A Mini Project Report on

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

Under the esteemed guidance of

Mr. V. Chengal Reddy, M.Tech.(Ph.D)
Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING

CHADALAWADA RAMANAMMA ENGINEERING COLLEGE
(AUTONOMOUS)
(Affiliated to JNT University, ANANTAPUR, Approved by AICTE)
(AN ISO 9001-2000 Certified Institution, Accredited by NAAC with ‘A’ Grade)
Chadalawada Nagar, Renigunta Road,
Tirupati - 517 506
2021
 DEPARTMENT OF MECHANICAL ENGINEERING
CHADALAWADA RAMANAMMA ENGINEERING COLLEGE
(AUTONOMOUS)
(Affiliated to JNT University, ANANTAPUR, Approved By AICTE)
(AN ISO 9001-2000 Certified Institution, Accredited by NAAC with ‘A’ Grade)
Chadalawada Nagar, Renigunta Road,
Tirupati - 517 50

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

Supervisor Head of the Department

Mr.Chengal reddy, M.Tech., (Ph.D) Dr. B. Narayana Reddy, M.Tech., Ph.D.
Assistant Professor Professor
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
CREC, Tirupati. CREC, Tirupati.
This is to certify that the candidates were examined by me in the viva-voce
Examination held on at CREC, Tirupati.

INTERNALEXAMINER EXTERNALEXAMINER
 DECLARATION

We here by declare that the project report entitled “IMPACT OF

3D PRINTING” submitted to the Department of Mechanical Engineering, Chadalawada
Ramanamma Engineering College, Tirupati during the academic year 2020-2021 in partial
fulfillment of requirements for the award of degree of Bachelor of Technology. The project
result is of our own effort and is not submitted to any other university/Institution for the
award of any degree.

K.PAVAN KALYAN REDDY 19P15A0317

B .SOBHAN BABU 19P15A0304
A.S. ANIL KUMAR 19P15A0301
C. SHANKAR 19P15A0309
V PUNITH 18P11A0370

Date:

Place:
 ACKNOWLEDGEMENT

We express our sincere thanks to our supervisor Mr. V. Chengal Reddy, M.Tech.(Ph.D)

Assistant Professor in Mechanical Engineering Department, CREC - Tirupati, for her

inspiring intellectual guidance, constructive criticism and valuable suggestion throughout
the project work.
With deep sense of gratitude we express our heartful thanks to Professor & Head
of the Mechanical Engineering Department, Dr. B.Naryana Reddy M.Tech (Ph.D), for giving
us his valuable suggestions and providing necessary facilities in completion of this
project.
We express our sincere thanks to our beloved Principal Dr. P.Sanjeeva Rayudu, M.Tech,
, for providing all sorts of help during the project work.
(Ph.D)

We are extremely grateful to our honorable chairman Dr. Chadalawada

Krishna Murthy garu for providing needful sources for successful completion of
project work.
We wish to convey our sincere thanks to Project Review Committee members
and faculty of Mechanical Engineering Department for their support and co-operation
rendered for successful submission of project work.
Project Associates

K . PAVAN KAKYAN REDDY

B. SOBHAN BABU
C. SANKAR
A.S. ANIL KUMAR
V. PUNITH
 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 Z 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. Z Corp. pioneered the commercial use of 3DP technology, developing 3D
printers that leading manufacturers use to produce early concept models and product
prototypes. Utilizing 3DP technology, Z Corp. has developed 3D printers that operate at
unprecedented speeds, extremely low costs, and within a broad range of applications. This
paper describes the core technology and its related applications.

Additive manufacturing, often referred to as 3D printing, is a new way of making

products and components from a digital model. Like an office printer that puts 2D digital
files on a piece of paper, a 3D printer creates components by depositing thin layers of
material one after another ,only where required , using a digital blueprint until the exact
component has been created.

Interest in additive techniques is growing swiftly as applications have progressed

from rapid prototyping to the production of end-use products. Additive equipment can now
use metals, polymers, composites, or other powders to “print” a range of functional
components, layer by layer, including complex structures that cannot be manufactured by
other means.

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
defence, aerospace, automotive, biomedical, consumer products, and metals manufacturing.
 CONTENTS

Title

COVER PAGE

CERTIFICATE

ACKNOWLEDGEMENT

ABSTRACT

CONTENTS

1 INTRODUCTION

2 3D-PRINTER

3 ARCHITECTURE

4 ADDITIVE MANUFACTURING

1. EXTRUSION DEPOSITION

2. GRANULAR MATERIAL BINDING

3. PHOTOPOLYMERISZATION

4. LAMINATION

5 PROCEDURES FOR PRINTING

1. DESIGNING USING CAD

2. CONVERSION TO STL FILE FORMAT

3. CHOOSING PRINTING INKS

v
6 APPLICATIONS

1. RAPID PROTOTYPING

2. MASS CUSTOMIZATION

3. AUTOMOBILE

4. WEARABLES

7 ADVANTAGES

8 DISADVANTAGES

9 CONCLUSION

10 BIBLIOGRAPHY
 INTRODUCTION

3D printing or additive manufacturing (AM) 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.

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.

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, jeweler, eyewear, education, geographic information
systems, food, and many other fields.
 3D-PRINTER

3D-Printer is a machine reminiscent of the Star Trek Replicator, 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 nonsensical 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. 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
modeling 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.
 ARCHITECTURE

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

Additive manufacturing is a truly disruptive technology exploding on the manufacturing

scene as leading companies are transitioning from “analog” to “digital” manufacturing. 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 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.

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
shut downs and drastically compress the time it takes to machine a replacement 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.

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

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

(FDM) was developed by Stratasys in Eden Prairie, Minnesota. In this process, a plastic or wax
material is extruded through a nozzle that traces the part's cross 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 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
 GRANULAR MATERIAL GRINDING

GRANULAR MATERIAL GRINDING

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

Stereolithography was patented in 1986 by Chuck Hull.Photopolymerization is

primarily used in stereolithography (SLA) to produce a solid part from a liquid. This process
dramatically redefined previous efforts, from the "photosculpture" method of François
Willème (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, whence a pantograph was used to trace the outline onto modeling clay) through
the photopolymerisation of Mitsubishi's Matsubara in 1974.

In photopolymerisation, a vat of liquid polymer is exposed to control lighting under

safelight 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
solid model. The EnvisionTEC Perfactory is an example of a DLP rapid prototyping system.

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

Laminated Object Manufacturing works by layering sheets of material on top of one-

another, binding them together using glue. The printer then slices an outline of the object into
that cross section to be removed from the surrounding excess material later. Repeating this
process builds up the object one layer at a time. Objects printed using LOM are accurate,
strong, and durable and generally show no distortion over time 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.
 PROCEDURES FOR 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 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

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 counterclockwise 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 fulfill 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 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.

POLYELECTROLYTE INK: Polyelectrolyte complexes exhibit a rich phase behavior that

depends on several factors, including the polyelectrolyte type and architecture, their
individual molecular weight and molecular weight ratio, the polymer concentration and
mixing ratio, the ionic strength and pH of the solution, and the mixing conditions. So such
inks are used for creating sensors, transducers etc.

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

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 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

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.

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

Applications and are used to manufacture production-quality parts in relatively small

numbers if desired without the typical unfavorable short-run economics. This economy
encouraged online service bureaus. Historical surveys of RP technology start with
discussions of simulacra production techniques used by 19th-century sculptors. Some
modern sculptors use the progeny technology to produce exhibitions. The ability to
reproduce designs from a dataset has given rise to issues of rights, as it is now possible to
interpolate volumetric data from one-dimensional images. As with CNC subtractive methods,
the computer-aided-design computer-aided manufacturing CAD-CAM workflow in the
traditional Rapid Prototyping process starts with the creation of geometric data, either as a 3D
solid using a CAD workstation, or 2D slices using a scanning device. For RP this data must
represent a valid geometric model; namely, one whose boundary surfaces enclose a finite
volume, contain no holes exposing the interior, and do not fold back on themselves. In other
words, the object must have an “inside.”

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

Mass customization, in marketing, manufacturing, call centers and management, is the

use of flexible computer-aided manufacturing systems to produce custom output. Those
systems combine the low unit costs of mass production processes with the flexibility of
individual customization.

Mass customization of Glasses

Mass customization is the new frontier in business competition for both
manufacturing and service industries. At its core is a tremendous increase in variety and
customization without a corresponding increase in costs. At its limit, it is the mass production
individual of customized goods and services. At its best, it provides strategic advantage and
economic value.
 Mass customization is the method of "effectively postponing the task of
differentiating a product for a specific customer until the latest possible point in the supply
network." Chase, Jacobs. 419). Kamas, Kowaris and Stern (2008) conducted experiments to
test the impacts of mass customization when postponed to the stage of retail, online shopping.
They found that users perceive greater usefulness and enjoyment with a mass customization
interface vs. a more typical shopping interface, particularly in a task of moderate complexity.
From collaborative engineering perspective, mass customization can be viewed as
collaborative efforts between customers and manufacturers, who have different sets of
priorities and need to jointly search for solutions that best match customers’ individual
specific needs with manufacturers’ customization capabilities (Chen, Wang & Tseng (2009)).

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

San Francisco-based clothing company,Continuumis among the first to create

wearable, 3D printed pieces. Customers design bikinis on Continuum’s website, specifying
their body shapes and measurements. The company then uses nylon to print out each unique
order. Founder Mary Huang believes that this intersection of fashion and technology will be
the future because it “gives everyone access to creativity.”

Man use by 3D Wearable’s

 This year, architect Francis Bitonti and fashion designer Michael Schmidt collaborated to
make addressor burlesque diva Dita Von Tease. She wore the garment to the Ace Hotel in March for
a convention hosted by online 3D printing marketplace, Shapeways. The dress consists of 2,500
intersecting joint pieces that were linked together by hand. The finishing touches a black lacquer
coating and 12,000 hand-placed Swarovski crystals reflect Schmidt’s iconic glam that attracts a
clientele of Madonna, Rihanna, Lady Gaga, and the like. British designer Catherine is making moves
too. She is best known for her Project DNA collection, which includes avant-garde 3D printed
masks, accessories, and apparel, all printed with white nylon. The eccentric shapes of her garments
reflect that 3D printed clothing is still in its early stages. Today, the materials and technologies used
for 3D printing still dictate and affect garment design.

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

. 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 labour associated with it.
 3D printing is an energy efficient technology.
 Additive Manufacturing use up to 90% of standard materials and therefore creating
less waste.
 Lighter and stronger products can be printed.
 Increased operating life for the products.
  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.
 Printing 3D organs can revolution a rise the medical industry.
 Rapid prototyping causes faster product development.

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

It is generally accepted that 3D printing will be a revolutionary force in manufacturing,

whether positive or negative. Despite concerns over counterfeiting, many companies are already
using the technology to repeatable produce intricate components, for example in automotive and
aerospace manufacturing.

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

 The Book on 3D Printing Paperback – August 31, 2013 By Isaac Budmen

 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.3dprinting.com By Isaac Budmen

 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