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A Mini Project Report On 3d Project Edited College
A Mini Project Report On 3d Project Edited College
IMPACT OF 3D PRINTING
Submitted to
CHADALAWADA RAMANAMMA ENGINEERING COLLEGE
In partial fulfillment for the requirements for the award of the degree of
BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
Submitted by
K. PAVAN KALYAN REDDY 19P15A0317
B. SOBHAN BABU 19P15A0304
A.S.ANIL KUMAR 19P15A0301
C.SANKAR 19P15A0309
V. PUNITH 18P11A0370
CERTIFICATE
This is to certify that the Mini Project report entitled
“IMPACT OF 3DPRINTING”, is a bonafide work done by
K.PAVAN KALYAN REDDY 19P15A0317
B .SOBHAN BABU 19P15A0304
A.S. ANIL KUMAR 19P15A0301
C. SHANKAR 19P15A0309
V PUNITH 18P11A0370
in the Department of Mechanical Engineering in the partial fulfillment of the
requirements for the award of the degree of Bachelor of Technology in Mechanical
Engineering during the academic year 2019-2020. This work has been carried out under
my guidance and has not been submitted the same to any other University for the award
of any Degree/Diploma
INTERNALEXAMINER EXTERNALEXAMINER
DECLARATION
Date:
Place:
ACKNOWLEDGEMENT
We express our sincere thanks to our supervisor Mr. V. Chengal Reddy, M.Tech.(Ph.D)
Title
COVER PAGE
CERTIFICATE
ACKNOWLEDGEMENT
ABSTRACT
CONTENTS
1 INTRODUCTION
2 3D-PRINTER
3 ARCHITECTURE
4 ADDITIVE MANUFACTURING
1. EXTRUSION DEPOSITION
3. PHOTOPOLYMERISZATION
4. LAMINATION
v
6 APPLICATIONS
1. RAPID PROTOTYPING
2. MASS CUSTOMIZATION
3. AUTOMOBILE
4. WEARABLES
7 ADVANTAGES
8 DISADVANTAGES
9 CONCLUSION
10 BIBLIOGRAPHY
INTRODUCTION
Early AM equipment and materials were developed in the 1980s. In 1984, ChuckHull
of 3D Systems Corp, invented a process known as stereoithography 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 AM at the 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, ZCorporation commercialized an MIT-developed
additive process under the trademark 3D printing (3DP), referring at that time to a proprietary
process inkjet deposition of liquid binderon powder.
The picture shows the structure of a typical 3D printer. The print table is the platform
where the objects for printing has been situated. It provides the basic support for
manufacturing objects layer by layer.
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 movement 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 microcontroller 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 print table.
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 fall 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 need to access all the 3 coordinates in space to
print and object. The method used for that doesn’t matters much.
ADDITIVE MANUFACTURING
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 moulds 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 waste 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 waste that can be harmful to the environment. Additive manufacturing is a
very energy efficient and environmentally friendly manufacturing option.
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.
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 laser sintering(DMLS),
selective laser sintering (SLS), fused deposition modeling (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.
EXTRUSION DEPOSITION
Extrusion 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 infused 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 include selective laser sintering (SLS), with both metals and polymers (e.g. PA, PA-GF,
Rigid GF, PEEK, PS, Alumide, Carbonmide, elastomers), and direct metal laser sintering (DMLS).
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 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.
PHOTOPOLYMERISZATION
PHOTOPOLYMERISZATION PROCESS
Ultra-small features can be made with the 3D micro fabrication technique used in
multiphoton photopolymerisation. 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 interlocked parts.
LAMINATION
LAMINATION PROCESS
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 need to be modified. The
object file contains numerous amounts of curves. Curves cannot be printed by the printer
directly. The curve has 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 need 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 generates a
complete object.
DESIGNING 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 database 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 produce raster 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.
CONVERSION TO STL FILE FORMAT
(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 redundantly in two ways which must be consistent. First,
the direction of the normal is outward. Second, the vertices are listed in
counterclockwise 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).
CHOOSING PRINTING INKS
Printing inks are chosen according to the need and kind of object that has to print.
Different types of inks are available according to the size, type, resolution and function of the
object.
COLLOIDAL INKS: Three-dimensional periodic structures fabricated from colloidal
“building blocks” may find widespread technological application as advanced ceramics,
sensors, composites and tissue engineering scaffolds. These applications require both
functional materials, such as those exhibiting Ferro electricity, high strength, or
biocompatibility, and periodicity engineered at length scales (approximately several
micrometers to millimeters) far exceeding colloidal dimensions. Colloidal inks developed for
robotic deposition of 3-D periodic structures. These inks are also called general purpose inks.
FUGITIVE INK: These types of inks are used for creating soft devices. The type of ink is
capable for self-organizing which results in self regenerative devices.
NANOPARTICLE INK: The object that has to be printed sometimes need conductor for its
function. For printing conductors, special types of inks called Nanoparticle inks are used.
SOL-GEL INK: In this chemical procedure, the 'sol' (or solution) gradually evolves towards
the formation of a gel-like dysphasic system containing both a liquid phase and solid phase
whose morphologies range from discrete particles to continuous polymer networks. In the
case of the colloid, the volume fraction of particles (or particle density) may be so low that a
significant amount of fluid may need to be removed initially for the gel-like properties to be
recognized. These inks are very useful in creating power supply modules in the printed object
APPLICATIONS
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.
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 enhances 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.
RAPID PROTOTYPING
The first methods for rapid prototyping became available in the late 1980s and were
used to produce models and prototype parts. Today, they are used for a wide range of
Rapid Prototyping
The model is valid if for each point in 3D space the computer can determine uniquely
whether that point lies inside, on, or outside the boundary surface of the model. CAD post-
processors will approximate the application vendors’ internal CAD geometric forms (e.g., B-
splines) with a simplified mathematical form, which in turn is expressed in a specified data
format which is a common feature in Additive Manufacturing: STL (stereolithography) a de
facto standard for transferring solid geometric models to SFF machines. To obtain the
necessary motion control trajectories to drive the actual SFF, Rapid Prototyping, 3D Printing
or Additive Manufacturing mechanism
MASS CUSTOMIZATION
With the arrival of 3D printer, we are able to customize any products we want.
Consider you are in a shop to buy a spectacle. The only choice you have is to select a model
from the shop. If you didn’t like any model, you will probably go to another shop. By the
implementation of 3d printed spectacles, you are provided with power for creating any
spectacle in the world with just the CAD model. Many implementations of mass
customization are operational today, such as software-based product configurations that make
it possible to add and/or change functionalities of a core product or to build fully custom
enclosures from scratch.
AUTOMOBILES
In early 2014, the Swedish supercar manufacturer, Koenig egg, announced the ‘One:1’, a
supercar that utilizes many components that were 3D printed. In the limited run of vehicles Koenig
egg produces, the ‘One:1’ has side-mirror internals, air ducts, titanium exhaust components, and
even complete turbocharger assembles that have been 3D printed as part of the manufacturing
process
An American company, Local Motors is working with Oak Ridge National
Laboratory and Cincinnati Incorporated to develop large scale additive manufacturing
processes suitable for printing an entire car body.
The company plans to print the vehicle live in front of an audience in September 2014
at the International Manufacturing Technology Show. Produced from a new fiber-reinforced
thermoplastic strong enough for use in an automotive application, the chassis and body
without drive train, wheels and brakes weighs a scant 450 pounds and the completed car is
comprised of just 40 components, a number that gets smaller with every revision.
Fig shows the 3D CAD model of a bike, actually of a 3D printed scale replica
created by designer
Jacky Wan from Redicubricks. The 3D printed bike is made of over 40 individual
pieces and Wan details his print and build process over on Ultimate’s blog. He even includes
a link to his 3D files so you can build one yourself if you think you’re up to it. The project is
certainly not for beginners. When designing the bike replica, Wan imposed several goals on
himself; He wanted to maintain the external looks of the bike, all parts needed to snap fit
together to make gluing easier, keep seams and striation to a minimum and everything needed
to print on his Ultimate: Original. Of course 3D printing a realistic motorcycle replica wasn’t
going to make it easy for him to meet to those goals
WEARABLES
Dutch designer Iris Van Herpen has already put this new material to the test in her Voltage
Haute Couture collection, which raised eyebrows at Paris Fashion Week in January 2013. A
frontrunner in the realm of futuristic fashion design, Van Herpen has been taking her 3D printed
dress and shoes to the runways since 2010. Still, she admits that there are challenges associated with
incorporating a new medium into the manufacturing process. “I always work together with an
architect because I am not good with the 3D programs myself,” she said.
The idea of custom design has mass appeal and marketability. Who doesn’t want to wear a
one-of-a-kind, perfectly tailored piece? Perhaps the teenage girl of the future won’t have to suffer the
social agony of showing up to a school dance wearing the same dress as her archenemy
ADVANTAGES
DISADVANTAGES
Since the technology is new, limited materials are available for printing.
Consumes more time for less complicated pats.
Size of printable object is limited by the movement of extruder.
In additive manufacturing previous layer has to harden before creating next layer.
Curved geometry will not be much accurate while printing.
Since the technology is new, limited materials are available for printing.
Consumes more time for less complicated pats.
Size of printable object is limited by the movement of extruder.
In additive manufacturing previous layer has to harden before creating next layer.
Curved geometry will not be much accurate while printing.
CONCLUSION
As 3D printers become more affordable, they will inevitably be used for local, small scale
manufacturing, largely eliminating supply chains for many types of product. Consumer units for
home use will even become feasible, allowing end users to simply download a design for the product
they require and print it out.
There will be major challenges for the conventional manufacturing industry to adapt to these
changes. The opportunities for technology and engineering are clearly huge, however, and the
creative possibilities in product design and printing material formulation are nearly endless.
BIBLIOGRAPHY
Books
3D Printing: The Next Industrial Revolution Paperback – May 4, 2013 By Christopher Barnett
Fabricated: The New World of 3D Printing Paperback – February 11, 2013 By Hod Lipson
Links
www.3dprinter.net/reference
www.3dprintingindustry.com
www.stratasys.com/applications
www.en.wikipedia.org/wiki/3D_printing
www.3ders.org/3d-print-technology.html
www.zdnet.com/how-3d-printing-is-building-a-new-future-7000032248