Digital Manufacturing..and Rapid Prototyping
Digital Manufacturing..and Rapid Prototyping
BELAGAVI, 590014
A Bonafide student of MVJ College of Engineering in partial fulfilment for the award of
Bachelor of Engineering in Mechanical Engineering of the Visvesvaraya Technological
University, Belagavi, during the year 2020-21. It is certified that that all corrections/
suggestions indicated for Internal Assessment have been incorporated in the Report
deposited in the departmental library. The project report has been approved as it satisfies
the academic requirements in respect of Project work prescribed for the said Degree.
External Viva
1. …………………………… …………………………
STUDENT DECLARATION
Signature
Hassanian
1MJ17ME053
ACKNOWLEDGEMENT
I am thankful and greatly acknowledge the numerous personalities involved in lending their help to
make my training “Digital Manufacturing” a successful one.
First of all, I want to express my gratitude mainly to my supervisor Mr. Ankit Kumar, Mechanical
Engineer, Creativegenic Solutions Pvt. Ltd. , Kanpur, who helped me from the very beginning of my
training “Project using 3D Printing”. I was fully supported throughout the training duration with all the
required data and related details to prepare this report.
I also take this opportunity to express my deep sense of gratitude to our honorable Principal MVJCE
“Dr. P Mahabaleswarappa", for providing excellent academic climate in the college that made this
endeavor possible.
I give my whole hearted admiration and deep sense of gratitude to "Dr. Vivekananda Huddar", HOD,
“Mechanical Engineering”, MVJCE for his inspiration, valuable guidance, encouragement, suggestion
and overall help throughout.
I express my sincere thanks to my Guide “Prof. Akshita G”, Assistant Professor department
of“Mechanical Engineering”, MVJCE, for his keen interest and invaluable help throughout the project.
Finally, I express my gratitude to all the Teaching and Non-Teaching staff of “Mechanical Engineering”,
MVJCE for their timely support and suggestions.
Signature
Hassanian
1MJ17ME053
ABSTRACT
Six week online industrial training Course on CAD tool NX CAD, Rapid prototyping technologies using
software like CURA, MakerBot Print, laser cutting operation and vinyl plotter operation using Graphtec
software is undertaken from duration 29th September,2020 to 7th November,2020.
Live project were asked to design and 3D print using NX-CAD and 3D printing software CURA .
Design project has already been submitted for print and it is in process, though the project details can
be shared during this presentation.
Spanner Combination is the project chosen which was designed in NX-CAD and 3D printed.
3D printing software CURA is used to make strategy using FDM (Fused deposition Modeling) technique
for Stratasys F370 machine and adjusting several features like Infill density, Printing time etc.
Fused deposition modeling (FDM) is an additive manufacturing (AM) technology commonly used for
modeling, prototyping, and production applications. It is one of the techniques used for 3D printing.
List of Figures
Figure 1.1: 3D CAD Model ...................................................................................................................6
Figure 1.2: Spanner ..............................................................................................................................7
Figure 2.1: Process model machining ..................................................................................................8
Figure 2.2:Direct light processing .....................................................................................................10
Figure 2.3:SLA.....................................................................................................................................11
Figure 2.4: Binder jetting flow chart ..................................................................................................11
Figure 2.5:Flow chart of model ..........................................................................................................14
Figure 2.6:Work flow of RP processes ...............................................................................................14
Figure 2.7:Spanner combination drawing .........................................................................................15
Figure 2.8:Flow chart .........................................................................................................................15
Figure 2.9:Block diagram ...................................................................................................................16
Figure 2.10:Machine diagram ............................................................................................................16
Figure 2.11: During machine working ................................................................................................17
Figure 2.12: Spanner .stlfile ...............................................................................................................19
Figure 3.1:3D manufacturing spanner after printed .........................................................................20
• Project Introduction
3D printing refers to the manufacturing process that additively forms or creates a physical object from
a digital design. There are various 3D printing technologies and materials, and all are based on the
same principle that, a digital model is reshaped to the solid three-dimensional object by adding layer
after the layer.
3D Printing is a process for making a physical object from a three-dimensional digital model, typically
by laying down many successive thin layers of a material. It brings a digital object (its CAD
representation) into its physical form by adding layer by layer of materials.
There are several different techniques to 3D Print an object. We will go in further details later in the
Guide. 3D Printing brings two fundamental innovations: the manipulation of objects in their digital
format and the manufacturing of new shapes by addition of material.
• Creativegenic solutions pvt Ltd is an online skill development organization initiated by the
alumni of Delhi Technological University and MNIT Jaipur along with ex member of Mahindra
&mahindra R&D.
• This company is established in 2018 in the city of Ghaziabad, Uttar Pradesh.
• This organization under the Directorship of Mr. Vikram Singh Rajput, is working to achieve
solutions of various industrial based problems through digital platform.
• Creativegenic solutions deals in various Online training like Digital Manufacturing, Industrial
Automation, Electric Vehicle Design, Solar powered Vehicle Design and Many more.
• The earliest record of 3D printing through the additive process was the Japanese inventor Hideo
Kodama in 1981. He created a product that used ultraviolet lights to harden polymers and
create solid objects. This is a stepping stone to stereolithography (SLA).
• Charles Hull invented stereolithography, a process similar to 3D printing that uses technology to
create smaller versions of objects so they can be tested before spending time and money on
creating the actual product. The object is printed layer by layer, rinsed with a solvent, and
hardened with an ultraviolet light. The process uses computer-aided designs (CAD) to create
the 3D models.
• to define and establish standardisation, regulatory issues, qualifications and risks analysis
• to increase knowledge on modelling & characterizations and develop specific tools for that
Most of the current demand for 3D printing is industrial in nature. Acumen Research and Consulting
forecasts the global 3D printing market to reach $41 billion by 2026.
As it evolves, 3D printing technology is destined to transform almost every major industry and change
the way we live, work, and play in the future.
The Applications of 3D printing is very vast and it is almost there in every field. Now if you talk about
the scope of 3D Printing in India then it is having a long list:-
1.4.1 Medical Industry:- If you see the population of India you will realize that due to the lack of
medical facility to the children and adults they are suffering from many diseases like polio or
paralysis in which their body part is unable to move due to which they either sit back home or beg
for their earning but with the help of prostheses process of 3D Printing in which they prepare
limbs or legs or hands for the people to help them to get back to their normal life.
1.4.2 Fashion Industry:- With the increasing demand for clothing and fashion people are getting
attracted to new fashion trends coming in the market. Now if you see new fashion designers are
trying to do something new for the people and here with something new 3D printing comes in the
picture where we can 3D print dresses and accessories and start a new era of 3D Printing Fashion.
1.4.3 Automobile Industry:- As we all know that the automobile sector in India is growing at a fast
pace and due to the high demand for automobile the supply and production should be at a
running speed in this 3D Printing technique comes where we can 3D Print small parts and spare
parts and make the work easy for workers and meet the targets.
1.4.4 Furniture Industry:- The migration in India has to lead to the people running towards urban
areas and settle there, as a result, the economy is increasing and so the standard of living in India
is also increasing people are trying new ways to decorate there home and in this case, furniture
plays an important role in decoration. Customers in India are demanding a new form of Furniture,
which comes with 3D Printing.
With there are several other areas where we can use 3D Printing and it has a wide scope like
construction is also the one. But, the usage and technology awareness in India is very low due to which
the country is unable to take the benefit of 3D printing.
A few examples:
• – dental products
• – prosthetics
• – reconstructing fossils
• – movie props
Companies have used 3D printers in their design process to create prototypes since the late seventies.
Using 3D printers for these purposes is called rapid prototyping.
• Project Description
• Spanner Combination is the project chosen which was designed in NX-CAD and 3D printed.
• 3D printing software CURA is used to make strategy using FDM (Fused deposition Modeling)
technique for Stratasys F370 machine and adjusting several features like Infill density, Printing
time etc.
• FDM works on an "additive" principle by laying down material in layers; a plastic filament or
metal wire is unwound from a coil and supplies material to produce a part. Thus, FDM is also
known as a solid-based AM technology.
• The technology was developed by S. Scott Crump in the late 1980s and was commercialized in
1990.The term fused deposition modeling and its abbreviation to FDM are trademarked by
Stratasys.
Fig. 1-3D CAD Model
While there are many varieties in 3D printer technologies, there are seven most common types.
2.1.1 Fused Filament Fabrication (FFF, also known as Fused Deposition Modeling)
• 2.1.2 Continuous Filament Fabrication (CFF)
• 2.1.3 Atomic Diffusion Additive Manufacturing (ADAM, also known as Bound Powder
Deposition)
• 2.1.4 Selective Laser Sintering/Melting (SLS/SLM, also known as DMLS for metal)
In FFF, the printer heats up thermoplastic to near melting point and extrudes it out a nozzle that
traces the cross section of a part for each layer. This process repeats for each layer.
CFF is an augmented FFF process that works in addition to an FFF printer to lay continuous fiber in
a part. In this process, a printer utilizes a second nozzle to lay continuous strands of composite
fibersinside a convention FFF thermoplastic parts. Parts built with the CFF/FFF process are strong
ADAM uses a filament comprised of metal powder and plastic binder — after printing, the binder is
dissolved away and the metal powder is sintered into a full metal part.
Laser fusion printers use high powered lasers to fuse powdered media together. This base
technology can be used for plastic (SLS) and metal (SLM/DMLS). These machines are usually
industrial in nature, as both high powered lasers and powders are difficult to handle. They make
SLS yields incredibly precise plastic parts. In this process, a printer lays down an even layer of
powder and then precisely sinters a layer, repeating the deposition and sintering process until the
part is complete.
SLM and DMLS utilize the same process as SLS, but use metal powders. Due to metal’s higher
melting point and the added risks of metal powder, these machines require higher power lasers
DLP can be used to quickly fabricate photopolymer parts. These printers work in the same way as
SLA, but replace the actuated laser with a projector that can cure an entire layer at once.
SLA printers can quickly and affordably produce precise parts. They utilize a laser to selectively cure
a layer of resin, which is then pulled up and reset for the next layer. Typically, these parts are
Binder jetting is a cost effective, low-energy method of fabricating parts out of powder. In this
process, a machine uses the same powder spreading methods as SLS, but uses a liquid binding agent
to adhere parts instead of a laser. After printing, these parts need to either be cured (plastic) or
Component 1
Product Design
Product design deals with the conversion of a dream into reality in order to fulfill human needs. See
why am I putting this? Because you can think of a product and you can virtually draw product,but
virtual drawing does not give a satisfaction to the customer. When you talk about video games yes of
course. So, video games are more towards virtual, but when you want to have a feel for a product and
when this product has to be touched and used. So, then it is like a product designer deals with the
conversion of a dream into reality in order to fulfill human needs. A designer produces first a prototype
and this prototype is studied several times and got customer feedback, and then what he does is he
tries to freeze the design for mass production. So, a designer’s responsibility is to produce a prototype
and then try to freeze the prototype such that, he can make goods for customer needs. So, what is the
responsibility of a designer? The responsibility of the designer is to make sure that mass customization
happens in the product. So, he produces a sufficient number of prototypes, gets customer satisfaction
and then he freezes the production drawings or manufacturing process such that this process of
producing can be repeatable. If there is an error he has to go back reiterate and then come back and
start doing it.
Component 2
Rapid Prototyping
Rapid prototyping is a group of techniques used to quickly fabricate a scale model of a physical part or
assembly using three-dimensional computer aided design (CAD) data. Construction of the part or
assembly is usually done using 3D printing or "additive layer manufacturing" technology.
Rapid prototyping (RP) includes a variety of manufacturing technologies, although most utilise layered
additive manufacturing. However, other technologies used for RP include high-speed machining,
casting, moulding and extruding.
While additive manufacturing is the most common rapid prototyping process, other more conventional
processes can also be used to create prototypes.
• Subtractive - whereby a block of material is carved to produce the desired shape using milling,
grinding or turning.
• Compressive - whereby a semi-solid or liquid material is forced into the desired shape before
being solidified, such as with casting, compressive sintering or moulding.
Fig.2.5- Flow chart of model
Spaner Combination is the project choosen which was designed in NX-CAD and 3D printed.
3D printing software CURA is used to make strategy using FDM (Fused deposition Modeling) technique
for Stratasys F370 machine and adjusting several features like Infill density, Printing time etc.
I usually print it at 0.2mm layer height with the recommended settings for the material i use. If you
print this in PLA i recommend that you scale it up to around 150%. If your lucky the support structures
can be removed by hand without to much effort but if your unlucky all the parts may have fused
together and your stuck with a non-adjustable wrench. If your having problems removing the support
structures and loosen the internal part you can try to use a tool to do so.
Once the support parts are gone and parts a moving you can add some olive oil to the moving parts to
make them move smoother if needed. Now I made it. And while it may not be the easiest print i think
it´s ok share your wrench with the world, post a make or just post some pictures of your latest 3dprint.
This can be a fun experiment and a great project to showcase what you can do with a standard desktop
3D printer.
Fig.2.11 During machine working
Procedure:
First – the production of a 3D model with the help of computer-aided design software. The software is
likely to give you some suggestion or even a clue concerning the structure of the ultimate object
applying scientific facts about utilized materials. That will help to predict the behavior of the object
under various conditions.
Second – transformation to STL (standard tessellation language) – the sketch in CAD format is
converted to STL, which is the format initiated especially for 3D systems in 1987 so as to be used by
SLA – stereolithography apparatus. These STL files are sometimes used together with proprietary file
kinds like Obj DF or ZPR.
Third – removing to AM machine and STL file operating. An STL file is copied to the computer operating
a 3D printer. That’s the same as if you were to install a 2D printer.
Fourth – setting up the device. Each device has its own prerequisites for how to use it for each new
print. That would mean adding or refilling various materials the printer will use. That also means
adding a tray as a basis or adding some material to make up an interim water-dissoluble support.
Fifth – creating. The whole procedure is mainly automatic. The thickness of layers id about 0,1 mm
each. However they can be thicker or thinner. Hanging on the size of a thing, machine and materials
employed, the procedure might take several hours or even days. Don’t forget to check occasionally
there are no errors.
Sixth – removal. Take the printed object (or perhaps several objects) out of the printer. Take them as
carefully as possible to prevent injuries.
Seventh – post-processing. It may happen so that after an object is 3D printed it will require some
post-processing – either it is removing the remaining powder or the water-soluble supports.
Remember that sometimes materials may require some time to get solid. Be careful not to break the
object.
.stl file -
Software Programming
3.0.2 As 3D printing is a technique which is used to prototype industry based items though it is a costly
process
3.0.3 Thus various strategy used to reduce cost for our project.
3.0.4 Infill density were kept at 25% only to reduce its time and cost.
3.0.5 Main focus was also given on the aspect of support material removal it must be removed easily
otherwise cost will increase a lot because a solvent will be required in that case.
Fig. 3.1 3D manufacturing Spanner after printed
3.1 Observations
The demand for 3D printing and additive manufacturing is about to flourish globally. In the future, 3D
printing has potential to grow about 30% by creating high-tech jobs and start-ups across fields such as
scientific modeling, architecture, education etc.
use 3D printing software to create digital designs that can be turned into physical objects. It will also
demonstrate how 3D scanners work to turn physical objects into digital designs. This course is hands-
on in nature and will provide step-by-step instructions to guide you through two popular 3D modeling
programs.
• Conclusion
• Training help me to understand various aspect of designing through Industrial grade 3D printers
and CAD tool like NX CAD.
• This Ball-bearing can directly used as a prototype in sand casting. As 3D printing is a fast process
to manufacture benchmarked items at a fast rate.
• Support material can be easily removed as design feature is optimized.
• References