DESIGN AND MANUFACTURING OF A LEAF SPRING USING

3D PRINTING TECHNOLOGY

A mini project review report

In partial fulfillment of the requirement for the award of degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by
CH. PAVAN KUMAR 16831A0331
D. VIKAS REDDY 16831A0335
G. VENU MADHAV 16831A0352
A.MUKHUL VAMSHI 17835A0304

Under the guidance of

B.SUSHMA
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

GURU NANAK INSTITUTE OF TECHNOLOGY
(Affiliated to Jawaharlal Nehru Technological University)
Ibrahimpatnam, Ranga Reddy District – 501506
Telangana, India
2016-2020
 CERTIFICATE

This is to certify that the mini-project entitled, “DESIGN AND MANUFACTURING OF

A LEAF SPRING BY USING 3D PRINTING TECHNOLOGY” is being submitted by
CH. PAVAN KUMAR, D. VIKAS REDDY, G. VENU MADHAV, A. MUKHUL
VAMSHI bearing the Roll No. 16831A0331, 16831A0335, 16831A0352, 17835A0304
respectively in partial fulfillment for the award of the Degree of Bachelor of Technology
in Mechanical Engineering to the Jawaharlal Nehru Technological University,
Hyderabad is a record of bonafide work carried out by them under my guidance and
supervision.
The results embodied in this mini-project report have not been submitted to any other
University or Institute for the award of any Degree or Diploma.

Internal Guide Head of the Department

B. SUSHMA Dr. B. VIJAYA KUMAR

External Examiner
 DECLARATION
We hereby declare that mini-project entitled “DESIGN AND MANUFACTURING OF
A LEAF SPRING BY USING 3D PRINTING TECHNOLOGY” is the work done by,
CH. PAVAN KUMAR, D.VIKAS REDDY, G. VENUMADHAV, A. MUKHUL
VAMSHI bearing the Roll No. 16831A0331, 16831A0335, 16831A0352, 17835A0304
towards the fulfillment of the requirement for the award of the Degree of Bachelor of
Technology in Mechanical Engineering to Jawaharlal Nehru Technological
University, Hyderabad, is the result of the work carried out under the guidance of
B.Sushma, Assistant professor, Guru Nanak Institute of Technology, Hyderabad.
We further declare that this project report has not been previously submitted before either
in part or full for the award of any degree by any organization or any universities.

CH. PAVAN KUMAR 16831A0331

D. VIKAS REDDY 16831A0335
G. VENU MADHAV 16831A0352
A.MUKHUL VAMSHI 17835A0304
 ACKNOWLEDGEMENT

The Mini-project entitled “DESIGN AND MANUFACTURING OF A LEAF SPRING

BY USING 3D PRINTING TECHNOLOGY” is the sum of total efforts of our batch. It
is our duty to bring forward each and every one who is directly or indirectly in relation
with our project and without whom it would not have gained a structure.
We extend our sincere thanks to B. Sushma, Assistant Professor of Mechanical
Engineering for his valuable guidance and unstinting support which gave us the
confidence required to overcome the obstacles that we faced in the completion of this
project.
We owe our immense thanks to Dr. B. Vijay Kumar, Professor & Head of Department
of Mechanical Engineering, Guru Nanak Institute of Technology for his sustained
interest, constructive criticism and constant encouragement at every stage of this
Endeavour.
We extend our deep sense of gratitude to Dr. S. Sreenatha Reddy, Principal and the
Management of Guru Nanak Institute of Technology for providing us the best amenities
to enable us complete our project in the stipulated time.
Last but not least we are thankful to our parents, friends and other faculty of the
Department of Mechanical Engineering for their constant support for completion of this
project.

CH. PAVAN KUMAR 16831A0331

D. VIKAS REDDY 16831A0335

G. VENU MADHAV 16831A0352

A.MUKHUL VAMSHI 17835A0304

 ABSTRACT

Additive manufacturing, often referred to as 3D printing, has the potential to vastly

accelerate innovation, compress supply chains, minimize materials and energy usage, and
reduce waste.

Originally developed at the Massachusetts Institute of Technology in 1993. 3D printing

technology forms the basis of Corporation’s prototyping process.3DP technology creates
3D physical prototypes by solidifying layers of deposited powder using a liquid binder.
By definition 3DP is an extremely versatile and rapid process accommodating geometry
of varying complexity in hundreds of different applications, and supporting many types of
materials. .By eliminating production steps and using substantially less material,
‘additive’ processes could be able to reduce waste and save more than 50% of energy
compared to today’s ‘subtractive’ manufacturing processes, and reduce material costs by
up to 90%. The use of additive manufacturing can potentially benefit a wide range of
industries including defense , aerospace, automotive, biomedical, consumer products, and
metals manufacturing.

A leaf spring is a simple form of spring, normally used for the suspension in wheeled
cars. Leaf springs are long and narrow plates attached to the body of a trailer that rest
above or under the trailer's axle. For safe and cozy using, to prevent the street shocks
from being transmitted to the car components and to guard the occupants from road
shocks it's miles important to determine the maximum safe strain and deflection. The
objective is to find the stresses and deformation in the leaf spring via making use of static
load on it. one-of-a-kind materials with special mechanical properties are taken into
consideration for the structural static evaluation. consequently within the gift paintings,
leaf spring is designed by means of considering static load on automobile

All leafs has a linear characteristics. There is a linear dependence between force and
deflection this means that the 3D printed springs could be used as machine elements in
different applications
 CONTENTS

CONTENTS Page no

List of Figures vii

1. INTRODUCTION 1

1.1 3D-Printer 2

1.2 Architecture 3

2. ADDITIVE MANUFACTURING 5

2.1 Extrusion Deposition 7

2.2 Granular Material Binding 8

2.3 Photopolymerization 9

2.4 Lamination 10

3. LITERATURE 12

4. PROCEDURE FOR PRINTING 17

4.1 Designing Using CAD 18

4.2 Conversion to STL File Format 23

4.3 Choosing Filaments for 3D-Printing 26

4.4 Printing 3D model 30

5. APPLICATIONS 33

6. ADVANTAGES AND DISADVANTAGES 34

7. CONCLUSION 35

8. FUTURE SCOPE 36

8.1 Rocket Engine 37

8.2 3D Bio-Printing 38

8.3 3D Printing in Space 39

8.4 3D Printing in Defense 40

REFERENCES
 LIST OF FIGURES
Fig no. Title pages

1 Block diagram 3

2 Architecture 3

3 Additive manufacturing 6

4 Extrusion deposition 7

5 Granular deposition 8

6 Photo polymerization 9

7 Laminated object manufacturing 10

8 Procedures for 3-D printing 17

9 Catia (sketch 1) 19

10 Catia (extrude command 1) 19

11 Catia (sketch 2) 20

12 Catia (extrude command 2) 20

13 Catia (sketch 3) 20

14 Catia (sketch 4) 21

15 Catia (sketch 5) 21

16 Catia (sketch 6) 21

17 Catia (material selection) 22

18 LEAF SPRING 3-D model 22

19 Catia (file menu) 24

20 Catia (save as) 24

21 Saving part file 25

22 Selecting STL format 25

23 Saving .STL file 25

24 PLA filaments 26

25 ABS filament product 26

26 PETG printed product 27

27 Nylon printed product 27

28 Flexible filament product 28

29 Iron man suit by polycarbonate 28

30 Comparison of filaments Scaling LEAF SPRING in cura 29

31 Loading LEAF SPRING in cura 30

32 Scaling LEAF SPRING in cura 30

33 3-D printer 31

34 printing LEAF SPRING 32

35 3-D printed rocket engine 37

36 Bio-printing (heart) 38

37 Bio-printing (human skull) 38

38 3-D printer in space 39

39 3-D Tools used in Defense 40
 1. INTRODUCTION

3D printing or Additive manufacturing is any of various processes for making a three-

dimensional object of almost any shape from a 3D model or other electronic data source
primarily through additive processes in which successive layers of material are laid down
under computer control. A 3D printer is a type of industrial robot.[1]

Early AM equipment and materials were developed in the 1980s. In 1984, Chuck Hull of
3D Systems Corp, invented a process known as stereo lithography employing UV lasers
to cure photopolymers. Hull also developed the STL file format widely accepted by 3D
printing software, as well as the digital slicing and infill strategies common to many
processes today. Also, during the 1980s, the metal sintering forms of AM were being
developed (such as selective laser sintering and direct metal laser sintering), although they
were not yet called 3D printing or A Matthe time. In 1990,the plastic extrusion
technology most widely associated with the term “3D printing” was commercialized by
Stratasys under the name fused deposition modelling (FDM). In 1995, Z Corporation
commercialized an MIT-developed additive process under the trademark 3D printing
(3DP), referring at that time to a proprietary process inkjet deposition of liquid binder on
powder.[2]

AM technologies found applications starting in the 1980s in product development, data

visualization, rapid prototyping, and specialized manufacturing. Their expansion into
production (job production, mass production, and distributed manufacturing) has been
under development in the decades since. Industrial production roles within the
metalworking industries achieved significant scale for the first time in the early 2010s.
Since the start of the 21st century there has been a large growth in the sales of AM
machines, and their price has dropped substantially. According to Wohlers Associates, a
consultancy, the market for 3D printers and services was worth $2.2 billion worldwide in
2012, up 29% from 2011. Applications are many, including architecture, construction
(AEC), industrial design, automotive, aerospace, military, engineering, dental and
medical industries, biotech (human tissue replacement), fashion, footwear, jewellery,
eyewear, education, geographic information systems, food, and many other fields.[3]

1
1.1 3D-PRINTER

3D-Printer is a machine reminiscent of the Star Trek Replicator [4],something magical

that can create objects out of thin air. It can “print” in plastic, metal, nylon, and over a
hundred other materials. It can be used for making non sensical little models like the
over-printed Yoda, yet it can also print manufacturing prototypes, end user products,
quasi-legal guns, aircraft engine parts and even human organs using a person’s own cells.

We live in an age that is witness to what many are calling the Third Industrial
Revolution[5]. 3D printing, more professionally called additive manufacturing, moves us
away from the Henry Ford era mass production line, and will bring us to a new reality of
customizable, one-off production.

3D printers use a variety of very different types of additive manufacturing technologies,

but they all share one core thing in common: they create a three-dimensional object by
building it layer by successive layer, until the entire object is complete. It’s much like
printing in two dimensions on a sheet of paper ,but with an added third dimension : UP
The Z-axis.

Each of these printed layers is a thinly-sliced, horizontal cross-section of the eventual

object. Imagine a multi-layer cake, with the baker laying down each layer one at a time
until the entire cake is formed .3D printing is somewhat similar , but just a bit more
precise than 3D baking.

In the 2D world, a sheet of printed paper output from a printer was “designed” on the
computer in a program such as Microsoft Word. The file - the Word document which
contains the instructions that tell the printer what to do.

In the 3D world, a 3D printer also needs to have instructions for what to print. It needs a
file as well. The file, a Computer Aided Design (CAD) file is created with the use of a 3D
modelling program, either from scratch or beginning with a 3D model created by a 3D
scanner. Either way, the program creates a file that is sent to the 3D printer. Along the
way, software slices the design into hundreds, or more likely thousands, of horizontal
layers. These layers will be printed one atop the other until the 3D object is done.

2
1.2 ARCHITECTURE

Fig. 1 Block Diagram

Fig. 2 Architecture

The picture shows the structure of a typical 3D printer. The printable is the platform
where the object for printing has been situated. It provides the basic support for
manufacturing objects layer by layer.

3
The extruder is the most important part of a 3D-Printer. As the extruders in the normal
paper printers, this extruder is also used to pour ink for printing. The movements of
extruder in various dimensions create the 3D print. For printing a 3d object, the extruder
has to access X, Y and Z coordinates. For achieving this, many techniques are used
according to the printer specification required for various applications.

If the 3D-Printer is a desktop printer, the Z axis movement of the extruder can be avoided
and that function can be transferred to the print table. This will avoid complexity in 3D
printing as well as time consumption.

When the STL file is input to the printer, the micro controller extracts each layer from it
and also extracts each line segment from each layer. Then it gives controls to the
movement of the extruder at required rate. The X-direction movement of extruder is made
possible by the X-motor. When the X motor rotates, the shaft also rotates and the extruder
moves in X direction. The Y-direction movement of extruder is made possible by the Y-
motor. When the Y motor rotates, the shaft also rotates and the extruder moves in Y
direction. The X direction movement is made by the printable.

In the case of desktop printers, the printing ink is usually plastic wire that has been melted
by the extruder at the time of printing. While printing, the plastic wire will melt and when
it falls down to the printing table.

Consider printing larger objects like house using 3D printer. There will not be any X
motor or Y motor in that case. An extruder which can pour concrete mix is fixed on the
tip of a crane. The crane is programmed for the movement of extruder in X, Y and Z axis.
The concept and structure of 3d printer changes according to the type, size, accuracy and
material of the object that has to be printed.

Generalizing the facts, the extruder needs to access all the 3 coordinates in space to print
and object. The method used for that doesn’t matters much.

4
 2. ADDITIVE MANUFACTURING

Additive manufacturing is a truly disruptive technology exploding on the manufacturing

scene as leading companies are transitioning from “analogue” to “digital”
manufacturing[6]. Additive manufacturing uses three-dimensional printing to transform
engineering design files into fully functional and durable objects created from sand, metal
and glass. The technology creates products layer by layer – after a layer’s particles are
bound by heat or chemicals the next layer is added and the binding process is repeated. It
enables geometries not previously possible to be manufactured. Full-form parts are made
directly from computer-aided design (CAD) data for a variety of industrial, commercial
and art applications.

Manufacturers across several industries are using this digital manufacturing process to
produce a range of products, including: engine components for automotive applications,
impellers and blades for aerospace use, pattern less sand molds for pumps used in the oil
and energy industry, and medical prosthetics which require easily adaptable design
modifications.

This advanced manufacturing process starts with a CAD file that conveys information
about how the finished product is supposed to look. The CAD file is then sent to a
specialized printer where the product is created by the repeated laying of finely powdered
material (including sand, metal and glass) and binder to gradually build the finished
product. Since it works in a similar fashion to an office printer laying ink on paper, this
process is often referred to as 3D printing. The 3D printers can create a vast range of
products including parts for use in airplanes and automobiles, to replacing aging or
broken industrial equipment, or for precise components for medical needs.

There are tremendous cost advantages to using additive manufacturing. There is little to
no was to creating objects through additive manufacturing, as they are precisely built by
adding material layer by layer. In traditional manufacturing, objects are created in a
subtractive manner as metals are trimmed and shaped to fit together properly. This
process creates substantial was to that can be harmful to the environment. Additive
manufacturing is a very energy efficient and environmentally friendly manufacturing
option.

5
Additive manufacturing swiftly creates product prototypes – an increasingly critical
function that significantly reduces the traditional trial-and-error process – so new products
can enter the market more quickly. Likewise, it can promptly create unique or specialized
metal products that can replace worn or broken industrial parts .That means companies
can avoid costly shutdowns and drastically compress the time it takes to machine are
placement part. With additive manufacturing, once a CAD drawing is created the
replacement part can be printed. Storage of bulky patterns and tooling is virtually
eliminated.

Major global companies, including Ford, Sikorsky and Caterpillar, have recognized that
additive manufacturing can significantly reduce costs while offering design freedoms not
previously possible. They have begun to implement the technology into their
manufacturing processes. Additive manufacturing has robust market capabilities ranging
from aerospace to automotive to energy, and it is not uncommon to find 3D printers in use
at metal-working factories and in foundries alongside milling machines presses and
plastic injection moulding equipment.

Companies that use additive manufacturing reduce costs, lower the risk of trial and error,
and create opportunities for design innovation. A serious limitation of subtractive
manufacturing [7] is that part designs are often severely comprised to accommodate the
constraints of the subtractive process. Additive manufacturing enables both the design
and the materialization of objects by eliminating traditional manufacturing constraints.

Fig. 3 Additive Manufacturing

6
A large number of additive processes are now available. They differ in the way layers are
deposited to create parts and in the materials that can be used. Some methods melt or
soften material to produce the layers, e.g. selective laser melting (SLM) or direct metal
laser sintering (DMLS), selective laser sintering (SLS), fused deposition modelling
(FDM), while others cure liquid materials using different sophisticated technologies, e.g.
stereolithography (SLA). With laminated object manufacturing (LOM), thin layers are cut
to shape and joined together (e.g. paper, polymer and metal). Each method has its own
advantages and drawbacks, and some companies consequently offer a choice between
powder and polymer for the material from which the object is built. Some companies use
standard, off-the-shelf business paper as the build material to produce a durable
prototype.

2.1 Extrusion deposition:

Fig. 4 Extrusion Deposition

In extrusion deposition, Fused Deposition technique is used. Fused Deposition Modelling

(FDM)[8]was developed by Stratasys in Eden Prairie, Minnesota. In this process ,a plastic
or wax material is extruded through a nozzle that traces the parts across sectional
geometry layer by layer. The build material is usually supplied in filament form, but some
setups utilize plastic pellets fed from a hopper instead. The nozzle contains resistive
heaters that keep the plastic at a temperature just above its melting point so that it flows
easily through the nozzle and forms the layer. The plastic hardens immediately after
flowing from the nozzle and bonds to the layer below. Once a layer is built, the platform
7
lowers, and the extrusion nozzle deposits another layer. The layer thickness and vertical
dimensional accuracy is determined by the extruder die diameter, which ranges from 0.013
to 0.005 inches. In the X-Y plane, 0.001-inch resolution is achievable. A range of materials
are available including ABS, polyamide, polycarbonate, polyethylene, polypropylene, and
investment casting wax.

2.2 Granular Material Binding:

Fig. 5 Granular Deposition

Another 3D printing approach is the selective fusing of materials in a granular bed. The
technique fuses parts of the layer, and then moves the working area downwards, adding
another layer of granules and repeating the process until the piece has built-up. This
process uses the unfused media to support overhangs and thin walls in the part being
produced, which reduces the need for temporary auxiliary supports for the piece. A laser
is typically used to sinter the media into a solid. Examples includes elective laser
sintering(SLS),with both metal sand polymers (e.g. PA,PA-GF, Rigid GF, PEEK, PS,
Alumide, Carbonamide, elastomers), and direct metal laser sintering (DMLS)[9].
Selective Laser Melting (SLM) does not use sintering for the fusion of powder granules
but will completely melt the powder using a high-energy laser to create fully dense
materials in a layer wise method with similar mechanical properties to conventional
manufactured metals. Electron (EBM) is a similar type of additive manufacturing
technology for metal parts (e.g. titanium alloys). EBM manufactures parts by melting
metal powder layer by layer with an electron beam in solid model.

8
a high vacuum. Unlike metal sintering techniques that operate below melting point, EBM
parts are fully dense, void-free, and very strong. Another method consists of an inkjet 3D
printing system. The printer creates the model one layer at a time by spreading a layer of
powder (plaster, or resins) and printing a binder in the cross-section of the part using an
inkjet-like process. The strength of bonded powder prints can be enhanced with wax or
thermoset polymer impregnation.

2.3 Photopolymerization:

Fig. 6 Photopolymerization

Stereolithography was patented in 1986 by Chuck Hull. Photo polymerization [10] is

primarily
used in stereolithography (SLA)[11] to produce a solid part from a liquid. This process
dramatically redefined previous efforts, from the "photo sculpture" method of François
Willene (1830–1905) in 1860 (which consisted of photographing a subject from a variety of
angles (but all at the same distance from the subject) and then projecting each photograph
onto a screen, hence a pantograph was used to trace the outline onto modelling clay)
through the photopolymerization of Mitsubishi's Matsubara in1974.
In photo polymerization, a vat of liquid polymer is exposed to control lighting under safe
light conditions. The exposed liquid polymer hardens. The build plate then moves down in
small increments and the liquid polymer is again exposed to light. The process repeats until
the model has been built. The liquid polymer is then drained from the vat, leaving the

9
The Envision TEC Perfactory is an example of a DLP rapid prototyping system.

Ink jet printer systems like the Object PolyJet system spray photopolymer materials onto
a build tray in ultra- thin layers (between 16 and 30 μm) until the part is completed. Each
photopolymer layer is cured with UV light after it is jetted, producing fully cured models
that can be handled and used immediately, without post-curing. The gel-like support
material, which is designed to support complicated geometries, is removed by hand and
water jetting. It is also suitable for elastomers.

Ultra-small features can be made with the 3D micro fabrication technique used in multi
photon photo polymerization. This approach traces the desired 3D object in a block of
gel using a focused laser. Due to the nonlinear nature of photo excitation, the gel is
cured to a solid only in the places where the laser was focused and the remaining gel is
then washed away. Feature sizes of under 100 nm are easily produced, as well as
complex structures with moving and inter locked parts.

2.4 Lamination:

Fig. 7 Laminated object Manufacturing

Laminated Object Manufacturing [12] works by layering sheets of material on top of one-
another, binding them together using glue. The printer slices an outline of the object into
that cross section to be removed from the surrounding excess material later. Repeating

10
this process builds up the object one layer at a time. Objects printed using LOM are
accurate, strong and durable and generally shown distortion overtime which makes them
suitable for all stages of the design cycle. They can even be additionally modified by
machining or drilling after printing. Typical layer resolution for this process is defined by
the material feedstock and usually ranges in thickness from one to a few sheets of copy
paper. Mcor’s version of the technology makes LOM one of the few 3D printing
processes that can produce prints in full color.

Low cost due to readily available raw material

Paper models have wood like characteristics, and may be worked and finished
accordingly
Dimensional accuracy is slightly less than that of stereolithography and selective laser
sintering but no milling step is necessary.

11
 3. LITERATURE REVIEW

Literature Review of 3-D Printing:

Brogan Rylands and et.al in his paper “3D Printing - To print or not to print? Aspects to
consider before adoption - A supply chain perspective” has concluded that There is much
complexity around 3D printing, which brings about the need to essentially re-engineer
value streams. It is a collaborative attempt across the whole organization and there are
many aspects to be considered, stemming not only from a business and technical
perspective but also social and environmental aspects that require consideration.
This paper provided an overview of what 3D printing is, examples of industries that it is
currently deployed in, how it can influence supply chains and aspects for consideration
before adoption. It highlighted the need for increased awareness and collaboration in the
area and future challenges and opportunities.
However, how does a company prepare for such a change? How does it educate itself?
How can the fire for 3D printing be sparked in industry? When is the right time to adopt
3D printing? What additional aspects are managers currently considering when facing the
3D adoption challenge? Are all aspects of equally important or can even some aspects be
disregarded? How has 3D printing impacted on manufacturing and the wider supply chain
today? How will 3D printing impact manufacturing and the wider supply chain in future?
How well is Australia positioned when compared to their international counterparts in
regards to 3D printing? How does 3D supply chain costing compare with traditional
manufacturing supply chain costing? How mature does your supply chain need to be in
order to deploy 3D technology meaningfully and harvest its benefits?
It is expected that this research will contribute to academia/ theory and practice. A
conceptual model or framework incorporating major aspects to be considered for
businesses before pursuing 3D printing has been developed that will need to be verified
through case study/ field research in industry. It is further expected that businesses will
benefit from the model through informed and improved decision making prior to
deploying such cutting edge technology on their production line.[13]
Alexandru Pirjan Dana-Mihaela Petroşanu in his journal “The impact of 3D Printing
technology on the society and economy” concluded that, we have presented and analyzed
the impact of 3D printing technology on the society and economy. After presenting, in the
introduction, a brief history of 3D printing, in the second section we have

12
depicted the additive technology and the materials used in rapid prototyping. In the third
section, we have highlighted the main advantages and limitations of the 3D printing
technology, while in the fourth section we have made a survey of the most significant
existing 3D printing solutions. We have compared these 3D printing solutions, taking into
account their technical specifications and prices. One can conclude that the 3-D printing
technology’s importance and social impact increase gradually day after day and
significantly influence the human’s life, the economy and modern society.[14]

Vinod G. Gokhare and et.al in his paper titled “A Review paper on 3D-Printing Aspects
and Various Processes Used in the 3D-Printing” conclude that Introduction part is about
the brief history of 3D printing, in the next section we have depicted the 3D-printing and
the processes used in 3D-printing and the properties of the 3Dprinter materials.In the third
section, we have highlighted the main advantages and limitations of the 3D printing
technology. One can conclude that the 3-D printing technology's importance and social
impact increase gradually day by day and influence the human's life, the economy, and
modern society. 3D Printing technology could revolutionize the world. Advances in 3D
printing technology can significantly change and improve the way we manufacture
products and produce goods worldwide. An object is scanned or designed with Computer
Aided Design software, then sliced up into thin layers, which can then be printed out to
form a solid three-dimensional product. As shown, 3D printing can have an application in
almost all of the categories of human needs as described by Maslow. While it may not fill
an empty unloved heart, it will provide companies and individuals fast and easy
manufacturing in any size or scale limited only by their imagination. 3D printing, on the
other hand, can enable fast, reliable, and repeatable means of producing tailor-made
products which can still be made inexpensively due to automation of processes and
distribution of manufacturing needs.[15]

Thabiso Peter Mpofu and et.al from his journal paper titled “The Impact and
Application of 3D Printing Technology” concluded that The 3D printing industry is set on
a growth trajectory as evidenced by the growth forecasts. The applications of 3D printing
are increasing as more and more research is carried out.3D printing will change the way
people acquire products as evidenced by the Amazon proposed model. The field is
definitely a game changer with lots of prospects to look out for. [16]

13
Baljinder Singh Shahi in his paper titled “Advanced Manufacturing Techniques(3D
Printing)” concluded that Additive manufacturing, starting with today's infancy period,
requires manufacturing firms to be flexible, ever-improving users of all available
technologies to remain competitive. Advocates of additive manufacturing also predict that
this arc of technological development will counter globalization; a sensduser will do
much of their own manufacturing rather than engage in trade to buy products from other
people and corporations. The real integration of the new additive technologies into
commercial production, however, is more a matter of complementing traditional
subtractive methods rather than displacing them entirely.[17]

Literature Review:
K.Srinivasa Rao and et.al in his paper “Design and Analysis of LEAF SPRINGs”
concluded that from the analysis we came to know that all three designs are safe and are
within the standard limits. Among the three designs simple rim design is more promising
than centrifugal rim followed by pentagonal rim. Among the three-materials steel alloy is
the best material followed by aluminium and magnesium. Magnesium occupies last
position as it has more deformation for the same loading condition. From this result we
can then why magnesium alloy material is only used for pretty shorter period restricted to
racing cars only. From the fatigue analysis aluminium alloy has got more life than that of
the steel alloy. Even though the safety factor is almost equal for both the materials
aluminium is subjected to less damage compared to steel (for same loading conditions).
From the above results we define a new material (Al-Mg alloy) which is more promising
than other two i.e. these has got less deformations like Aluminium and more lifelike
Magnesium. Under the influence of radial load, the rim tends to vocalize about the point
of contact with maximum displacement occurring at the location of bead seat. The inside
bead seat reveals the greatest deflection and is concurrently prone to loss of air pressure
due to dislodgement of the tyre on the rim. Actually, failure of LEAF SPRING occurs
mostly at the areas where there is max stress values occur (predicted by analysis
software). More deformed areas are also in agreement with theoretical values. [18]

M. Suguna in her paper titled “Comparative Analysis of Automotive Wheel Rim by

using different materials” concluded that the modelling is done by using CATIA and the
file into ANSYS for software analysis. The results are tabulated by comparing in the
above table. Hereby we came to know that Mg alloy having less stress compared other
two materials. The wheel design with Mg alloy material is optimized in order to with
14
stand the existing load of the vehicle with factor of safety with least quantity of
manufacturing cost and losses. In this the life expectancy will increase and we are having
the flexibility and efficiency to resist the impact forces. When weight of the rim reduced
the overall efficiency will be increased.[19]
.
Nandigam Dayakara Rao and B. Kishore Kumar from his journal titled “Design and
Analysis of LEAF SPRING” concluded that Brief study about LEAF SPRING its
construction, type, materials is done in this project. By using 3D modelling software
CATIA V5 LEAF SPRING is modeled. Catia Model of alloy wheel is saved as IGES
(neutral) file and transferred to ANSYS workbench 14.5 software. Static structural
analysis is performed of alloy wheel by applying the pressure load of 1.5 MPA. Static
structural analysis is performed on five different materials on same boundary condition.
Analysis result is noted and tabulated. According to result table magnesium alloy showing
least stress value compare to other four materials. Meanwhile magnesium alloy is also
least dense material, i.e. its weight ratio is lowest than other four materials. So we can
conclude that magnesium alloy is best material for LEAF SPRING compare to other four
materials, because of its least weight and least stress value on load conditions. Design and
analysis on LEAF SPRING is done.[20]

Jitendra Shinde and et.al in his paper titled” Review Paper on Design and Analysis of
Automotive Wheel Rim Using Finite Element Analysis” concluded that it is necessary to
carry out experimental and finite element analysis of wheel rim to avoid the failure of the
rim by improving the geometry and material optimization with the help of design of
experiment. Results are to be validate by radial load test on wheel rim to check its fatigue
life.[21]

Rahul K. Jape and S. G. Jadhav in their paper entitled “CAD Modeling and FEA
Analysis of Wheel Rim for Weight Reduction” concluded that load acting on the LEAF
SPRING rim is calculated as per Japanese industrial standard given by the company. The
modelling is done as per drawings given by the company and made changes to reduce the
weight. Finite element analysis is performed on both wheel rim i.e. base wheel rim and
optimized wheel rim the stresses and fatigue life of the wheel is calculated which is
satisfying company criteria. The weight of the wheel is reduced from 7.7 Kg to 7.5 Kg by
using this finite element analysis approach of weight optimization. On trying on these two
cases with varying dimensions, one model is finally reached at with a total of 3%(200gm)
mass reduction without compromising its performance. The wheel International Journal
15
of Engineering Science and Computing, June 2016 7411 http://ijesc.org/ on subjection to
Cornering Fatigue Test and radial fatigue test is observed to pass through all the
requirements. There is a mass reduction of 200gm per wheel is achieved which mounts to
1kg per car considering the spare wheel. This mass reduction results in two benefits.
Decrease in total weight of the car and decrease in cost of production. Optimization
techniques help largely in reducing the mass of solid components which results in overall
body weight reduction and thus lesser cost. Lesser weight in turn gives better performance
and better fuel efficiency. These result in many indirect benefits to mankind which
includes conservation of natural resources to some extent, reduction in air pollution
etc.[22]

16
 4. PROCEDURE FOR 3D PRINTING

Fig. 8 Procedures for 3-D printing

There are some procedures for printing. First you must create a computer model for
printing the object. For creating that, you can use Computer Aided Design Software like
AutoCAD, 3DS Max etc. After the object file is created, the file needs to be modified.
The object file contains numerous amounts of curves. Curves cannot be printed by the
printer directly. The curves have to be converted to STL (Stereo lithography) file format.
The STL file format conversion removes all the curves and it is replaced with linear
shapes. Then the file needs to be sliced into layer by layer. The layer thickness is so
chosen to meet the resolution of the 3D printer we are using. If you are unable to draw
objects in CAD software, there are many websites available which are hosted by the 3D
printing companies to ease the creation of 3D object. The sliced file is processed and
generates the special coordinates. These coordinates can be processed by a controller to
generate required signal to the motor for driving extruder. This layer by layer process
generate a complete object.

17
4.1 Design Using CAD:
Computer-aided design (CAD) is the use of computer systems to assist in the creation,
modification, analysis, or optimization of a design. CAD software is used to increase the
productivity of the designer, improve the quality of design, improve communications
through documentation, and to create a data base for manufacturing. CAD output is often
in the form of electronic files for print, machining, or other manufacturing operations.

CAD software for mechanical design uses either vector-based graphics to depict the
objects of traditional drafting, or may also producer aster graphics showing the overall
appearance of designed objects. However, it involves more than just shapes. As in the
manual drafting of technical and engineering drawings, the output of CAD must convey
information, such as materials, processes, dimensions, and tolerances, according to
application- specific conventions.

CAD may be used to design curves and figures in two-dimensional (2D) space; or curves,
surfaces, and solids in three-dimensional (3D) space. CAD is an important industrial art
extensively used in many applications, including automotive, shipbuilding, and aerospace
industries, industrial and architectural design, prosthetics, and many more. CAD is also
widely used to produce computer animation for special effects in movies, advertising and
technical manuals, often called DCC digital content creation. The modern ubiquity and
power of computers means that even perfume bottles and shampoo dispensers are
designed using techniques unheard of by engineers of the 1960s. Because of its enormous
economic importance, CAD has been a major driving force for research in computational
geometry, computer graphics (both hardware and software), and discrete differential
geometry.

The design of geometric models for object shapes, in particular, is occasionally called
computer-aided geometric design (CAGD). Unexpected capabilities of these associative
relationships have led to a new form of prototyping called digital prototyping. In contrast
to physical prototypes, which entail manufacturing time in the design. That said, CAD
models can be generated by a computer after the physical prototype has been scanned
using an industrial CT scanning machine. Depending on the nature of the business, digital
or physical prototypes can be initially chosen according to specific needs.

18
 Today, CAD systems exist for all the major platforms (Windows, Linux, UNIX and Mac
OS X); some packages even support multiple platforms which enhances the capabilities
of 3D printing into a new level.

The LEAF SPRING that is to be printed in this project is designed in one of the popular
CAD software, CATIA.
The LEAF SPRING is designed in Catia in the following way:

 In Catia, part modelling is to be selected first. Then, by selecting one of the three
planes, the following 2-d sketch is drawn using appropriate measurements.

Fig. 9 Catia (sketch 1)

 Extrude the 2d figure for 12.5mm 

Fig. 10 Catia (extrude command 1)

.

19
 Using sketcher,draw the second leaf with respect to the first one

Fig. 11 Catia (sketch 2)

 Using extrude command, extrude the second leaf up to the first one 

Fig. 12 Catia (extrude command 2)

Fig. 13 Catia (sketch 3)

20
 

Fig. 14 Catia (sketch 4)



Fig. 15 Catia(sketch 5)

Fig. 16 Catia (sketch 6)

21
 Fig. 17 Catia material selection

The LEAF SPRING that is to be 3-d printed is designed and saved in the computer and it
has to be modified further to print it in a 3-d printer

Fig. 18 LEAF SPRING 3-D model

22
4.2 Conversion to STL File Format:

An STL file is a triangular representation of a 3D surface geometry. The surface is

tessellated logically into a set of oriented triangles (facets). Each facet is described by the
unit outward normal and three points listed in counter clockwise order representing the
vertices of the triangle. While the aspect ratio and orientation of individual facets is
governed by the surface curvature, the size of the facets is driven by the tolerance
controlling the quality of the surface representation in terms of the distance of the facets
from the surface. The choice of the tolerance is strongly dependent on the target
application of the produced STL file. In industrial processing, where stereolithography
machines perform a computer-controlled layer by layer laser curing of a photo-sensitive
resin, the tolerance may be in order of 0.1 mm to make the produced 3D part precise with
highly worked out details. However much larger values are typically used in pre-
production STL prototypes, for example for visualization purposes.

The native STL format has to fulfil the following specifications:

(i) The normal and each vertex of every facet are specified by three coordinates
each, so there is a total of 12 numbers stored for each facet.
(ii) Each facet is part of the boundary between the interior and the exterior of the
object. The orientation of the facets(which way is ``out’’ and which way is
``in’’) is specified in two ways which must be consistent. First, the direction
of the normal is outward. Second, the vertices are listed in counter clockwise
order when looking at the object from the outside (right-hand rule).
(iii) Each triangle must share two vertices with each of its adjacent triangles. This
is known as vertex-to-vertex rule.
(iv) The object represented must be located in the all-positive octant (all vertex
coordinates must be positive).

However, for non-native STL applications, the STL format can be generalized. The
normal, if not specified (three zeroes might be used instead), can be easily computed
from the coordinates of the vertices using the right-hand rule. Moreover, the vertices
can be located in any octant. And finally, the facet can even be on the interface
between two objects ( or two parts of the same object).This makes the generalized
STL format suitable for modelling of 3D non-manifold objects
23
The object (LEAF SPRING, in this case) can be converted to STL format file by the following
procedure:
o Open the previously saved design file in the CAD software (CATIA, in this
case) and find ‘File’ on the menu

Fig. 19 Catia (file menu)

o Click on the ‘File’ menu and select ‘Save as’ as shown in the figure below.

Fig. 20 Catia (save as)

24
 o After selecting ‘Save as’, the following window appears.

Fig. 21 Saving part file

o Now select ‘. Stl’ from the list of options to save the file.

Fig. 22 Selecting STL format

o Save the file in the respective folder.

Fig. 23 Saving .stl file

The 3d printer should be connected to the pc or laptop, on which you have been working
and the software like CURA from Ultimaker or Ideamaker has to be pre-installed on the
computer.

25
4.3 Choosing Filaments for 3D-Printing:

Filaments are chosen according to the need and kind of object that has to be printed.
Different types of filaments are available according to the size, type, resolution and
function of the object.

PLA: PLA stands for Polylactic Acid. PLA has a lower printing temperature than ABS,
and it doesn’t warps easily, meaning it doesn’t require a heating bed (although it
definitely helps).Another benefit to using PLA is that it doesn’t give off a bad smell
during printing. Finally, as a biodegradable thermoplastic, PLA is more environmentally
friendly than most types of 3D printer filament, being made from annually renewable
resources such as corn starch or sugarcane.

Fig. 24 PLA filaments

ABS: ABS stands for Acrylonitrile Buta-diene Styrene. Products made of ABS boast high
durability and a capacity to withstand high temperatures, but 3D printer enthusiasts
should be mindful of the filament’s high printing temperature, tendency to warp during
cooling, and intense fumes. ABS is tough – able to withstand high stress and
temperature. It’s also moderately flexible. Together these properties make ABS a good
general-purpose 3D printer filament, but where it really shines is with items that are
frequently handled, dropped, or heated.

Fig. 25 ABS filament product

26
PETG(PET,PETT):Poly ethylene terephthalate(PET)is the most commonly used plastic
in the world. Best known as the polymer used in water bottles, it is also found in clothing
fibers and food containers. While “raw” PET is rarely used in 3D printing, its variant
PETG is a popular 3D printer filament. The ‘G’ in PETG stands for “glycol-modified”,
and the result is a filament which is clearer, less brittle, and most importantly, easier to
use than its base form. For this reason, PETG is often considered a good middle ground
between ABS and PLA, the two most commonly used types of 3D printer filament, as it is
more flexible and durable than PLA and easier to print than ABS.

Fig. 26 PETG printed product

NYLON: Nylon, a popular family of synthetic polymers used in many industrial

applications, is the heavyweight champion of the 3D printing world. Compared to most
other types of 3D printer filament, it ranks as the number one contender when together
considering strength, flexibility, and durability. Another unique characteristic of this 3D
printer filament is that you can dye it, either before or after the printing process.

Fig. 27 Nylon printed product

27
TPE,TPU,TPC(FLEXIBLE):As the name implies, thermoplastic elastomers(TPE) are
essentially plastics with rubber-like qualities, making them extremely flexible and
durable. As such, TPE is commonly found in automotive parts, household appliances, and
medical supplies. Thermoplastic polyurethane(TPU)is a particular variety of TPE, and is
itself a popular 3D printer filament. Compared to generic TPE, TPU is slightly more rigid
– making it easier to print. It’s also a little more durable and can better retain its elasticity
in the cold. Thermoplastic copolyester (TPC) is another variety of TPE, though not as
commonly used as TPU. Similar in most respects to TPE, TPC’s main advantage is its
higher resistance to chemical and UV exposure, as well to heat (up to 150°C).

Fig. 28 Flexible filament product

PC (POLYCARBONATE): Polycarbonate (PC), in addition to being the strongest 3D
printer filament presented in this list, is extremely durable and resistant to both physical
impact and heat, able to withstand temperatures of up to 110°C.It’s also transparent,
which explains its use in commercial items such as bullet-proof glass, scuba masks, and
electronic display screens.

Fig. 29 Iron man suit by polycarbonate material

28
Fig. 30 Comparision of filaments Scaling LEAF SPRING in cura

29
4.4 Printing 3-D Model:

Before printing the 3-D model file, the 3d printer should be connected to the pc or the
laptop, on which you have been working and the software like CURA from Ultimaker or
Ideamaker has to be pre-installed on the computer.
o The filament used to print the 3-D model of LEAF SPRING in this case is PLA.
o The specifications of the PLA filament are:
 Diameter of filament: 1.75mm
 Certification: Roots approved
 Printing temperature: 190° to 210°C
 Bed temperature: 50° to 60°C
 Colour: White

o Now open the Idea maker or Cura software and load the STL file that has been
saved using CAD software.

Fig. 31 Loading LEAF SPRING in cura

o Necessary modifications should be done after the file has been loaded, like
rotating and scaling(since the maximum printing capacity of most of the printers is
20cm×20cm×20cm, along X, Y and Z axes).

Fig. 32 Scaling LEAF SPRING in cura

30
 The printing process has to be set to the following settings from the available
options, that the software has to offer.
 Layer height:0.1mm
 Fill density:8%
 Shell thickness: 2%
 Extruder temperature: 200°C
 Heat bed temperature: 50°C
 Printing speed: 60mm/s

Fig. 33 3-D printer

After the settings have been done, the following information regarding the model to be
printed will be displayed:
 Dimension (mm): 59.4×9.0×58.9 (in mm)
 Triangle:2822
 Edges:1015
 Non-manifold edges:0
 Error orientation faces:0
 Layers:88
 Steps:271
 Time duration; 1 hr 1min
 Left filament: ---
 Right filament: 240°C

31
 Price:$1
 Estimated amount: 5.3g
 Length: 1.96m

Now, the processed STL file has to be mounted onto the external storage device like
memory card or a pen drive that is compatible with the 3-D printer, and it should be
mounted on the printer, where the object would be printed in solid material of the
filament.

Fig. 34 Printing LEAF SPRING

32
 5. APPLICATIONS

Three-dimensional printing makes it as cheap to create single items as it is to produce

thousands and thus undermines economies of scale. It may have as profound an impact on
the world as the coming of the factory did....Just as nobody could have predicted the
impact of the steam engine in 1750 or the printing press in 1450, or the transistor in 1950.
It is impossible to foresee the long-term impact of 3D printing. But the technology is
coming, and it is likely to disrupt every field it touches.

Additive manufacturing's earliest applications have been on the tool room end of the
manufacturing spectrum. For example, rapid prototyping was one of the earliest additive
variants, and its mission was to reduce the lead time and cost of developing prototypes of
new parts and devices, which was earlier only done with subtractive tool room methods
(typically slowly and expensively). With technological advances in additive
manufacturing, however, and the dissemination of those advances into the business world,
additive methods are moving ever further into the production end of manufacturing in
creative and sometimes unexpected ways. Parts that were formerly the sole province of
subtractive methods can now in some cases be made more profitably via additive ones.

Standard applications include design visualization, prototyping/CAD, metal casting,

architecture, education, geospatial, healthcare, and entertainment/retail. 3D printer came
with immense number of applications. All the traditional methods of printing causes
wastage of resources. But 3D printer only uses the exact amount of material for printing.
This enhances the efficiency. If the material is very costly, 3d printing techniques can be
used to reduce the wastage of material.

Consider printing of a complex geometry like combustion chamber of a rocket engine.

The 3D printing will enhance the strength and accuracy of the object. Conventional
methods use parts by parts alignment. This will cause weak points in structures. But in the
case of 3D printed object, the whole structure is a single piece.

3D printer has numerous applications in every field it touches. Since it is a product

development device, rate of production, customization and prototyping capabilities need
to be considered.

33
 6. ADVANTAGES AND DISADVANTAGES

Advantages:
Create anything with great geometrical complexity.

Ability to personalize every product with individual customer needs.

Produce products which involve great level of complexity that simply could not be

produced physically in any other way.

Additive manufacturing can eliminate the need for tool production and therefore reduce

the costs, lead time and labor associated with it.

3D printing is an energy efficient technology.

Additive Manufacturing use up to 90% of standard materials.

Lighter and stronger products can be printed.

Production has been brought closer to the end user or consumer.

Spare parts can be printed on site which will eliminate shipping cost.

Wider adoption of 3D printing would likely cause re-invention of a number of already

invented products.

3D printing can create new industries and completely new professions.

Using 3D printing for building organs has been a revolution in medical industry.

Rapid prototyping can be time saving (50-60%) when compared to CNC and conventional
machining

Disadvantages:

Since the technology is new, limited materials are available for printing.

In additive manufacturing previous layer has to harden before creating next layer.

Curved geometry will not be much accurate while printing.

34
 7. CONCLUSION

As the 3D printer is a device, it should be analyzed with the advantages and

disadvantages, how the device can change the society and engineering etc. i n mind. The
very nature of 3D printing, creating a part layer by layer, instead of subtractive methods
of manufacturing lend themselves to lower costs in raw material. Instead of starting with a
big chunk of plastic and carving away (milling or turning) the surface in order to produce
your product. Additive manufacturing only “prints” what you want, where you want it.
Other manufacturing techniques can be just as wasteful. 3D printing is the ultimate just-
in-time method of manufacturing. No longer do you need aware houseful of inventory
waiting for customers. Just have a 3D printer waiting to print your next order. On top of
that, you can also offer almost infinite design options and custom products. It doesn’t cost
more to add a company logo to every product you have or let your customers pick every
feature on their next order, the sky is the limit with additive manufacturing.

Whether you are designing tennis shoes or space shuttles, you can’t just design whatever
you feel like, a good designer always takes into account whether or not his design can be
manufactured cost effectively. Additive manufacturing open up your designs to a whole
new level. Because undercuts, complex geometry and thin walled parts are difficult to
manufacture using traditional methods, but are sometimes a piece of cake with 3D
printing. In addition, the mathematics behind 3D printing are simpler than subtractive
methods. For instance, the blades on a centrifugal super charger would require very
difficult path planning using a 5-axis CNC machine. The same geometry using additive
manufacturing techniques is very simple to calculate, since each layer is analyzed
separately and 2D information is always simpler than 3D. This mathematical difference,
while hard to explain is the fundamental reason why 3D printing is superior to other
manufacturing techniques. It almost always better to keep things simple and additive
manufacturing is simple by its very nature.

With so many potential benefits of 3D printing, there’s no surprise that this method is
making its way through a diverse number of industries and quickly becoming a favorite
tool of progressive marketers.

Comparing the numerous advantages, applications and future scope, we can conclude that
the 3D printer and its technology is able to create next industrial revolution.
35
 8. FUTURE SCOPE

NASA engineers are manufacturing 3-D printed parts, which are structurally stronger and
more reliable than conventionally crafted parts, for its space launch system. The Mars
Rover comprises some 70 3-D-printed custom parts. Scientists are also exploring the use
of 3-D printers at the International Space Station to make spare parts on the spot. What
once was the province of science fiction has now become a reality.

Medicine is perhaps one of the most exciting areas of application. Beyond the use of 3-D
printing in producing prosthetics and hearing aids, it is being deployed to treat
challenging medical conditions, and to advance medical research, including in the area of
regenerative medicine. The breakthroughs in this area are rapid and awe-inspiring.

Whether or not they arrive en-mass in the home,3D printers have many promising areas
of potential future application. They may, for example, be used to output spare parts for
all manner of products, and which could not possibly be stocked as part of the inventory
of even the best physical store. Hence, rather than throwing away a broken item
(something unlikely to be justified a decade or two hence due to resource depletion and
enforced recycling), faulty goods will be able to be taken to a local facility that will call
up the appropriate spare parts online and simply print them out. NASA has already tested
a 3D printer on the International Space Station, and recently announced its requirement
for a high-resolution 3D printer to produce spacecraft parts during deep space missions.
The US Army has also experimented with a truck-mounted 3D printer capable of
outputting spare tank and other vehicle components in the battle field.

As noted above, 3D printers may also be used to make future buildings. To this end, a
team at Southborough University is working on a 3D concrete printing project that could
allow large building components to be 3D printed on-site to any design, and with
improved thermal properties.

Another possible future application is in the use of 3D printers to create replacement

organs for the human body. This is known as bio printing, and is an area of rapid
development. You can learn more on the bio printing page, or see more in my bio printing
or the Future Visions gallery.

36
8.1 Rocket Engine:
NASA’s first attempt at using 3D-printed parts for rocket engines has passed its biggest,
and hottest, test yet. The largest 3D-printed rocket part built to date, a rocket engine
injector, survived a major hot-fire test. The injector generated 10 times more thrust than
any injector made by 3D printing before, the space agency announced. A NASA video of
the 3D-printed rocket part test shows the engine blazing to life at the agency’s Marshall
Space Flight Centre (MSFC) in Huntsville Ala.

SpaceX’s Dragon capsule has been taking cargo to the International Space Station since
2012. Dragon V2 comes with new “Super Draco” 16,000 lb.thrust engines that can be
restarted multiple times if necessary. In addition, the engines have the ability to deep
throttle, providing astronauts with precise control and enormous power.

Fig. 35 3-D printed rocket engine

The SuperDraco engine chamber is manufactured using 3D printing technology, the state-
of-the-art direct metal laser sintering (DMLS) which uses lasers to quickly manufacture
high-quality parts from metal powder layer by layer. The chamber is generatively cooled
and printed in Inconel, a high-performance superalloy that offers both high strength and
toughness for increased reliability. Fig.14 shows the image of the SuperDraco engine.

Totally eight SuperDraco engines built into the side walls of the Dragon spacecraft will
produce up to 120,000 pounds of axial thrust to carry astronauts to safety should an
emergency occur during launch. As a result, Dragon will be able to provide astronauts
with the unprecedented ability to escape from danger at any point during the ascent
trajectory, not just in the first few minutes. In addition, the eight SuperDraco provide
redundancy, so that even if one engine fails an escape can still be carried out successfully.

37
8.2 3D Bio-Printing:
3D bio-printing is the process of generating spatially-controlled cell patterns using 3D
printing technologies, where cell function and viability are preserved within the printed
construct. Using 3D bio-printing for fabricating biological constructs typically involved is
pensing cells onto a bio-compatible scaffold using a successive layer-by-layer approach to
generate tissue-like three-dimensional structures. Given that every tissue in the body is
naturally compartmentalized of different cell types, many technologies for printing these
cells vary in their ability to ensure stability and viability of the cells during the
manufacturing process. Some of the methods that are used for 3D bioprinting of cells are
photolithography, magnetic bio-printing, stereolithography, and direct cell extrusion.
When a bio printed pre-tissue is transferred to an incubator then this cell-based pre-tissue
matures into a tissue.

Fig. 36 Bio-printing(heart)

3D-bioprinting attributes to significant advances in the medical field of tissue engineering

by allowing for research to be done on innovative materials called biomaterials.
Case Study:

Fig. 37 Bio-printing (human skull)

The operation was done at the University Medical Center (UMC) in Utrecht, the
Netherlands, and was actually performed almost three months ago, but the results were
announced publicly only after it was clear that the operation had been successful. The 22-
year-old patient is already back at work with nothing to indicate anything out of the
ordinary. The doctors used this method to solve a serious problem that affected the bone
structure in the patient’s skull.

38
8.3 3D Printing in Space:

In one small step towards space manufacturing, NASA is sending a 3D printer to the
International Space Station. Astronauts will be able to make plastic objects of almost any
shape they like inside a box about the size of a microwave oven enabling them to print
new parts to replace broken ones, and perhaps even to invent useful tools. The launch,
slated for around September 19, will be the first time that a 3D printer flies in space. The
agency has already embraced ground-based 3D printing as a fast, cheap way to make
spacecraft parts, including rocket engine components that are being tested for its next
generation of heavy-lift launch vehicles. NASA hopes that the new capability will allow
future explorers to make spacecraft parts literally on the fly.

Space experts say that the promise of 3D printing is real ,but a long way from the hype
that surrounds it. The printer selected by NASA was built by the company Made in Space,
which is based at a technology park next to NASA’s Ames Research Centre in Moffett
Field, California. During the printer’s sojourn on the space station, it will create objects
from a heat-sensitive plastic that can be shaped when it reaches temperature so far about
225– 250 °C. The team is keeping quiet about what type of object, it plans to print first,
but the general idea is to fashion tools for use aboard the station.

Fig. 38 3-D printer in space

The Made in Space printer is also a test bed for performance of the technology in near-
zero gravity. The machines work by spraying individual layers of a material that build up
to form a complete,3D object. But in near-weightless environments, there is no
gravitational pull to hold the material down.

39
8.4 3D Printing in Defense:

The US ARMY has long been putting 3D printing to good use . In an article published in
the latest edition of Army AL&T Magazine, senior editor Steve Stark takes a deep dive into
just how this branch of the military is using 3D printing, and what barriers stand in its way.
Stark wrote that 3D printing “is a natural fit for the Army” as the military branch works to
upgrade its manufacturing technologies. Dr. Philip Perconti, director of the US Army
Research Laboratory (ARL), says the technology “is at a pivotal stage in development.”

Fig 39: Tools used in defense

Mike Nikodinovski, a mechanical engineer and additive expert with the Army’s Tank
Automotive Research, Development and Engineering Center (TARDEC), explained that
various places around the Army, like its Research, Development and Engineering Command
(RDECOM) and the Aviation and Missile Research, Development and Engineering Center
(AMRDEC), are currently enhancing readiness, and speeding up the sustainment process, by
experimenting with the 3D printing of plastic and metal parts.

40
 9. REFERENCES
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Search for Authenticity in George O. Smith's Venus Equilateral Series". Durham
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