All basic about 3D printing ony overview

1. National institute of Technology
(Hamirpur)
Topic :- 3D Printing
Subject:- Laser Material Processing
Course-code:- MSD-314
Submitted to :- Dr. Raj Bahadur Singh Sir
Submitted by :-
Ashish Kumar(188016)
Muskan Negi(188017)
Anubhav Sharma(188018)
Kartik(188020)
Branch:- Materials Science
& Engineering

2. 3D printing

3. What is 3D Printing?
3D printing, also known as additive manufacturing, is a process
by which physical objects are created by depositing material
layer by layer based on a digital model.
By using 3D Printing it is possible to produce objects of almost
any shape and form.
Curently many different 3D printing technologies and materials
are used. Recently 3D printing tools are available for industrial
manufacturing and for home users as well.
First commercial 3D printer
CAD Model
Prototype from 3D Printing

4. • Arthur C. Clarke, was the first to describe the basic functions
of a 3D printer back in 1964.
• The first 3D printer was released in 1987 by Chuck Hull of 3D
Systems and it was using the "stereolithography" (SLA)
process.
• In the 90's other 3D printing technologies were released,
including FDM by Stratasys and SLS by 3D Systems. These
printers were expensive and mainly used for industrial
prototyping.
• In 2009, the ASTM Committee F42 published a document
containing the standard terminology on Additive
Manufacturing. This established 3D printing as an industrial
manufacturing technology.
A brief history of 3D printing

5. The first 3D printed part

6. Basic Working principle of 3 printer ?

7. 1. Modeling:
• A person creates a 3D image of an item using a computer-aided design (CAD) software program.
• Additive manufacturing takes virtual blueprints from computer design (CAD) or animation modeling software and "slices" them into digital
aided cross-sections for the machine to successively use as a guideline for printing.
2. Printing:
• The CAD information is sent to the printer.
• To perform a print, the machine reads the design and lays down successive layers of liquid, powder, or sheet material to build the model from a
series of cross sections. These layers, which correspond to the virtual cross sections from the CAD model, are joined together or automatically
fused to create the final shape. The primary advantage of this technique is its ability to create almost any shape or geometric feature.
3. finishing:
• The printer forms the item by depositing the material in layers starting from the bottom layer-onto a platform. In some cases light or lasers are
used to harden the material
• To perform a print, the machine reads the design and lays down successive layers of liquid, powder, or sheet material to build the model from
a series of cross sections. These layers, which comespond to the virtual cross sections from the CAD model, are joined together or
automatically fused to create the final shape. The primary advantage of this technique is is ability to create almost any shape or geometric
feature. The model to be manufactured is built up a layer at a time. A layer of powder is automatically deposited in the model tray. The print
head then applies resin in the shape of the model The layer dries solid almost immediately. The model tray then moves down the distance of a
layer and another layer of power is deposited in position, in the model tray. The print head again applies resin in shape of the model, binding it
to first layer.

8. • Stereo lithography
• Selective laser sintering (SLS)
• Fused deposition modeling (FDM)
• Ink-jet 3D Printing
Different methods of 3D Printing

9. Metallic materials – Plain Carbon Steel, Tool Steel, Stainless steel, Aluminium, Copper, Titanium, Bronze, Nickel Alumides
Polymers and Polymeric Composites - ABS, Nylon (Polyamide), Polycarbonate, PP, Epoxies, Glass filled polyamide, Windform,
Polystyrene, Polyester, Polyphenylesulfone
Others - Sand, Ceramics, Elastomers, Tungsten, Wax, Starch, Plaster
Bio Compatible Materials - Polycaprolactone (PCL), polypropylene-tricalcium phosphate, (PP-TCP), PCL-hydroxyapatite (HA),
polyetheretherketone-hydroxyapatite, (PEEK-HA), tetracalcium phosphate (TTCP), beta – tricalcium phosphate (TCP), Polymethyl methacrylate
(PMMA)
Materials Options for 3D Printing

10. Controller Board:-
The controller board, also referred to as the
motherboard or mainboard, is the brain of the
3D printer. It’s the one responsible for the
core operation, directing the motion
components based on commands sent from a
computer and interpreting input from the
sensors. The controller board’s quality has a
major effect on the overall performance of
the 3D printer. A machine made of high-end
parts from top to bottom won’t be able to
print as well as it should if the controller
board is crap.
Parts of a 3D Printer

11. Filament:- The filament is the material
used to print objects on a 3D printer. It’s the
equivalent of the ink used on a regular office
2D printer. It comes in a spool, which is
loaded into the spool holder of the 3D
printer, with the end of the filament inserted
into the extruder. There are different kinds of
filaments, each with their own properties and
pros and cons.
Parts of a 3D Printer

12. Frame:- The frame is the chassis of the
3D printer. It holds the other components
together and is directly responsible for the
stability and durability of the machine. These
days, 3D printer frames are made of either
acrylic or metal, but in the early days of
consumer-level 3D printers, wood is often
the go-to frame material.
3D printers with a metal frame are the most
recommended simply because they are more
stable and more durable.
Parts of a 3D Printer

13. • Motion Components
• Stepper Motors
• Belts
• Threaded rods
• End Stops
• Power Supply Unit (PSU)
• Print Bed
• Print Bed Surface
• Print Head
• Feeder System
• Dual Extrusion
• User Interface and Connectivity
• File Transfer Options
Parts of a 3D Printer

14. 3D Printing application fields

15. 3D printing in the automotive
industry is used to both
prototypes and finished parts.
Many Formula 1 racing
teams have been using 3D
printing for prototyping,
testing and ultimately, creating
custom car parts that are used
in competitive races.
Automotive industry

16. This Michelin concept tire
doesn‘t need air because it is
3D printed and would never
need replacing.
Automotive industry
A structural bracket 3D printed in carbon fibre-reinforced
nylon for a McLaren F1 MCL32 race car

17. One of the most important
applications of 3D printing is
in the medical industry. With
3D printing, surgeons can
produce patientspecific 3D
printed models
of patients' body parts or
organs. They can use these
models to plan and practice
surgeries, potentially saving
lives.
Medical industry
The first 3D printed polymer implant to receive FDA approval

18. Prosthesis

19. GE Aviation and Safran have
developed a method to 3D
print fuel nozzles for jet
engines. The technology
allows engineers to replace
complex assemblies with
a single part that is lighter
than previous designs, saves
weight and boosts a jet
engine’s fuel efficiency by up
to 15%.
Aircraft

20. Elon Musk’s commercial
space company SpaceX used
3D printing to manufacture
the engine chambers for their
Super Draco engine that will
be
installed on the company’s
Dragon spacecraft.
Aerospace
A 3-D printed SuperDraco combustion chamber.

21. • Entertainment
• Art/Design/Sculpture
• Architecture
• Jewelry
• Fashion
• Food
• Education
Other applications

22. Benefits & Limitations of 3D printing

23. Geometric complexity at no extra cost
3D printing allows easy fabrication of complex
shapes, many of which cannot be produced by
any other manufacturing method.
The additive nature of the technology means that
geometric complexity does not come at a higher
price. Parts with complex or organic geometry
optimized for performance cost just as much to
3D print as simpler parts designed for traditional
manufacturing (and sometimes even cheaper
since less material is used).
Benefits of 3D printing

24. Customization of each and every part
Have you ever wondered why we buy our
clothing in standardized sizes? For the
reasons we just mentioned, with traditional
manufacturing, it is simply cheaper to make
and sell identical products to the consumer.
3D printing though allows for easy
customization. Since start-up costs are so
low, one only needs to change the digital 3D
model to create a custom part. The result?
Each and every item can be customized to
meet a user's specific needs without
impacting the manufacturing costs.
Benefits of 3D printing

25. • Very low start-up costs
• Low-cost prototyping with very quick turnaround
• Large range of (speciality) materials:-The most common
3D printing materials used today are plastics. Metal 3D printing finds also an
increasing number of industrial applications.
• The 3D printing pallet also includes speciality materials with properties tailored for
specific applications. 3D printed parts today can have high heat resistance, high
strength or stiffness and even be biocompatible.
• Composites are also common in 3D printing. The materials can be filled with metal,
ceramic, wood or carbon particles, or reinforced with carbon fibers. This results in
parts with unique properties suitable for specific applications.
Benefits of 3D printing

26. Less cost-competitive at higher volumes
3D printing cannot compete with traditional
manufacturing processes when it comes to large
production runs. The lack of a custom tool or mold
means that start-up costs are low, so prototypes and a
small number of identical parts (up to ten) can be
manufactured economically. It also means though
that the unit price decreases only slightly at higher
quantities, so economies of scale cannot kick in.
In most cases, this turning point is at around 100
units, depending on the material, 3D printing process
and part design. After that, other technologies, like
CNC machining and Injection Molding, are more
cost effective.
Limitations of 3D printing

27. Post-processing & support removal
Printed parts are rarely ready to use off the printer.
They usually require one or more post-processing
steps.
For example, support removal is needed in most 3D
printing processes. 3D printers cannot add material
on thin air, so supports are structures that are printed
with the part to add material under an overhang or to
anchor the printed part on the build platform.
When removed, they often leave marks or blemishes
on the surface of the part they came in contact with.
These areas need additional operations (sanding,
smoothing, painting) to achieve a high quallity
surface finish.
Limitations of 3D printing

28. • Limited accuracy & tolerances
• Lower strength & anisotropic material properties:-Generally, 3D printed parts have physical
properties that are not as good as the bulk material: since they are built layer-by-layer, they are weaker and more brittle in one
direction by approximately 10% to 50%.
• Because of this, plastic 3D printed parts are most often used for non-critical functional applications. DMLS & SLM though can
produce metal 3D printed parts with excellent mechanical properties (often better than the bulk material). For this reason, they
have found applications in the most demanding industries, like aerospace.
Limitations of 3D printing