PRACTICUM

ADDITIVE MANUFACTURING

(3D PRINTING)

FUNDAMENTAL OF SYSTEM ENGINEERING

Instructor: Dr. Robert J. Cloutier

Student: Bikash Ranabhat

J00563923

Date: 12/5/2016

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 Table of Contents

1.0 System of Interest overview . 3

2.0Stakeholder Desirements . 5
3.0System Purpose and Concepts of Operations . 6
4.0Context diagram . 14
5.0System requirements . 16
6.0Functional definition . 18
7.0Conclusions 25

1.0 System of interest overview

Additive manufacturing is a technology in which a part can be built layer by layer to
desired geometry based on a computer aided design (CAD) model. With additive
manufacturing, complex parts can easily be built in reasonable timeframes [1-3]. It is
necessary to be familiar with the terms additive manufacturing, rapid prototyping,
and 3D printing as these terms are frequently used these days.AM refers to the
process of adding and joining material layer- by layer to form a part. Rapid prototyping
is a process for rapidly creating a system or part representation before the final release
or commercialization [4].3D printing is interchangeably used with AM.
Subtracting manufacturing(SM) has significant limitations. SM yield the desired parts
by selectively removing material from the materials with series of cutting operations
example include cutting, drilling, milling, abrasive machining, turning, and electro-

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discharge machining. Since the desired part is produced by the removal of material
there is loss of material, if the material is expensive SM could be highly undesirable.
Moreover, it is cumbersome for complex parts and deep internal features. AM
manufacturing overcome these limitations as it prints the parts by adding layer and layer
and can print complex parts. As AM machines use a single material deposition tool to
build the entire part, which saves time since no part refixturing, zeroing, or tool setup is
necessary [5].

Fig.3.Subtracting manufacturing(SM) technologies carve a final part from a stock

geometry of material (a) while additive manufacturing (AM) technologies deposit
material in prescribed locations to build the final part (b) [6].
3 D printing have become more and more prominent in the past few years as new
materials and processes have expanded the capabilities and lowered the cost to the point
where small business and even individual consumers can now afford to create their own
3 dimensional objects. Medical applications of 3 D printing are also starting to appear.
These applications are surprisingly varied. 3 D printing is moving in several directions
now and all indications are that it will continue to expand in many area in future. Some
of the prominent areas include medical applications, aerospace and defense, custom
parts replacement, and customized consumer products. Manufacturing in the future will
boom with this the use of this technology, which will save our cost and time.

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 Fig: 3D Printer

Fig: Printing complex object

2.0 Stakeholder Desirements:

Some stakeholder Desirements or voice of customers are as follows:
1. 3 D printer needs to print the models that ranges from simple like small square box
to complex like bird inside the cage.
2. It needs to support various ranges of materials like polymers, metals, ceramics &
composites.
3. Printing head needs to have multiple axis of freedom.
4. Printing should be smooth and make less noise.
5. Rapid Cooling of printing head.
6. It needs to support multiple file type for printing.
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 7. Printer needs to have higher resolution.
8. Build volume should be 223*223*305mm.
9. The parts printed should not stick to bed.
10. Automatic levelling of printing bed.
11. Fault indication with beep sound should be generated in case of any faults.
12. Cost to produce part should be less.
13. High Travel speed.
14. Swappable Nozzles for greater control.
15. Supports Windows/Mac/Linux.
16. Allow to print from SD card.
17. Software needs to be user friendly.
18. High Positioning precision in X/Y/Z
19. Exhaust fumes generated during printing.
20. Clear monitoring of printing process.
21. Consume low energy.
22. Clogged nozzle indicator on when clogged.
23. Geared feeder for greater reliability.
24. Wi-fi and Ethernet Connectivity
25. Built in camera
Table: Concept Selection-Pugh Matrix for 3 D printing of polymer composite
Fused Selecti
Three- Laser Laminated
depositi ve Paste
Stereolith dimensio engineer Polyj object
on laser extrusi
ography nal ed net et manufacturi
modeli sinterin on
Printing shaping ng
ng g
Simple to use 1 1 1 0 -1 0 0 0

Set up cost 1 0 1 0 0 0 0 0
Cost-low
1 1 0 1 1 1 0
volume
Surface
0 -1 -1 -1 -1 1
finish
Integrated
1 1 1 1 0 1 0 0
Assembly
Complexity 1 1 1 1 1 1 1 1
Customizabil
1 1 0 1 0 1 0 0
ity
Resolution 0 1 1 1 1 0 0 1

Total 6 5 4 4 1 3 2 3

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Pugh matrix choose Fused Deposition modeling over other Additive Manufacturing technique
with polymer composite.

3.0 System purpose and concept of operations

3 D printing is transforming three- dimensional models into physical objects that is
tangible and feels in hand. It is also called Additive manufacturing as the 3 D model is
created by adding layers upon layers of material until the object is fully formed.
Process:
1) Make or download a 3D model
2) Slice and export the 3D model
3) Build the 3D model
1) Make or download a 3D model: Currently, there are three ways of creating a 3D
model.
Designing from scratch: Free CAD (computer -aided design) software such as
AutoCAD, SolidWorks, Pro-E to design own 3D model.
3D Scanners: An alternative method to create 3 D model is to scan an object.3D
scanners work by digitizing a physical object, collecting its geometric data, and
saving it to a file on PC.
From the cloud; the most popular way of obtaining a 3D model is to download it
from websites that allow users to upload 3D models that they designed.
2) Slice and Export the 3D Model: Slice software is the software that prepares 3D
models for printing and turns them into instructions for the 3D printers. Example: Flash
Print is the slicing software used for the Flash Forge Creator Pro.
3) Build the 3D Model: Once the output file has been transferred to the printer, it will
start to turn the 3D model into a physical object by laying down layers of filament.
There have been different techniques developed for AM. In general, different
techniques share a common layer-by layer deposition process whereas 2-dimensional
pattern is first printed on the xy plane to form a single layer, followed by deposition of
subsequent layers along the z axis to generate a 3-dimensional structure. Because of this
universal printing strategy, a universal STL file, developed by 3D system is commonly
used to generate the layer printing structure. Different software, including CAD,
Sketch UP etc., can be used to draw the desired 3 D structure. The computer program
then analyzes the structure and slices it to certain number of different layers to convert it
to STL format. The corresponding STL file will then be converted to the file type that

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can be ready by specific 3 D printers. After loading the compatible file into the 3D
printer, the structure will be printed based on the slicing of STL file [15].
3 D printing has been mostly use for the designing of the prototype till date but the
advancement in the materials and technology has made it possible to use this
technology to produce functional parts. Subtracting manufacturing has been the
backbone of manufacturing till date but this technology cost too much of waste of
material which in intolerable in case where material cost is too high. Moreover, the time
required for subtracting technology is also very much.
Some the additive manufacturing technique are described below:
1. Fused deposition modeling
Fused deposition modeling (FDM) is an additive manufacturing process used to make
thermoplastic parts through heated extrusion and deposition of materials layer by layer
[8]. FDM continues to be versatile process for rapid manufacturing of extrusion
materials in applications including short-run tooling molds, casting end-use parts, and
more [9]. Extrusion based techniques greatest strength is its versatility of
manufacturing across length scales as shown in fig.4.

Fig.4. extrusion-based AM can operate from the micro to macro scale [10]

Instead of using a mold and high temperature heating, FDM heats the filament a little
above its melting temperature, extrudes to generate thin fiber with diameter around
0.25mm and deposits onto a platform in a 2-dimensional pattern, where it cools below
melting point and solidifies immediately. Another layer will be subsequently deposited
on top. One limitation of FDM is that the printing mechanism involves melting and
extrusion, thus only thermoplastic polymer can be printed [12]. With the continued
improvement of printing head technologies, several companies, including Stratasys and
Arevo labs, have successfully printed high performance polymer with FDM, for
example Polyphenylsulfone(PPSU), Polyehteretherketone(PEEK),
Polyaryletherketone(PAEK) etc. [11-12].

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 Fig.5. Schematic of FDM process [13].

2. Stereolithography
This technique is based on a photoinitiated polymerization printing mechanism [14].
The material that can be printed by SLA should be photocurable. Liquid resin composed
of photocurable monomer/oligomer, photo initiator and other additives, is placed in a
reservoir where a building platform is used to control the motion of resin. Two printing
directions, bottom-up and top-down [15] are applied in different SLA printers, as shown
in fig.6.

Fig.6. Schematic diagram of SLA setup. Left: top-down printing SLA; Right: bottom-
up printing SLA [16].

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For the top-down approach, the building platform is lifted to the surface of resin bath so
that the resin flows to the bottom and only a thin layer of resin, with a thickness equal to
layer thickness in sliced STL file, is on top of the platform. During printing, laser
light shown with specific wavelength shone from top initiate polymerization. Once a
layer is printed the platform will lower down and roller will place another layer of resin
on top of solidified resin for subsequent curing. On the other hand, the building
platform of the bottom-up printer is moved to a position near the bottom where a
narrow gap will be left between the reservoir and the platform so that a thin layer of
resin can be placed inside the gap. The laser light will be shone from beneath the
reservoir to cure exposed resin. After printing each layer, platform will be lifted to
expose another thin layer of resin. In this case roller requirement is not avoided due to
the gravity effect [12].

Fig. schematic diagram of three-dimensional printing (3DP) set up.

3. Selective laser sintering
This is also powder based technique like 3DP. Instead of liquid binder, SLS shines a
high-power laser selectively sinter the powder particles, which fuse powder to form a 2-
dimansional pattern. The platform is also heated a little below melting point of building
powders so that the heating dissipation and distortion can be diminished [18]. The
surface finish of SLS is better than 3DP but not as SLA, printing cost is high due to use
of high power laser source [17].

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 Fig. Selective laser sintering (SLS)

4. Laser engineered net shaping

This is also powder based technique which uses nozzle to spray powder onto a substrate
and high power laser is shone to simultaneously melt the sprayed powder. Subsequent
molten layer will deposit onto previous layer to form a 3 D structure [22]. This
technique could be used to repair damaged parts as there is no need to build a platform.

Fig. Laser engineered net shaping

5. Polyjet

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Polyjet is a photopolymerization printing technique; the resin is supplied via injection
from a printing head to form a 2-dimensional pattern. UV light is shone right after to
cure and solidify the injected resin. This technique can be used to print different resin
materials in one part together. Although resolution of Polyjet is very high, its
mechanical strength is weaker than SLA or SLS [20, 21].

Fig. Polyjet
6. Laminated object manufacturing
It is a combination of subtractive and additive manufacturing. Subtractive component of
the process form a 2-dimensional pattern from the bulk material sheet. Additive
component involves the adhesion of one layer of bulk material sheet to another to form
a 3-dimensional structure [22].

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 Fig. Laminated object manufacturing
7. Paste extrusion printing
Paste extrusion printing, also called direct-writing 3D printing, is a newly developed
technique [24, 25]. The process is like FDM except instead of filament it uses printable
ink, which is highly viscous and shear thinning fluid composed of single or multiple
components. The ink needs to have lower viscosity while being extruded to flow
smoothly and solid like after extrusion to maintain its shape as well as to support the
subsequent layers [26].

Fig.7. Schematic of paste extrusion printer setup a) full setup, b) deposition from
printing nozzle, c) the printed paste [27].

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 Challenges with 3D printing
Print speed: most of the 3D printers function in the Cartesian plane where the
movements gets restricted to vertical and horizontal direction. The time
necessary for printing objects is increased and chances of errors increases.
Material mixing: It is quite difficult to find a printer that can mix different
materials to print a single object.
Finished product: failure rate is high with 3D printers. So most popular uses
for 3D printing are limited to prototyping. The required safety standard does
not comply with normal standards in the more advanced countries.
Energy inefficiency: 3D printers consume 50 to 100 times more energy as
compared to energy consumed during the conventional moulding of plastic.
Health risk: the printer emits particles like the kind given off by cigarettes
which can cause serious health related issues.
3D printing security: Hackers can get into the system and destroy the system
or can make system to work differently.
4.0 Context Diagram

Aerospace & Architecture

Defense
Environment

Automotive

Maintenance
and diagnostic

Medical Device
Prototyping
Electricity 3D Printing

Entertainment

Commercial
product
prototyping

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 Education

Consumer
products Digital Dentistry
prototyping

Fig. context diagram

Aerospace and defense industry: The use of 3D printed parts in Aerospace

industry reduce fuel costs and increase payload. The late design changes are
possible with 3D printer so the impact of design change is softened. It
provides maximum flexibility.3D printers avoid high machining costs for
parts that can be built from durable thermoplastics and even greater
complexity wont cost too much. Custom tools and parts for individual
repairs and restorations can be easily created using this technology. They play
an important role in eliminating high costs for low-volume parts in these
industries.
Automotive industry: The use of 3D printers in Automotive industry enables
continuous production for individual parts and thus, prevents losses that take
place during normal production process. They could be helpful in situation
where manufacturers need traditional part, which is not included in mass
production, they can be easily printed simply settings on the printer. The
possibilities when it comes to design flexibility are far vaster with 3D
printing. Audi is using 3D printing to produce spare parts and disrupted the
whole supply chain. Many customers currently must wait for dealers to order
parts from a central silo and that is a time consuming and costly exercise. In
future, accredited service centers could simply print the part as and when they
need it. The revolution in Automotive industry is possible with the
development of 3D printing technology.
Architectural industry: 3D printer is a game changer for the architectural
design. The model can be printed and modification required can be done in a
less time as it offers more flexibility in design. The model can be printed in
different scale from small to large that gives the real scenario of the design.
3D printer has reduced the time to prepare of handmade model so in short
period, model can be prepared for the project.

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 Commercial products prototyping: Commercial manufacturers with 3D
printing capabilities have the power to say yes to more opportunities, when
clients make tough demands. Designers and engineers can skip expensive,
time intensive machining and gain the agility to make changes any time.
Consumer product prototyping: Consumer have grown incredibly discerning
and they have keener eye for aesthetics, a greater expectation for
customization and less patience for products that arent just right. 3D printers
in customer product prototyping improve customization, turn great ideas into
successful products, maintain confidentiality and avoid IP theft by keeping
sensitive designs in-house until youre ready to unveil the product.
Dental: 3D printing in dental and orthodontic labs can speed production while
improving quality and precision. By combing oral scanning, CAD/CAM
design and 3D printing, dental labs can accurately and rapidly produce
crowns, bridges, stone models and a range of orthodontic appliances. With
the aid of 3D printer dental labs eliminate the bottleneck of manual modeling
and let the business grow.
Education: Presence of 3D printer quickly turn idea to prototypes and keeps
student engaged. And it gives them time to explore more ideas, analyze
problems in-depth, and develop the persistence they will need to excel in
todays fastest growing and most rewarding fields. They are powerful to
convey the meaning and importance of research with realistic models that
illustrate the findings in vivid detail. 3D printing in research field save time
by making lab more efficient and responsive. 3D printed custom fixtures and
lab instruments improve accuracy, repeatability and safety.
Entertainment: Effects studios, filmmakers and game designers use 3D
printing technology in some of their most demanding projects. Hollywood
special effects studio Legacy Effects uses 3D printing to make blockbuster
movies like farm family.
Medical: 3D printing empowers doctors, researchers and medical device
manufacturers to work faster, test more thoroughly and personalize care like
never. They have been extensively use in the medical field to medical training
models, personalized patient care, medical device innovation, preclinical
device testing, medical manufacturing, sales aids and demos, orthotics,
Prosthetics and Bionics, etc.
Maintenance and diagnostic: Maintenance and diagnostic is equally
important to keep the system useful and upgrade. Timely maintenance and
diagnostic will improve the system efficiency and monitor the possible
problems before it arrives.
Electricity: Electricity is the backbone of the 3D printing system s it runs
only with electrical supply.

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5.0 System Requirements:
The system shall print the simple and complex models.
3D printers shall support wide range of materials for printing.
The system shall produce noise below 100dB.
3D printers shall have at least 6 degrees of freedom.
3D printers shall have effective air cooling for extruders and bed.
The system shall support. STL, OBJ, VRML,.X3G, PLY, FBX file type for printing.
The system shall have resolution below 200-micron.
3D printers shall have automatic printing bed levelling.
The printed parts shall be easily taken out of the system without sticking in the
printing bed.
The system shall feature safety features to indicate faults in the system.
The cost to produce part by the system shall be less than 0.06/cm3.
The system shall have travel speed 30mm/s-300mm/s when not printing.
The system shall support windows/Mac/Linux.
The system shall be able to print using SD card, computers, laptops.
The system shall use open source software.
The system shall consume average 110 watts in 30 mins.
The system shall have Wi-fi and Ethernet connectivity.
The system shall have built in camera to monitor the process.
The system shall effectively exhaust the fumes generated during printing
The system shall have set up cost of $1000 for normal small size printing.
The system shall have clear instructions for the user to use the system.
The printed part by the system shall have mechanical properties as produce by the
others method.
The system shall have material mixing capabilities to print the object.
The system shall have low failure rate.
The system shall not produce any health risk to the users.
The system shall have strong printing security.
The system lifecycle should not affect the natural environment.
The system shall be timely monitored for the maintenance
The system used in Aerospace and Defense industry shall be able to reduce fuel cost
and increase payload by printing less weight object.
The system shall offer maximum flexibility to the design engineers for rapid changes
and modification in printing object.

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6.0 Functional definition:
The use of most feature rich software CORE helped to present requirement, functional,
and component diagram of 3D printer clearly. The images from the software are
presented below.

Fig: 3D printing hierarchy

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Some details which are hiding on the above hierarchy diagram are presented below in
details. The stakeholder and system requirements are followed by the function (which
will state how that requirement will be fulfilled) then component (which will perform
that function is a basic structure to accomplish the requirement of customer).

Fig: Hierarchy of requirement allow print from SD card.

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 Fig: Clear monitoring of process

Fig: Hierarchy diagram for automatic printing bed level

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 Fig: hierarchy of print simple to complex model

Enhanced function flow block diagram:

Fig: EFFBD for levelling of bed

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Fig: EFFBD diagram for accepting SD card.

Fig: EFFBD for activate monitoring chart

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Fig: IDEF0 diagram

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Fig: component diagram

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Fig: House of Quality

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7.0 Conclusion:
After going through the fundamentals of system engineering course, I realized system
engineering typically follows top-down processing approach which means big picture first.
System engineering is driven by the users/stakeholder requirements, these requirements are
translated to concepts and to system requirements which follows analysis-synthesis-
evaluation to have tangible, visible physical system. So as a system engineer it is our first
duty to know our stakeholders requirements. To get the fertile information out of
stakeholder, system engineer must ask why five times and system engineer should be
active listener and able to paraphrase their requirements in their words. By the time
system-level architecture and high level design is complete 85 % of the total costs will be
used, this is the area where system engineers come into the picture. So, system engineers
are the backbone in design of large complex system. Investing in system engineering
during the big project has a huge pay off in the system design.
The best part of practicum which I enjoyed most is the use of highly feature software
CORE. As a system engineer in the future this software could really help a lot to design a
system. Through the requirements diagrams hierarchy, it is easy to communicate between
the customers and engineers and it saves time to know the system. The diagram clearly
communicates. The software provides the special feature to draw Enhanced function flow
block diagram which relates the relationship between functions and interactions thats
present in the system between various functions. Another part is to draw the house of
quality, which is voice of customer analysis tool and key component of the Quality
Functional Deployment technique. It begins with the voice of customer, in system
engineering which is a big picture. It helped me to know what the customer wants into
products or services that meet the customer wants in terms of engineering design values
by creating a relationship matrix. It could be very helpful in trading the system
requirements as well. Pugh matrix is also a fun part of the practicum. The Pugh Matrix is
easy to use and relies upon of pairwise comparisons between design candidates against
several criteria or requirements. Whenever, I will be stuck with confusion amongst number
of alternatives, the first idea will be use Pugh matrix.
At the end of semester, after going through the course and practicum, I felt like I learnt
some new things and get to know the basics of fundamental of system engineering. The
things I learned are the basics for my future work and I think it will be used time and again.
Introducing the concept of software Core for the System engineer is vital which I enjoyed
the most. The House of Quality and Pugh matrix concept were equally helpful to design
the system. As a system thinker, we should think our system from birth to death. I felt like
the world needs system engineer for the optimization of system.

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