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Revolutionizing the future of manufacturing
with One MACHINE-
3D Printers (using Additive manufacturing)
Mustafa Z Jawadwala
Mechanical Engineering Department
Finolex Academy of Management and Technology-Ratnagiri
Mumbai University
Contact: 9167194815
Email: mc_tita999@yahoo.com
Abstract
3 Dimensional Printing isa newandexciting technique
which has the potential to create anything such as body
organs, chocolates, design prototype, defense
equipments, automotive parts, prosthetic limbs,
aerospace parts, castings, clothes, to even your kitchen
table handle and any stationary item you can think of
and that to in the variety of material to choose from. It
involves the use of FUSED DEPOSITION
MODELLING (FDM) technique forits operation. The
most interesting part of this 3d printing technology is
it can print things right from nanometer scale up to
several feet. This technical paper puts emphasis on
design of such machines (Extruder), various types of
extruding material, and its cutting edge application in
some of the core engineering, medical and defense
fields.
Introduction
A 3D printer is a machine that creates objects from
plastic or other materials using an additive
manufacturing process. Additive manufacturing
produces objects in a succession of layers from the
bottom, up. This is the opposite of traditional
subtractive manufacturing processes,which produce
objects by cutting material away from a block to
create the shape desired.3D printing changes the
calculus of manufacturing by optimizing for batches
of one. 3D printers are being used to economically
create custom, improved and sometimes even
impossible-to-manufacture products right where
they will be used.A single printer can produce a vast
range of products sometimes already assembled. It’s
a factory without a factory floor and it has created a
platform for innovation, enabling manufacturing to
flourish in uncommon areas and spawning a new
generation of do it yourself (DIY) manufacturers.
Figure 17. TheMakerBot Replicator2 comes fully assembled,
unlike its predecessor, andis designedfor high-quality DIY
manufacturing.
Source: MakerBot
The Economist calls 3Dprinting the third Industrial
Revolution, following mechanization in the 19th
century and assembly-line mass productionin the
20th century.
Types of 3d printers
Based on way these printers print:
1)Powder Binder layering
Fig:schematic representation of 3d printing
system

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2) Fused Deposition Modelling (using Extruder)
3) Stereolitography
4)Bioplotter System
Extrusion Techniques(FDM)
The printing process begins in one of two build-
preparation programs, In FDM(Fused Deposition
Modelling) operation, your first step is to import a
design file, pick options, and create slices (layers).
The preprocessing software calculates sections and
“slices” the part design into many layers, ranging
from 0.005 inches (0.127 mm) to 0.013 inches
(0.3302 mm) in height. Using the sectioning data,
the software then generates “tool paths” or building
instructions which will drive the extrusion head.
This step is automatic
Materials which can be used in Extruder
1) Plastics
 PLA
 ABS
 Acrylic
2) Metals
 Stainless Steel
 Sterling Silver
3) Glass
4) Ceramic
5) Resin
6) Sandstone
7) Rubber
8) Human Tissue (To construct Scaffold)
9) Chocolate
10) Food Materials
Application
Fig. This pie chart shows the percentage of3dPrinting
Technology beingusedin different sections of societies
Medical:
The most inspiring use of 3D printing is in the
healthcare industry, where 3D printing has the
potential to save lives or dramatically improve them
Using a patient’s own cultured cells or stem cells,
the Wake Forest Institute for Regenerative Medicine
has developed a 3D printing technique for
engineering tissue and organs. The ultimate goal is
to help solve the shortage of donated organs
available for transplant.
Scientists are working on a variety of projects
including ear, muscle and a long-term effort to print
a human kidney. (See Figure) The printer is

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designed to print organ and tissue structures using
data from medical scans, such as CT or MRI. The
basic idea is to print living cells — and the
biomaterials that hold cells together — into a 3D
shape. This organ or tissue structure would then be
implanted into the body,where it would continue to
develop. In addition, there are a growing number of
applications for 3D printing in surgery.
Figure 12. These 3D–printedstructures — kidney
(top left),ear (topright)andfinger— couldone day help
address the organ shortage andtheneedto repair if not replace
damagedbody parts.
Source: Wake Forest Institute for Regenerative Medicine
For example, the Walter Reed Army Medical
Center has created and successfully implanted over
60 titanium cranial plates Aliphatic polyesters such
as polyglycolic acid (PGA), polylactic acid (PLLA),
their copolymers (e.g. PLGA) and polycaprolactone
(PCL) are the most commonly used polymers for
tissue engineering scaffold applications (Freed and
Vunjak-Novakovic, 1998; Agrawal and Ray, 2001;
Hutmacher 2001).
Perfectly matching a person’s body is key for
prosthetic devices too. 3D printing is ideal for these
highly customized,small production runs (quantities
of one) that demand strong but light-weight
materials. 3D printing would enable those with limb
loss to get exactly what they want for look, feel, size
and weight, all for a fraction of the cost of a
traditionally- made prosthetic.
Defense:
Components used in military equipment must be
strong,durable and,above all, reliable, as failure can
put lives at risk. Consider the mount for camera gun
sights on the M1 Abrams tank and Bradley fighting
vehicles. These high-precision components are
mounted on the external body of the tanks, where
they must survive incredibly harsh shock, vibration
and environmental conditions.EOIR Technology,a
leading defense system design and development
company, was able to manufacture mounts
durable enough for use on the tanks using a 3D
printer. What’s more, by switching to 3D printing
technology,the company reduced the manufacturing
costs from over $100,000 per unit to under
$40,000.26 In the future, it may be possible for the
military to print replacement parts on the battlefield
instead of relying on limited spares or the supply
chain. While this is still some time away, there are
developments that suggest movement in the right
direction. For example, the Trainer Development
Flight (TDF) facility at Sheppard Air Force Base in
Texas is using 3D printing to develop training aids
for the Air Force and other U.S. Department of
Defense branches. Given the highly specialized
nature of the equipment, such as unmanned aerial
vehicles (UAVs), and the low volumes required,
using original parts or even manufacturing replicas
is a lengthy and expensive exercise. However, using
3D printing in combination with traditional
manufacturing techniques has enabled the
government to save over $3.8million from 2004-
2009, not to mention provide improved and timely
training in areas including avionics, weapons
systems,medical readiness and telecommunications
systems. More recently, student interns working on
a U.S. Army research project created and flew a 6.5-
foot-wingspan plane (a UAV) made entirely of 3D–
printed parts to help study the feasibility of using
such planes. A quite different military application of
3D printing is the creation of topographical models
to provide betterintelligence. The U.S. Army Corps
of Engineers used this technique when responding to
Hurricane Katrina.
General Engineering
 MANUFACTURING TOOLS: In your
company’s manufacturing process,is there
a need for jigs, fixtures, gauges, patterns,
molds, and dies? You can make them with
production printers instead of spending the
time and money to machine, fabricate,
mold or cast them. FDM production
printers not only reduce time and cost for
manufacturing tools, they can improve
your production assembly process. Layer-
based production gives you the freedom to
design lightweight, complex, ergonomic
shapes that can make your assembly
process more efficient.

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 FINISHED GOODS: Follow the lead of
visionary entrepreneurs, aerospace
companies, medical device makers, and
limited-production automakers. For runs of
5,000 or less, instead of using the
traditional manufacturing processes of
molding, machining or tooling, consider
using a production printer to make your
parts. Eliminating traditional
manufacturing processes cutstime and cost
while freeing you to make design revisions
whenever necessary. Free from the
constraints of traditional manufacturing
processes, you can also create new
opportunities in custom or extremely low
quantity applications.
Aerospace
Like many industries, aerospace is also depending
on 3D printing to improve the performance of assets,
reducing maintenance requirements, consolidating
components and saving fuel costs with lighter parts.
Boeing, a pioneer in 3D printing, has printed
22,000components that are used in a variety of
aircraft.
Figure 8. This 3D–printedmetal Airbus wingbracket is lighter
andstronger thanthe conventional wingbracket in the
backgroundthat it couldpotentiallyreplace.
Source: EADS
For example, Boeing has used 3D printing to
produce environmental control ducting (ECD) for its
new 787 aircraft. With traditional techniques, the
ECD is created from up to 20 parts due to its
complex internal structure. However, with 3D
printing, Boeing produces the ECD as one piece.
The new component reduces inventory, does not
require assembly and improves inspection and
maintenance times. As the 3D–printed parts weigh
less, the aircraft’s operating weight decreases,
resulting in fuel savings.
Automotive
Figure 11. TheUrbee (“urbanelectric”) boasts the world’s first
3D–printedcar body, an ultra aerodynamic designandhigh
energy efficiency
Source: KOR EcoLogic
Even automotive industries are not far back from
using 3d printing technology. Take, for example, the
Urbee, called as the world’s first printed car. The
two passenger Urbee, created by KOREcoLogic,
dismisses preconceptions about limits to 3D printing
sizes. To be clear, not all parts are 3D–printed — just
the shell of this hybrid prototype car — though
interior components are planned to be 3D printed.
(See Figure) The Urbee, which could be in low-
volume production by 2014, has planted the seed for
mass customization of large-scale car components.
Engineers at BMW have utilised 3D printing to
create ergonomic, lighter versions of their assembly
tools to increase worker productivity. By improving
the design, workers are carrying 2.9 pounds (1.3
kilograms) less and have improved handling and
balance. As BMW engineer Günter Schmid says,
“This may not seem like much, but when a worker
uses the tool hundreds of times in a shift, it makes a
big difference.”
Future Research
Figure 20. TheVienna University ofTechnology’s
3D–printedrace car,approximately 285microns long,
was printedin four minutes, demonstratingthat highspeed
ultra-precise 3D printingis possible, opening
doors for innovationin areas such as medicine.
Source: Vienna University of Technology

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Researchers at the Vienna University of Technology
have created 3D objects only microns in size using a
technique called two-photon lithography.The
researchers’ breakthrough has been to speed the
technique, making it more feasible for industry.
Whereas printing speeds used to be measured in
millimeters per second, they are now measured in
meters per second. The race car in Figure,
approximately 285 microns long (the average human
hair is 40-120 microns in diameter), has 100 layers
that were printed in four minutes. While the
structure is already miniscule, it is expected that
printers will one day produce even smaller objects,
opening new possibilities for innovation in areas
such as medicine.
Fig:Printedribs on theinteriorof the 8mmx 8mmchannels for
heat transfer augmentationthe ribs are approx.. 200microns high
and 500 microns wide.
Source:Technical Paper,Massachusetts institute of Technology
Conclusion
Part/Tool FDM Alternative
method
End of arm
robot
$600
24 hours
$10000
4 weeks
Automated
Turntable
$8800
2 Weeks
$50000
8Weeks
Steel Plates $20
2 Hours
$200
2 Weeks
Figure 4. This table shows the benefits of Fused Deposition
Modeling(FDM) 3D printingcompared totraditional
manufacturingmethods.
Source: Stratasys
Today you can make parts, appliances and tools in a
wide variety of materials right from your home or
workplace. Using a computer, simply create, modify
or download a digital 3D model of an object. Click
“print,” just as you would for a document, and watch
your physical 3D object take shape. No longer the
stuff of science fiction, 3D printing is a new reality.
While this new reality is exciting, it also poses
significant questions for the future of how we
manufacture goods. Factories will not disappear,but
the face of the manufacturing industry will change
as new entrants, new products and new materials
emerge, and mainstay processes like distribution
may no longer be needed. Today’s consumers
clamour for customized products and services and
for speed of delivery. Yet customization and
immediacy — right here, right now — are not
economical with traditional manufacturing
processes,which are optimized for large volumes of
consistent output in a factory far away.
References:
[1] Joe Hiemenz,Stratasys, Inc., (3D PRINTING WITH FDM:
How it Works. )
[2] LeadindEdge Forum, Technology Program.”3D printing
and future of manufacturing.”
[3] Sean O’Shea, GlobalTV16X9,”make Anything You Want.”
[4] Laurie Seagull, CNN Money Tech Correspondent,”CNN-
Explains 3D printing.”
[5] Massachusetts Institute of Technology,“Progress on tooling
by 3D PrintingConformal Cooling,dimensional Control, Surface
finish and Hardness.”
[6]European Cells and Material Vol.5.” MAKING TISSUE
ENGINEERING SCAFFOLDS W ORK. REVIEW ON THE APPLICATION
OF SOLID FREEFORM FABRICATION TECHNOLOGY TO THE
PRODUCTION OF TISSUE ENGINEERING SCAFFOLDS.” ISSN-
14732262, Department of materials,