3D PRINTING

TECHNOLOGY SUPPLY CHAIN MANAGEMENT

N.G.DINESH KUMAR (13UTB09)

3D Printing Technology

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

arequickly 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.

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 jewelry, footwear, industrial design, architecture,

engineering and construction, automotive, aerospace, dental and medical

industries, education and consumer products.

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 Modeling (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. In 2005, Z Corp. launched a breakthrough product, named

Spectrum Z510, which was the first high definition color 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

selfreplicating 3D printer.

MANUFACTURING A MODEL WITH THE 3D PRINTER

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

Very recently Engineers at the University of Southampton in the UK have

designed, printed, and sent skyward the world’s 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.

World’s First 3D Printed Plane Takes Flight

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.

Current 3D Printing Technologies Stereo lithography - Stereo lithographic 3D printers (known as SLAs or stereo

lithography apparatus) position a perforated platform just below the surface of a

vat of liquid photo curable polymer. A UV laser beam then traces the first slice

of an object on the surface of this liquid, causing a very thin layer of

photopolymer to harden. The perforated platform is then lowered very slightly

and another slice is traced out and hardened by the laser. Another slice is then

created, and then another, until a complete object has been printed and can be

removed from the vat of photopolymer, drained of excess liquid, and cured.

Fused deposition modelling - Here a hot thermoplastic is extruded from a

Temperature-controlled print head to produce fairly robust objects to a high

degree of accuracy.

Selective laser sintering (SLS) - This builds objects by using a laser to

selectively fuse together successive layers of a cocktail of powdered wax,

ceramic, metal, nylon or one of a range of other materials.

Multi-jet modelling (MJM )- This again builds up objects from successive layers

of powder, with an inkjet-like print head used to spray on a binder solution that

glues only the required granules together.

The VFlash printer, manufactured by Canon, is low-cost 3D printer. It’s known

to build layers with a light-curable film. Unlike other printers, the VFlash builds

its parts from the top down. Desktop Factory is a startup launched by the

Idealab incubator in Pasadena, California.

Fab@home, an experimental project based at Cornell University, uses a syringe

to deposit material in a manner similar to FDM. The inexpensive syringe makes

it easy to experiment with different materials from glues to cake frosting.

The Nanofactory 3D printing technologies are introduced that are related to the

nanotechnologies. .

3D Printing Capabilities: 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 organs.

3. Architects need to create mockups of their designs. 3D printing allows them to

come up with these mockups 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.

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 efficient and competent technological product.

The evolution of 3d printing This reality of affordable on-demand prototyping was first conceived by

visionaries at mit who in 1993 developed the fastest and most affordable method

of prototyping — 3d printing. Upon z corporation’s founding in 1994 by some of

these same Visionaries, we promised to put on-demand prototyping within the

reach of every designer or engineer. This promise would entail developing 3d

printers that would follow the footsteps of document printers and quickly evolve

to deliver speed, Affordability, accuracy, color and usability. We are working to

keep that promise:

First generation —3d printing arrives In 1996, we introduced the z®402, the market’s first 3d printer, redefining

speed and affordability in rapid prototyping. Later Versions like the z402c and

z406 introduced multicolor 3d printing for more vivid and informative models

when needed.

Second generation – improved performance, affordability

and color our release of the zprinter® 310 in 2003 introduced breakthrough speed, a

simplified user experience and unprecedented Affordability. In 2005, the

spectrum z™510 redefined 3d printing with a new generation of high -resolution

printing and Vivid color.

Third generation – focus on ease of use In 2007, the zprinter 450 kicked off the third generation of 3d printers with a

focus on ease of use and office compatibility. The Automated, self -contained, all-

in-one (print, depowder) solution improved convenience and office -friendliness.

It was followed By the zprinter 650 in 2008, with increased size and

performance, and the zprinter 350 in 2009, which introduced a new level Of 3d

printing affordability. These printers increased the accessibility for new classes

of users

How Does 3D printing Work?

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 (see Figure 1.1 on page 5). 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 variation s).

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 (see Figure 1.2).

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. We’ll 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

3D PRINTING CYCLE

THE BUILD CHAMBER