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3D Printing

3D Printing. Introduction. 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 Additive manufacturing.

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3D Printing

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  1. 3D Printing

  2. Introduction 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 Additive manufacturing. 3D printing is achieved using an additive process, where successive layers of material are laid down in different shapes.

  3. History 3D printing, also called additive manufacturing, has been one of the breakout technologies of the last 18 months. People are now beginning to get involved with the technology, with printable objects ranging from tools to medical equipment. Yet, despite its recent popular emergence and contrary to popular belief, 3D printing has been existence for more than 35years, with the inception of the concept traced back to 1976 and the first example of it coming in the early 1980s.

  4. History

  5. History The Infancy of Additive Manufacturing 1981/2 The first published account of a printed solid model was made by Hideo Kodama from the Nagoya Municipal Industrial Research Institute in either 1981 or 1982 (accounts vary).

  6. History The Infancy of Additive Manufacturing 1981/2 Kodama’s paper theorized about the potential behind a rapid prototyping system that usedphotopolymersto build a solid, ‘printed’ object that was built up in layers, each of which would correspond to a cross-sectional slice in a model.

  7. Polymer (Greek poly-, "many" + -mer, "part") A large molecule composed of many repeated subunits. Polymers have a broad range of properties. Because of their broad range of properties, both synthetic and natural polymers play essential roles in everyday life. Polymers range from familiar synthetic plastics such as polystyrene to natural biopolymers such as DNA and proteins.

  8. Polymers Synthetic plastics Polystyrene Natural biopolymers DNA

  9. Resin Asolid or highly viscous substance of plant or synthetic origin that is typically convertible into polymers.

  10. History The Infancy of Additive Manufacturing 1984 Charles Hull, who at the time worked for 3D Systems Corporation, invented stereolithography. Hull went on to publish a number of patents on the concept of 3D printing, many of which are used in today’s processes.

  11. Stereolithography a process which lets designers create 3D models using digital data which can then be used to create a tangible object.

  12. History The Infancy of Additive Manufacturing 1992 3D Systems Corporation built the first stereolithographic apparatus (SLA) machine. It used a UV laser to solidify photopolymers, thus making 3D objects layer-by-layer. Although the machine faced difficulties, it was the first time it was proved that complex objects could be ‘printed’ overnight.

  13. Photopolymer A light-activated resin that changes its properties when exposed to light. (usually ultraviolet)

  14. History The key to stereolithography is a kind of acrylic-based material known as photopolymer. Hit a vat of liquid photopolymer with a UV laser beam, and the light-exposed portion will instantly turn into solid piece of plastic, molded into the shape of your 3D-model design. Needless to say, this new technology was big news to inventors, who could now theoretically prototype and test their designs without having to make a huge upfront investment in manufacturing.

  15. History That same year, startup DTM produced the world’s first selective laser sintering (SLS) machine—which shoots a laser at a powder instead of a liquid.

  16. History These technologies were in their infancy and weren’t perfect; there was some warping in the material as it hardened, and the machines were prohibitively expensive for home inventors, but their potential was undeniable. Decades later, 3D-printing history has shown that this potential is still unfolding.

  17. History 3D Printing’s Adolescent History 1999–2010 Medically speaking, this was a great decade in the history of 3D printing. The first 3D printed organ was transplanted into a human. This was also the decade when 3D printing met the open-source movement.

  18. History 3D Printing’s Adolescent History 1999 Created by scientists at Wake Forest Institute for Regenerative Medicine, a human bladder was printed, covered in the recipient’s own cells, and then the newly generated tissue was then implanted into the patients. It was a scientific breakthrough; because the device used the patient’s own cells,there was little to no chance that their immune systems would reject the implants.

  19. History 3D Printing’s Adolescent History 2002 Scientists engineer a miniature functioning e kidney that is able to filter blood and produce urine in an animal.

  20. History 3D Printing’s Adolescent History 2005 3D printing collided with the open source movement for the first time in the middle of the decade. The idea was championed by Dr Adrian Bowyer at the University of Bath in England. His idea was to create a printer than could print itself – thus making units and parts cheaper, more accessible, and easier to distribute.

  21. History 3D Printing’s Adolescent History 2005 In 2005, Dr. Adrian Bowyer’s RepRap Project launched an open-source initiative to create a 3D printer that could basically build itself—or at least print most of its own parts.

  22. History 3D Printing’s Adolescent History 2008 The release of , Darwin, a self-replicating printer. Suddenly, people everywhere had the power to create whatever stuff they could dream up on their own. Kickstarter, which launched in 2009 and has since crowdfunded countless 3D-printing-related projects).

  23. History 3D Printing’s Adolescent History 2008 The first person walks on a 3D printed prosthetic leg. It incorporated all parts of a biological limb; knee, foot, socket, etc. It was ready ‘as is’, without the need for any latter assembly. The development guided the creation of Bespoke Innovations, a manufacturer which makes customized coverings that surround prosthetic legs.

  24. History 3D Printing’s Adolescent History A team of scientists based at Brigham and Women’s hospital has made significant progress towards the manufacture of blood vessels for tissue engineering using 3D bioprinting.

  25. History 3D Printing’s Adolescent History 2011 The world’s first 3D printed car was launched by Kor Ecologic at the TEDxWinnipeg conference. Designed to be ‘green’, the prototype could reportedly do 200 mpg and would retail for between $10,000 and $50,000, depending on the model.

  26. Terminology • Additive manufacturing - refers to technologies that create objects through sequential layering. • 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. • Subtractive processes - removal of material by methods such as cutting or drilling. • Stereolithography - was defined by Charles W. Hull as a "system for generating three-dimensional objects by creating a cross-sectional pattern of the object to be formed"

  27. 3D Printable Models • 3D printable models may be created with a computer aided design package or via 3D scanner. • The manual modeling process of preparing geometric data for 3D computer graphics is similar to plastic arts such as sculpting. • 3D scanning is a process of analyzing and collecting data of real object; its shape and appearance and builds digital, three dimensional models.

  28. Rapid Prototyping Slicing

  29. Printing • To perform a print, the machine reads the design from 3D printable file (STL file). • STL file – STereoLithography • It lays down successive layers of liquid, powder, paper or sheet material to build the model from a series of cross sections. • These layers, which correspond to the virtual cross sections from the CAD model, are joined or automatically fused to create the final shape.

  30. Printing

  31. Finishing • Supports are removable or dissolvable upon completion of the print, and are used to support overhanging features during construction.

  32. Additive Processes • Extrusion deposition (Fused deposition modeling) • Granular materials binding • Lamination • Photopolymerization • Mask-image-projection-based stereolithography

  33. Extrusion deposition (Fused Deposition Modeling) • Fused deposition modeling (FDM) is an additive manufacturing technology commonly used for modeling, prototyping, and production applications. • FDM works on an "additive" principle by laying down material in layers; a plastic filament or metal wire is unwound from a coil and supplies material to produce a part. • Various polymers are used • Acrylonitrile Butadiene Styrene (ABS) • Polycarbonate (PC), • Polylactic Acid (PLA) • High Density Polyethylene (HDPE) • PC/ABS • Polyphenylsulfone(PPSU).

  34. 1 – nozzle ejecting molten plastic 2 – deposited material (modeled part) 3 – controlled movable table

  35. Granular Materials Binding • 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 unfused media to support overhangs and thin walls in the part being produced. • A laser is typically used to sinter the media into a solid.

  36. Granular Materials Binding • Selective Laser Sintering (SLS) --- uses lasers as its power source to sinter powdered material, binding it together to create a solid structure. • Selective Laser Melting (SLM) -- uses 3D CAD data as a digital information source and energy in the form of a high powered laser to create three-dimensional metal parts by fusing fine metallic powders together. • Electron beam melting (EBM) -- EBM manufactures parts by melting metal powder layer by layer with an electron beam in a high vacuum.

  37. Lamination • Sheet is adhered to a substrate with a heated roller. • Laser traces desired dimensions of prototype. • Laser cross hatches non-part area to facilitate waste removal. • Platform with completed layer moves down out of the way. • Fresh sheet of material is rolled into position. • Platform moves up into position to receive next layer. • The process is repeated.

  38. 1. Foil supply 2. Heated roller 3. Laser beam 4. Scanning prism 5. Laser unit 6. Layers 7. Moving platform 8. Waste

  39. Photopolymerization • Photopolymerization is primarily used in stereolithography (SLA) to produce a solid part from a liquid. • In Digital Light Processing (DLP), a vat of liquid polymer is exposed to light from a DLP projector 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. • Inkjet printer systems like the Objet PolyJet system spray photopolymer materials onto a build tray in ultra-thin layers (between 16 and 30 µm) until the part is completed.

  40. StereolithographyApparatus

  41. Mask-image-projection-based stereolithography • In this technique a 3D digital model is sliced by a set of horizontal planes. • Each slice is converted into a two-dimensional mask image. • The mask image is then projected onto a photocurable liquid resin surface. • Light is projected onto the resin to cure it in the shape of the layer.

  42. Printers RepRapversion 2.0 (Mendel) MakerBotCupcake CNC. Airwolf3D AW3D v.4 (Prusa)

  43. Applications Industrial uses Rapid Prototyping Rapid Manufacturing Mass Customization Mass Production Domestic and hobbyist uses Clothing 3D Bio-printing 3D Printing For Implant And Medical Device 3D Printing Services

  44. Future • Future applications for 3D printing might include creating open-source scientific equipment to create open source labs. • Science-based applications like reconstructing fossils in paleontology. • Replicating ancient and priceless artifacts in archaeology. • Reconstructing bones and body parts in forensic pathology. • Reconstructing heavily damaged evidence acquired from crime scene investigations. • The technology currently being researched for building construction.

  45. Effects of 3D printing Space exploration • Making spare parts on the fly • Cheaper and more efficient space exploration Social change • Conventional relationship between the home and the workplace might get further eroded. • It becomes easier to transmit designs for new objects around the globe.

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