LAMINATED OBJECT MFG. (LOM)

LOM uses layers of adhesive-coated paper, plastic or metal

laminates, which are fused under heat and pressure and
shaped by cutting with a computer controlled laser or knife.
This is sometimes followed by machining and drilling.
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 LITERATURES

Sidharth Bhandari et al. [1] defined what is meant by 3D

printing and what is so significant about it. The history of 3D
printing is provided at a glance. Brief description on the processes
of 3D printing and the materials used during the manufacture of
3D printed objects.

L Villalpando et al. [2] studied about material usage, build time,

and loading characteristics for a variety of parametric structures.

D. Brackett et al. [3] studied on overview of the issues and

opportunities for the application of topology optimization methods
for additive manufacturing (AM).

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 LITERATURES contd.

A. Panesar et al. [4] performed Topology Optimization (TO) is

combined with an automated placement and routing approach
that enables determination of an efficient internal system
configuration.

David D. Hernandez et al. [5] focused on dimensional

precision of a consumer grade parts using design of
experiments in FDM process.

Suchana A. Jahan et al. [6] studied thermal and mechanical

behavior of cavity and core with conformal cooling channels to
find an optimum design for molding tools.
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 LITERATURES contd.

W. Wang et al [7] used algorithms to decomposes a given

polygon model into parts such that each part can be 3D
printed with high (outer) surface quality.

Filip Gorski et al. [8] identified the relation between model

orientation during manufacturing, dimensional accuracy and
repeatability of obtained products during FDM process.

Michael Montero el at [9] studied process parameters of

FDM, such as raster orientation, air gap, bead width, color,
and model temperature

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 LITERATURES contd.

K. Thrimurthulu et al [10] obtained an optimum part

deposition orientation for fused deposition modeling process
for enhancing part surface finish and reducing build time.

P.M. Pandey et al [11] compared various attempts made to

determine part deposition orientation.

Tejendrasinh S. Raol et al [12] investigated the effect of

process parameters on surface roughness of fused deposition
modeling built parts.

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 LITERATURES contd.

M. SZILVI-NAGY et al [13] found a method to detect defects in

the surface representation and to analyze the shape of the
approximated surface

Textbooks

I. Gibson et al [14]

Alan R. Parkinson et al [15]

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 ABOUT THE PROJECT

The present work focuses on extensive study to gain detailed

knowledge on working principle and the effect of various
important parameters in one of the Additive manufacturing
techniques namely Fused Deposition Modeling (or commonly
known as 3D Printing). The study involves influence of various
parameters on the final built parts when we use FDM process
and challenges faced in 3D printing Technology.

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 3D PRINTING PROCESS

1. CAD

2. Conversion to STL

3. Transfer to AM machine and STL file manipulation

4. Machine setup

5. Build

6. Removal

7. Post processing

8. Application

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 TYPE OF MATERIAL PROCESSED

1. Liquid based : SLA processes

2. Powder based : SLS processes

3. Solid based : FDM processes

4. Paper based : LOM processes

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 PARAMETERS IN 3D PRINTING

1. Build orientation
2. Layer thickness
3. Air gap
4. Raster angle
5. Raster width
6. Contour
7. Perimeter to raster air gap
8. Contour to contour air gap
9. Necking
10. Cusp height
11. Speed of deposition
12. Shrinkage
13. Model Build Temperature

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PARAMETER REPRESENTATION

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 CHALLENGES IN 3D PRINTING

CAD models are mostly developed using designing sotwares such

as ProEngineer, Unigraphics, SolidEdge, CATIA, and SolidWorks.

Geometric complexity – need to support models with tens and

hundreds of thousands of features.

Physically based material representations – material

compositions and distributions must be represented and must be
physically meaningful.

Physically based property representations – desired

distributions of physical and mechanical properties must be
represented and tested for their physical basis.

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 CHALLENGES WITH RESPECT TO
STL FILE

Res: 18674 Res: 4614 Res: 689

File Size: 944KB File Size: 225KB File Size: 34KB

Errors in the triangulation like gaps and multiple facets result in

incorrect cross-sections which cannot be manufactured as
layers. The other problem is the high complexity of such meshes.
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 CONCLUSION AND FUTURE SCOPE

After reviewing the published literatures, it is clear that

optimization of process parameters of 3D printing or additive
manufacturing technology is one of the most critical design
tasks in quality evaluation indicators for obtaining high quality
parts, enhanced material response and enhanced properties.

After the detailed study on 3D printing processes, with respect

to parameters discussed in the present study, it can be
concluded that there is vast scope to optimize these
parameters using different optimization techniques. The
further work is proposed to manipulation of STL file of a part to
optimize additive manufacturing process.
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 REFERENCES

1. Sidharth Bhandari, B Regina, “3D Printing And Its

Applications”, International Journal of Computer Science and
Information Technology Research, Vol. 2, Issue 2, 2014, pp. 378-
380

2. L. Villalpamdo, H. Eiliat, R. J. Urbanic, “ An optimization

approach for components built by fused deposition modelling with
parametric internal structures”, CIRP Conference on Industrial
Product Service System, Vol. 17, 2014, pp. 800-805

3. D. Brackett, I. Ashcroft, R. Hague, “Topology Optimization for

Additive manufacturing”, CIRP Journal of manufacturing science
and technology, Vol. 3, 2011, pp. 348-362

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 REFERENCES contd.

4. A Panesar, D. Brackett, I. Ashcroft, R. Wildman, R. Hague,

“Design Optimization Strategy for Multifunctional 3D Printing”,
Advances in science and technology research journal, Vol. 7, 2013,
pp. 1179-1193

5. David D. Hernandez, “Factors Affecting Dimensional Precision

of
Consumer 3D Printing”, International Journal of Aviation,
Aeronautics, and Aerospace, Vol. 2, Issue 4, 2015, pp. 1-42
6. Suchana A. Jahan, Tong Wu, Yi Zhang, Hazim El-Mounayri,
Andres Tovar, Jing Zhang, Douglas Acheson, Razi Nalim,
Xingye Guo, Weng Hoh Lee, “ Implementation of Conformal
Cooling and Topology Optimization in 3D Printed Stainless Steel
Porous Structure Injection Molds”, Proceedings of North American
Manufacturing, Vol. 5, 2016, pp. 901-915
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 REFERENCES contd.

7. W. Wang, C Zanni, L. Kobbelt, “ Improved Surface Quality in

3D Printing by Optimizing the Printing Direction”.
EUROGRAPHICS, Vol. 35, 2016, pp. 1-12

8. Filip Gorski, Wiesław Kuczko, Radosław Wichniarek,

“Influence Of Process Parameters On Dimensional Accuracy Of
Parts Manufactured Using Fused Deposition Modelling
Technology”, Advances in Science and Technology Research
Journal, Vol. 7, 2013, pp. 27-35

9. Michael Montero, Shad Roundy, Dan Odell, Sung-Hoon Ahn

, Paul K. Wright, “Society of Manufacturing Engineers”, Vol. 11,
2011, pp. 1-22

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 REFERENCES

10. K. Thrimurthulu, Pulak M. Pandey, N. Venkata Reddy,

“Optimum part deposition orientation in fused deposition
modelling”, International Journal of Machine Tools &
Manufacture, Vol. 44, 2004, pp. 585-594
11. P.M. Pandey, N. Venkata Reddy,S.G Dhande, “Part
deposition orientation studies in layered manufacturing”, Journal
of Materials Processing Technology , Vol. 11, 2006, pp. 1-7

12. Tejendrasinh S. Raol, Dr. K. G. Dave, Dharmesh B. Patel,

Viral N. Talati, “An Experimental Investigation of Effect of Process
Parameters on Surface Roughness of Fused Deposition Modeling
Built Parts”, International Journal of Engineering Research &
Technology, Vol. 3, 2014, pp. 2270-2274

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 REFERENCES contd.

13. M. SZILVI-NAGY, GY. MATYLSI, “Analysis of STL Files”,

Mathematical and Computer Modelling, Vol. 38, 2009, pp. 945-
960

TEXTBOOKS

14. I. Gibson, D. W. Rosen, B. Stucker, “Additive Manufacturing

Technologies: Rapid Prototyping to Direct Digital Manufacturing”,
Springer New York Heidelberg Dordrecht London, Vol. 2, 2010, pp.
1-498

15. Alan R. Parkinson, Richard J. Balling, John D. Hedengren,

“Optimization Methods for Engineering Design”, Brigham Young
University, Vol. 1, pp.1-208
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THANK YOU

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