A technical description for anyone interested in 3D printing.

Corey Campbell
August 1, 2014




Audience and Scope
The information in this document is intended to be a useful resource to anyone who wants to learn about
the 3D printing process. While technical terms are used in this document, no prior knowledge about
3D printing is expected.

In todays world the term 3D printing is used a lot, but what is 3D printing and how is it done? The
purpose of this document is to answer those questions. Specifically, this document will describe the
3D printing process. Attention will also be given to the various methods of 3D printing.

Introduction
3D printing is the process by which objects are constructed layer by layer through the deposition of
materials. 3D printing builds objects from 3D model data designed using CAD software or generated
using 3D scanning technology. The 3D model is sliced into layers to form virtual cross sections of
the 3D model. The cross sections are printed by a 3D printer one layer at a time.

Note: The term 3D printing is often used when referring to additive manufacturing (AM).

The 3D Printing Process

Three Methods to Obtain a 3D Model
When you use a desktop printer to print a document of picture, you are sending the printer a set of
instructions; those instructions tell the printer where to put ink on the paper. 3D printers also need
instructions, the difference is that there instructions for layers of a 3D model to print, not for a
document on paper. A 3D model can be made from two different methods, the use of CAD software
or 3D scanning.

1. Design a Model Using CAD Software
CAD software utilizes computers to design 3D models. This
method tends to be more difficult for people without
experience using CAD software, but through the use of
tutorials and hands-on experience, 3D models can be made by
almost anyone.

2. Use 3D Scanning to Digitize a Real World Object
Generate a 3D model of an object using a 3D scanner. 3D
scanning can take a real world object and make a virtual clone
of it. This method utilizes physical probes, optical probes, or
some other device to produce a digital copy of a real world
object. This method is a favorite among artists who like to
model their object in the real world before manufacturing.

3. Buy a 3D Model
3D models are sold online. These 3D models can be used in any
3D printer. This is a new emerging market place where
purchased models can be sent to local 3D print shops to make
the object or used in any other 3D printer the user may choose.

3D Model Undergoes Tessellation
3D printers use the extension STL for 3D model files. This file is
generated from the 3D model. The STL format, in binary and
ASCII forms, uses triangular facets to approximate the shape of an
object. The format lists the vertices, ordered by the right-hand rule,
and unit normals of the triangles, and excludes CAD model
attributes [1].

3D Model is Sliced into Layers
The STL file is sliced into layers that the 3D printer can produce. The thicknesses of the layers
determine how precise the object will be when it is constructed. The thinner the layer, the more layers
that are needed to make the object, the more precise the object will be.

Figure 1: Example of CAD software:
Solid Works [2].
Figure 2: VIUscan handheld 3D
scanner in use [3].
Figure 3: Example of tessellation:
Elephant Model with Quad
Tessellation [4].
3D Printer Constructs Model
With the layer information feed into the 3D printer and printing material in the printer, the 3D printing
process can begin. There are many different methods of 3D printing; different methods use different
materials. The printing process can take a very long time to complete depending on the 3D model and
the 3D printer. Some 3D printers utilize multiple print heads that can deposit different materials
allowing for various colors and metals to be used to make one part.


3D Printing Methods
There are many types of 3D printing methods that fall into several categories.
Extrusion
o Fused Deposition Modeling (FDM)
o Electron Beam Free Form Fabrication (EBF
3
)
Powder Bed
o Direct Metal Laser Sintering (DMLS)
o Electron Beam Melting (EBM)
o Selective Laser Melting (SLM)
o Selective Heat Sintering (SHS)
o Selective Laser Sintering (SLS)
o Inkjet Head 3D Printing
Lamination
o Laminated Object Manufacturing (LOM)
Light Polymerization
o Stereolithography (SLA)


Extrusion

Fused Deposition Modeling (FDM)
Also known as Fused Filament Fabrication (FFF), material is taken from a spool and extruded from a
heated nozzle as tiny beads to form layers. The beads harden once deposited. Materials used by this
method include: thermoplastics, rubber, modeling clay, porcelain, and metal clay.

Electron Beam Free Form Fabrication (EBF
3
)
An electron beam is used to melt material from a spool, binding the material together layer by layer. This
method is similar to EBM however it uses significantly less power and melts a much more focused
area which allows for more complex geometries to be constructed. Complex geometries allow for less
material to be used to make a part while adding more strength to the part than a conventionally built
part would have [7]. Metal wire is the main material used by this method. Using EBF
3
with multiple
material sources, various alloys can be made in such a way that the material chemistry can vary
throughout the model.


Figure 4: Fused deposition modeling:
1. nozzle ejecting molten plastic.
2. deposited material (modeled part).
3. controlled movable table [6].
Powder Bed

Direct Metal Laser Sintering (DMLS)
A laser is used to sinter powdered material, binding the material together layer by layer. As each layer is
formed, an apparatus dispenses new powdered material over the previous layer. Metal powder is the
main material used in this method.

Electron-Beam Melting (EBM)
An electron beam is used to melt powdered material, binding the material together layer by layer. As each
layer is formed, an apparatus dispenses new powdered material over the previous layer. Metal powder
is the main material used in this method.

Selective Laser Melting (SLM)
A laser is used to melt powdered material, binding the material together layer by layer. As each layer is
formed, an apparatus dispenses new powdered material over the previous layer. Metal powder is the
main material used in this method.

Selective Heat Sintering (SHS)
A laser is used to sinter powdered material, binding the material together layer by layer. As each layer is
formed, an apparatus dispenses new powdered material over the previous layer. Thermoplastic
powder is the main material used in this method.

Selective Laser Sintering (SLS)
A thermal print head is used to sinter powdered material, binding the material together layer by layer. As
each layer is formed, an apparatus dispenses new powdered material over the previous layer.
Thermoplastic powders, metal powders, and ceramic powders are all materials used by this method.


Figure 5: Selective laser sintering method [9].
Inkjet Head 3D Printing
Also known as binder jetting, an inkjet print head deposits a liquid binding material over a powdered
material, binding the material together layer by layer. As each layer is formed, an apparatus dispenses
new powdered material over the previous layer. Possible materials used by this method include:
plaster, sand, calcium carbonate, acrylic powder, ceramic powder, and sugar (used to make 3D
printed candy).


Lamination

Laminated Object Manufacturing (LOM)
Paper, plastic, or metal laminates are coated with an
adhesive and glued together and cut to shape using a
blade or laser. Materials used by this method include
paper, metal foil, and plastic film.


Light Polymerization
Stereolithography (SLA)
An UV laser or similar device is used to cure a photo-
reactive resin within a vat binding each layer to the
previous. The materials used by this process are
some type of photopolymer.


Future Development
3D printing is a relatively new technology which is being
developed more each day. Current research areas
include printing organs, food, nano-scale objects and
structures, and much more. One example of recent
development is the production of a functioning
human liver made by bioengineers.


Conclusion
3D printing is an exciting technology with tremendous possibilities. The 3D printing process can utilize a
variety of methods, but follows the same sub-processes.

Figure 6: Laminated object manufacturing:
1. Foil supply.
2. Heated roller.
3. Laser beam.
4. Scanning prism.
5. Laser unit.
6. Layers.
7. Moving platform.
8. Waste [10].
Figure 7: Stereolithography apparatus [11].
Glossary
3D printing, nthe fabrication of objects through the deposition of a material using a print head, nozzle, or another
printer technology [1].
CAD, nComputer-Aided Design. The use of computers for the design of real or virtual objects [1].
additive manufacturing (AM), na process of joining materials to make objects from 3D model data, usually
layer upon layer, as opposed to subtractive manufacturing methodologies [1].
subtractive manufacturing, nmaking objects by removing of material (for example, milling, drilling, grinding,
carving, etc.) from a bulk solid to leave a desired shape, as opposed to additive manufacturing [1].
3D scanning, na method of acquiring the shape and size of an object as a 3-dimensional representation by
recording x, y, z coordinates on the objects surface and through software the collection of points is converted
into digital data [1].
fused deposition modeling (FDM), na material extrusion process used to make thermoplastic parts through
heated extrusion and deposition of materials layer by layer; term denotes machines built by Stratasys, Inc. [1].
direct metal laser sintering (DMLS), na powder bed fusion process used to make metal parts directly from
metal powders without intermediate green or brown parts; term denotes metal-based laser sintering systems
from EOS GmbH - Electro Optical Systems. Synonym: direct metal laser melting [1].
thermoplastic, na plastic that repeatedly can be softened by heating and hardened by cooling through a
temperature range characteristic of the plastic, and that in the softened state can be shaped by flow into articles
by molding or extrusion [5].
sinter, vto increase the bonding in a mass of powder or a compact by heating below the melting point of the main
constituent [8].
STL, nin additive manufacturing, file format for 3D model data used by machines to build physical parts; STL is
the de facto standard interface for additive manufacturing systems. STL originated from the term
stereolithography [1].
binder jetting, nan additive manufacturing process in which a liquid bonding agent is selectively deposited to join
powder materials [1].
directed energy deposition, nan additive manufacturing process in which focused thermal energy is used to fuse
materials by melting as they are being deposited [1].
laser sintering (LS), na powder bed fusion process used to produce objects from powdered materials using one or
more lasers to selectively fuse or melt the particles at the surface, layer by layer, in an enclosed chamber [1].
material extrusion, nan additive manufacturing process in which material is selectively dispensed through a
nozzle or orifice [1].
material jetting, nan additive manufacturing process in which droplets of build material are selectively deposited
[1].
powder bed fusion, nan additive manufacturing process in which thermal energy selectively fuses regions of a
powder bed [1].
sheet lamination, nan additive manufacturing process in which sheets of material are bonded to form an object
[1].
stereolithography (SL), na vat photopolymerization process used to produce parts from photopolymer materials
in a liquid state using one or more lasers to selectively cure to a predetermined thickness and harden the
material into shape layer upon layer [1].
vat photopolymerization, nan additive manufacturing process in which liquid photopolymer in a vat is
selectively cured by light-activated polymerization [1].

Works Cited
[1] Standard Terminology for Additive Manufacturing Technologies, ASTM Standard F2792-12a, 2012, DOI: 10.1520/F2792-12A.

[2] SolidWorks CAD (recent)\measure_non-modal(demo),
http://files.solidworks.com/InternalMarketing/PressRoom/SolidWorks%20CAD%20%28recent%29%5Cmeasure_non-
modal%28demo%29.jpg.

[3] VIUscan handheld 3D scanner in use, http://upload.wikimedia.org/wikipedia/commons/2/26/VIUscan_handheld_3D_scanner_in_use.jpg.

[4] Quad Tessellation with OpenGL 4.0, removed background, http://prideout.net/blog/p49/Gumbo.png.

[5] Standard Terminology Relating to Plastic Piping Systems, ASTM Standard F412-13, 2013, DOI: 10.1520/F0412-13.

[6] FDM by Zureks, http://upload.wikimedia.org/wikipedia/commons/4/42/FDM_by_Zureks.png.

[7] National Aeronautics and Space Administration, Johnson Space Center, Technology Transfer & Commercialization Office, JSC Technology
Catalogue, NP-2013-05-004-JSC (Houston, TX: Technology Transfer & Commercialization Office, 2013), 43-44.

[8] Standard Terminology Relating to Plastic Piping Systems, ASTM Standard B243-13, 2013, DOI: 10.1520/B0243.

[9] Selective laser melting system schematic,
http://upload.wikimedia.org/wikipedia/commons/3/33/Selective_laser_melting_system_schematic.jpg.

[10] Laminated object manufacturing, http://upload.wikimedia.org/wikipedia/commons/a/a1/Laminated_object_manufacturing.png.

[11] Stereolithography apparatus, http://upload.wikimedia.org/wikipedia/commons/1/1e/Stereolithography_apparatus.jpg.