3D Printing

1.INTRODUCTION TO 3D PRINTING
3D printing is a form of additive manufacturing technology where a three dimensional
object is created by laying down successive layers of material. It is also known as rapid
prototyping, is a mechanized method whereby 3D objects are quickly made on a reasonably
sized machine connected to a computer containing blueprints for the object. The 3D printing
concept of custom manufacturing is exciting to nearly everyone. This revolutionary method
for creating 3D models with the use of inkjet technology saves time and cost by eliminating
the need to design print and glue together separate model parts. Now, you can create a
complete model in a single process using 3D printing. The basic principles include materials
cartridges, flexibility of output, and translation of code into a visible pattern.

Fig(i) : Typical 3D printer

3D Printers are machines that produce physical 3D models from digital
data by printing layer by layer. It can make physical models of objects
either designed with a CAD program or scanned with a 3D Scanner. It is
used in a variety of industries including jewellery, footwear, industrial
design, architecture, engineering and construction, automotive,
aerospace, dental and medical industries, education and consumer
products.

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2.HISTORY OF 3D PRINTING
The technology for printing physical 3D objects from digital data
was first developed by Charles Hull in 1984. He named the technique as
Stereo lithography and obtained a patent for the technique in 1986.
While Stereo lithography systems had become popular by the end of
1980s, other similar technologies such as Fused Deposition Modelling
(FDM) and Selective Laser Sintering (SLS) were introduced.
In 1993, Massachusetts Institute of Technology (MIT) patented
another
technology, named "3 Dimensional Printing techniques", which is similar
to the
inkjet technology used in 2D Printers.
In 1996, three major products, "Genisys" from Stratasys, "Actua
2100" from 3D Systems and "Z402" from Z Corporation, were introduced.

Fig(ii) : Side view of printing Process

In 2005, Z Corp. launched a breakthrough product, named Spectrum
Z510, which was the first high definition colour 3D Printer in the
market.Another breakthrough in 3D Printing occurred in 2006 with the
initiation of an open source project, named Reprap, which was aimed at
developing a self replicating 3D printer.

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The model to be manufactured is built up a layer at a time. A layer
of powder is automatically deposited in the model tray. The print head
then applies resin in the shape of the model. The layer dries solid almost
immediately. The model tray then moves down the distance of a layer and
another layer of power is deposited in position, in the model tray. The print
head again applies resin in the shape of the model, binding it to the first
layer. This sequence occurs one layer at a time until the model is
complete.

Fig(iii) : Manufacturing model

Very recently Engineers at the University of Southampton in the UK have designed,
printed, and sent skyward the worlds first aircraft manufactured almost entirely via 3-D
printing technology. The UAV dubbed SULSA is powered by an electric motor that is pretty
much the only part of the aircraft not created via additive manufacturing methods.

3D Printing
Fig(iv) : Aircraft manufacturing 3D printing technology
Created on an EOS EOSINT P730 nylon laser sintering machine, its wings, hatches
and control surfaces basically everything that makes up its structure and aerodynamic
controls was custom printed to snap together. It requires no fasteners and no tools to
assemble.

3.GENERAL PRINCIPLES
3.1 Modeling:
3D printable models may be created with a computer aided design (CAD) package or via a
3D scanner or via a plain digital camera and photogrammetry software.
The manual modelling process of preparing geometric data for 3D computer graphics is
similar to plastic arts such as sculpting. 3D scanning is a process of analysing and collecting
digital data on the shape and appearance of a real object. Based on this data, threedimensional models of the scanned object can then be produced.
Regardless of the 3D modelling software used, the 3D model (often in .skp, .dae, .3ds
or some other format) then needs to be converted to either a.STL or a .OBJ format, to allow
the printing (a.k.a. "CAM") software to be able to read it.

3.2 Printing:
Before printing a 3D model from an STL file, it must first be examined for "manifold
errors", this step being called the "fixup". Especially STL's that have been produced from a
model obtained through 3D scanning often have many manifold errors in them that need to be
fixed. Examples of manifold errors are surfaces that do not connect, gaps in the models,
Examples of software that can be used to fix these errors are netfabb and Meshmixer, or even
Cura, or Slic3r.
Once that's done, the .STL file needs to be processed by a piece of software called a
"slicer" which converts the model into a series of thin layers and produces a G-code file
containing instructions tailored to a specific type of 3D printer (FDM printers). This G-code
file can then be printed with 3D printing client software (which loads the G-code, and uses it
to instruct the 3D printer during the 3D printing process). It should be noted here that often,
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the client software and the slicer are combined into one software program in practice. Several
open source slicer programs exist, including Skeinforge, Slic3r, and Cura as well as closed
source programs including Simplify3D and KISSlicer. Examples of 3D printing clients
include Repetier-Host, ReplicatorG, Printrun/Pronterface, ....
Note that there is one other piece of software that is often used by people using 3D
printing, namely a GCode viewer. This software lets one examine the route of travel of the
printer nozzle. By examining this, the user can decide to modify the GCode to print the model
a different way (for example in a different position, e.g. standing versus lying down) so as to
save plastic (depending on the position and nozzle travel, more or less support material may
be needed). Examples of GCode viewers are Gcode Viewer for Blender and Pleasant3D.
The 3D printer follows the G-code instructions to lay down successive layers of
liquid, powder, paper or sheet material to build the model from a series of cross sections.
Materials such as plastic, sand, metal, or even chocolate can be used through a print nozzle.
These layers, which correspond to the virtual cross sections from the CAD model, are joined
or automatically fused to create the final shape. Depending on what the printer is making, the
process could take up to minutes or days. The primary advantage of this technique is its
ability to create almost any shape or geometric feature.
Printer resolution describes layer thickness and X-Y resolution in dots per inch (dpi)
or micrometres (m). Typical layer thickness is around 100 m (250 DPI), although some
machines such as the Objet Cornex series and 3D Systems' Project series can print layers as
thin as 16 m (1,600 DPI). X-Y resolution is comparable to that of laser printers. The
particles (3D dots) are around 50 to 100 m (510 to 250 DPI) in diameter.
Construction of a model with contemporary methods can take anywhere from several hours
to several days, depending on the method used and the size and complexity of the model.
Additive systems can typically reduce this time to a few hours, although it varies widely
depending on the type of machine used and the size and number of models being produced
simultaneously.
Traditional techniques like injection moulding can be less expensive for manufacturing
polymer products in high quantities, but additive manufacturing can be faster, more flexible
and less expensive when producing relatively small quantities of parts. 3D printers give
designers and concept development teams the ability to produce parts and concept models
using a desktop size printer.

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3.3 Finishing:
Though the printer-produced resolution is sufficient for many applications, printing a slightly
oversized version of the desired object in standard resolution and then removing material
with a higher-resolution subtractive process can achieve greater precision.
Some printable polymers allow the surface finish to be smoothed and improved using
chemical vapour processes.
Some additive manufacturing techniques are capable of using multiple materials in the course
of constructing parts. These techniques are able to print in multiple colours and colour
combinations simultaneously, and would not necessarily require painting.
Some printing techniques require internal supports to be built for overhanging features during
construction. These supports must be mechanically removed or dissolved upon completion of
the print.
All of the commercialized metal 3-D printers involve cutting the metal component off
of the metal substrate after deposition. A new process for the GMAW 3-D printing allows for
substrate surface modifications to remove aluminium components manually with a hammer.

4. WORKING OF 3D PRINTING
The fundamental purpose of a 3D printer is to quickly transform an idea into a
physical object. That idea is usually first embodied in a 3D computer model created in 3D
CAD software like SolidWorks, Autodesk Inventor or Pro/ENGINEER.
All of these software tools export 3D models as files in standard formats for 3D
printing, including .STL, .WRL(VRML), .PLY, .3DSand .ZPR. The exported file is a mesh,
or series of triangles oriented in space, that enclose a 3D volume. This mesh must be water
tight so that the model is a solid, not just surfaces that may not have any thickness. In other
words, the design at this point must be ready to exist in the real world, not just on a computer.
With the file now in a printable format, you launch ZPrint software on your PC.
Using ZPrint, you can scale up or scale down the file you wish to print, orient the part in the
build chamber, and direct the 3D printer to print multiple versions of the part in the same
build (with or without variations).
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3D Printing
Then ZPrint slices the 3D model file into hundreds of digital cross-sections, or layers.
Each 0.004 inch (0.1 mm ) slice corresponds to a layer of the model to be fabricated in the
ZPrinter .
Sample CAD Software
Producing 3D Printingready Files
3D studio Max
Microstation
3Dstudio viz

Mimics

Alias

Pro/engineer

AutocAD

Bentley triforma

raindrop
geoMagic
rapidform

Blender

rasMol

cAtiA

revit

cosMos

rhinoceros

form Z

sketchup

inventor

solid edge

lightwave 3D

solidworks

Magics e-rP

ugs nX

Maya

vectorworks

When ready to start the print job, you click 3D Print. This sends the digital layer
files to the ZPrinter, and the model begins printing immediately.
The ZPrinter prints each layer, one atop another, as the physical part is constructed
within the build chamber of the machine. Well detail how the ZPrinter accomplishes this task
next. Once the ZPrinter completes the final layer, a short drying cycle runs. Then the physical
object can be removed

The 3D printing process

CAD software exports files in standard formats for 3D printing.the exported
file is a mesh that encloses a 3D volume.
CAD software exports files in standard formats for 3D printing.
the exported file is a mesh that encloses a 3D volume.

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ZPrint
1.2 ZPrint software

Lay
ers

slices the 3D
model file into
hundreds of
digital crosssections, each
corresponding to a layer of the model to be printed.

Fig(v) : Inside the Printer

3D Printing
A. Automatic air filter: ensures that all powder stays within the confines of the machine,
emitting only clean air into the office or workroom environment.
B. Binder cartridge: contains the water-based adhesive that solidifies the powder.
C. Build chamber: the area where the part is produced.
D. Carriage: slides along the gantry to position the print heads.
E. Compressor: generates compressed air to depowder finished parts.
Debris filter: prevents any solids from entering the hopper during post-build powder
recycling, ensuring a clean next build
F. Electronics box: on-board computer controlling all the action of the ZPrinter.
G. Gantry: horizontal bar that travels back and forth across each build layer.
H. Hopper: contains powder from which the model is created.
I. Reservoir: collects binder from the binder cartridges, and supplies binder to the gantry.
K. Service station: automatically cleans the print heads as required.
L.

Vacuum valve: the brains of the powdering system, vacuuming powder from the build

chamber, overflow, depowering station or vacuum hose back to the hopper.

5.Methods of 3d Printing
There are a few different methods of 3d printing, of which I will explain the pro's and
con's for instrument making.

5.1 Selective laser sintering (SLS)

This method uses a high powered laser to melt powder together. When set up
carefully, this can create an almost perfectly uniform material of nearly injection mold
quality. This make for very durable products. This is very interesting for musical instruments,
as this allows us to create objects with the same materials as conventional instruments, but
with the ease of printing instead of manual labour. The method is relatively simple, due to
inherent supports it avoids additional step in between the 3d model and printing. The surface
quality is fair, but not as detailed as other techniques.
Materials : Plastics, Elastomers, Metal, Ceramics, Glass
Product example

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Machines which use this technique1

5.2 Stereolithography (SLA)

A layer of fluid resin is hardened by UV or laser. It makes for great surface quality
and build accuracy. Useful, as this removes the need for post-finishing. But the products
remain brittle, which disqualifies this method for musical instruments, because an instrument
which could break during performance, is no use at all.
Materials
Epoxy polymers, both rigid or flexible

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Product example

Machines which use this technique

5.3 Polyjet or Jetted Photopolymer (J-P)

Extrudes a photo polymer which hardens with UV light. Can create rubber-like
objects. This could be interesting for creating one-piece string instruments (is 1 - 20 MPa
Tensile strength enough??
Materials
Photopolymers, both solid as rubber-like.
Product example

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Machines which use this technique

5.4 Fused deposition modelling/fused filament fabrication (FDM/FFF)
The most seen 3d printing method, as most inexpensive machines use this method.
(Usually) A plastic wire is molten and laid down in layers. Inherently unsolid material,
always has air-spaces and fuse lines. In default setting this provides a material which is not
interesting for musical instruments, but with a careful setup, the air spaces could be tuned, so
it could resonate in a controlled fashion. A big advantage is that is method is used in the
cheapest and most common 3d printers. This is also the method that seems to make most
promise for cheap home printers.
Materials
ABS, PC, concrete, chocolate, icing and other food
Product example

Machines which use this technique

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5.5 Cladding or Laser Powder Forming or Laser Fusing

Instead of feeding the printing head a solid core of material, a powder is fed. This
provides a more accurate method. It creates a full density product without porosity or weldlines. A method for making very detailed and small parts. This method seem perfect for 3d
printing replica's of mouthpieces. The biggest disadvantage is that this is one of the most
expensive 3d printing methods.
Materials
Metal, Ceramic, Polymer
Product example

Machines which use this technique

5.6 Laminated object manufacturing or LOM
Sheets of raw material are laid on each other, after which it will be cut out by laser or
knife. Objects can get wood-like properties, by simulating year ring.
Materials
Paper, Plastic or Metals.

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Product example

Machines which use this technique

6.Advantages of 3D Printing
As anticipated, this modern technology has smoothed the path for
numerous new possibilities in various fields. The list below details the
advantages of 3D printing
in certain fields.
1. Product formation is currently the main use of 3D printing technology.
These
machines allow designers and engineers to test out ideas for dimensional
products
cheaply before committing to expensive tooling and manufacturing
processes.
2. In Medical Field, Surgeons are using 3d printing machines to print body
parts
for reference before complex surgeries. Other machines are used to
construct bone
grafts for patients who have suffered traumatic injuries. Looking further in
the
future, research is underway as scientists are working on creating
replacement

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organs.
3. Architects need to create mock-ups of their designs. 3D printing allows
them to
come up with these mock-ups in a short period of time and with a higher
degree of
accuracy.
4. 3D printing allows artists to create objects that would be incredibly
difficult,
costly, or time intensive using traditional processes.

6.1 3D Saves Time and Cost

Creating complete models in a single process using 3D printing has great
benefits.
This innovative technology has been proven to save companies time,
manpower
and money. Companies providing 3D printing solutions have brought to
life an efficiency.

7.Applications
7.1 Industry use
As of October 2012, Stratasys now sells additive manufacturing systems that range from
$2,000 to $500,000 in price and are employed in several industries: aerospace, architecture,
automotive, defense, and dental, among many others. For example, General Electric uses the
high-end model to build parts for turbines.

7.2 Consumer use

Printing in progress in a Ultimaker 3D printer during Mozilla Maker party, Bangalore
Several projects and companies are making efforts to develop affordable 3D printers for
home desktop use. Much of this work has been driven by and targeted at DIY/enthusiast/early
adopter communities, with additional ties to the academic and hacker communities.
RepRap is one of the longest running projects in the desktop category. The RepRap project
aims to produce a free and open source hardware (FOSH) 3D printer, whose full
specifications are released under the GNU General Public License, and which is capable of
replicating itself by printing many of its own (plastic) parts to create more machines.
RepRaps have already been shown to be able to print circuit boardsand metal parts.

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Because of the FOSH aims of RepRap, many related projects have used their design for
inspiration, creating an ecosystem of related or derivative 3D printers, most of which are also
open source designs. The availability of these open source designs means that variants of 3D
printers are easy to invent. The quality and complexity of printer designs, however, as well as
the quality of kit or finished products, varies greatly from project to project. This rapid
development of open source 3D printers is gaining interest in many spheres as it enables
hyper-customization and the use of public domain designs to fabricate open source
appropriate technology. This technology can also assist initiatives in sustainable development
since technologies are easily and economically made from resources available to local
communities.
The cost of 3D printers has decreased dramatically since about 2010, with machines
that used to cost $20,000 now costing less than $1,000 For instance, as of 2013, several
companies and individuals are selling parts to build various RepRap designs, with prices
starting at about 400 / US$500. The open source Fab@Home project has developed printers
for general use with anything that can be squirted through a nozzle, from chocolate to silicone
sealant and chemical reactants. Printers following the project's designs have been available
from suppliers in kits or in pre-assembled form since 2012 at prices in the US$2000
range.The Kickstarter funded Peachy Printer is designed to cost $100 and several other new
3D printers are aimed at the small, inexpensive market including the mUVe3D and Lumifold.
Rapide 3D has designed a professional grade crowdsourced 3D-printer costing $1499 which
has no fumes nor constant rattle during use. The 3Doodler, "3D printing pen", raised $2.3
million on Kickstarter with the pens selling at $99, though the 3D Doodler has been criticised
for being more of a crafting pen than a 3D printer.
As the costs of 3D printers have come down they are becoming more appealing financially to
use for self-manufacturing of personal products. In addition, 3D printing products at home
may reduce the environmental impacts of manufacturing by reducing material use and
distribution impacts.
In addition, several RecycleBots such as the commercialised Filastruder have been
designed and fabricated to convert waste plastic, such as shampoo containers and milk jugs,
into inexpensive RepRap filament. There is some evidence that using this approach of
distributed recycling is better for the environment.
The development and hyper-customization of the RepRap-based 3D printers has
produced a new category of printers suitable for small business and consumer use.
Manufacturers such as Solidoodle, RoBo, RepRapPro and Pirx 3D have introduced models
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and kits priced at less than $1,000, thousands less than they were in September 2012.
Depending on the application, the print resolution and speed of manufacturing lies
somewhere between a personal printer and an industrial printer. A list of printers with pricing
and other information is maintained. Most recently delta robots, like the TripodMaker, have
been utilised for 3D printing to increase fabrication speed further. For delta 3D printers, due
to its geometry and differentiation movements, the accuracy of the print depends on the
position of the printer head.

7.3 Large 3D printers

Large 3D printers have been developed for industrial, education, and demonstrative
uses. A large delta-style 3D printer was built in 2014 by SeeMeCNC. The printer is capable
of making an object with diameter of up to 4 feet (1.2 m) and up to 10 feet (3.0 m) in height.
It also uses plastic pellets as the raw material instead of the typical plastic filaments used in
other 3D printers.

Another type of large printer is Big Area Additive Manufacturing (BAAM). The goal
is to develop printers that can produce a large object in high speed. A BAAM machine of
Cincinnati Incorporated can produce an object at the speeds 200-500 times faster than typical
3D printers available in 2014. Another BAAM machine is being developed by Lockheed
Martin with an aim to print long objects of up to 100 feet (30 m) to be used in aerospace
industries

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8.Limitations

Process is slow

Components do not have enough strength.

COST OF RAW MATERIALS

3-D printers are still expensive.

Misuse of technology

Although 3-D printers have the potential of creating many jobs and
opportunities, they might also put certain jobs at risk .

Oral.below example

(for example, you can make your toys at home so toy stores and toy makers might go
out of business).

9.Future Scenarios
It is predicted by some additive manufacturing advocates that this technological
development will change the nature of commerce, because end users will be able to do much
of their own manufacturing rather than engaging in trade to buy products from other people
and corporations.
3D printers capable of outputting in colour and multiple materials already exist and
will continue to improve to a point where functional products will be able to be output. With
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effects on energy use, waste reduction, customization, product availability, medicine, art,
construction and sciences, 3D printing will change the manufacturing world as we know it.

10.Conclusion
3D Printing technology could revolutionize and re-shape the world. Advances in 3D
printing technology can significantly change and improve the way we manufacture products
and produce goods worldwide. An object is scanned or designed with Computer Aided
Design software, then sliced up into thin layers, which can then be printed out to form a solid
three-dimensional product. As previously described, the importance of an invention can be
appraised by determining which of the human needs it fulfills.
As shown, 3D printing can have an application in almost all of the categories of
human needs as described by Maslow. While it may not fill an empty unloved heart, it will
provide companies and individuals fast and easy manufacturing in any size or scale limited
only by their imagination. One of the main advantages of the industrialization revolution was
that parts could be made nearly identically which meant they could be easily replaced without
individual tailoring.
3D printing, on the other hand, can enable fast, reliable, and repeatable means of
producing tailor-made products which can still be made inexpensively due to
automation of processes and distribution of manufacturing needs. If the last
industrial revolution brought us mass production and the advent of
economies of scale - the digital 3D printing revolution could bring mass
manufacturing back a full circle - to an era of mass personalization, and a
return to individual craftsmanship.

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11.References
http://www.explainingthefuture.com/3dprinting.html
http://en.wikipedia.org/wiki/3D_printing
http://www.mahalo.com/3d-printers/
http://net.educause.edu/ir/library/pdf/DEC0702.pdf
http://www.inventioncity.com/intro-to-3-d-printing.html
http://desktop3dprinters.net/773374/3d-printing-technologies

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