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3D Printing: Everything you ever wanted to know and more
- 1. 3D Printing: Everything you ever wanted to know and more Cassidy Silbernagel January 17, 2014
- 2. Theory 1. Take a 3D model 2. Slice model into a number of layers 3. Print first 2D slice 4. Increment height 5. Print next layer 6. Repeat until finished 1 2 3 5 4
- 3. 3D Printing Core Technologies SLA - Steriolithography Apparatus Liquid resin cured solid via UV light/laser SLS/SLM - Selective Laser Sintering / Selective Laser Melting Powders sintered/fused together via laser FDM/FFF – Fused Deposition Modeling / Fused Filament Fabrication Partially melted plastics extruded through a nozzle and cooled LOM - Laminated Object Manufacturing Layers of solid material fused together with binder or pressure/heat Zprinting Powders combined together with binder via actual printer print heads Polyjet Liquid resin jetted out of actual printer print heads and cured with UV light Many others
- 4. History 1980 First patents issued for aspects of 3D printing, Fujitsu Ltd, NEC Corp 1986 Chuck Hull invents Stereolithography (SLA), the STL file format, and founds 3D Systems Late 1986 Carl Deckard and the University of Texas patent Selective Laser Sintering (SLS)
- 5. History 1989 Stratasys is founded using Fused Deposition Modeling (FDM) technology Late 1989 MIT develops new technique called Zprinting and starts Zcorp 1999 Objet based in Isreal invents PolyJet technology which leads to multi-material 3D printing
- 6. History 2005 Some FDM patents about to expire and personal printers emerge starting with the Open Source RepRap 2008 Various companies take the design and create new printers and sell kits costing between $500-$2000 2009 MakerBot is founded and becomes popular with their “Cupcake CNC”
- 7. History 2007 Ponoko became one of the first sites where one could upload a design and have it made 2008 Shapeways is founded upon same principles Late 2008 Thingiverse becomes the universe of free things to download which can be 3D printed
- 8. History Now Bigger, faster and cheaper DIY kits very cheap and popular Many large acquisitions Lawsuits against others Key patents expiring allowing new players to enter the game
- 9. Paper Layers Mcor Technologies Based in Ireland Uses plain paper (white or colored) Now prints in full color (like inkjet printers) Has partnered with Staples in Netherlands to provide in store pickup of 3D prints
- 10. Plastic Layers Solido 3D Based in USA Uses a roll of plastic and glue sticks Targeted household buyers but didn’t find enough buyers Currently in receivership
- 11. Sweet Printer CandyFab Based in USA Primarily hobbyist driven Low resolution Extremely cheap parts Hot air melting jet
- 12. Solar Power Solar Sinter Developed by Markus Kayser while a student at the Royal College of Art Uses nothing but the Sun and Sand
- 13. Selective laser sintering - SLS 3D Systems Based in USA Sinters various plastics, primarily Nylon Really fast build speeds Parts can be flexible Can be dyed any colour
- 14. Selective laser melting - SLM Realizer GmbH Based in Germany Sinters many metals Aluminum Titanium Stainless Steel Gold Inconel Incredibly fine resolution Fairly slow and costly process
- 15. Starch Based Powder ZCorporation Based in USA Started with starch based powders and now can do more types Able to do full color Cheap materials result in low cost parts Now owned by 3D Systems
- 16. Casting Sand Based Powder The Ex One Company Based in Germany Activated casting sand Metal parts can then be cast Can nest multiple parts at a time
- 17. Stereolithography 3D Systems Founded SLA 59” x 30” x 22” Up to 330lb parts
- 18. PolyJet Technology Objet Ltd. Based in Israel Able to print multi-materials including digital materials Both soft and hard in the same part Now owned by Stratasys
- 19. FDM Machines Stratasys Inc. Based in USA Initially only ABS plastic but now many high end plastics Most stable and strong of any non- metal 3D printing material
- 20. Cement Extruders Large scale printers Primarily for building structures / components Integrated plumbing and electrical
- 22. Icing, Sugar, and Meat Printing
- 23. DIY Revolution Nearing a hundred different kits available, a new one every week Several online groups for enthusiasts Open source hardware and software
- 24. Future Developments So where is all of this going?
- 25. Micro/Nano Scale Nano:Vienna University of Technology Two-photon SLA Micro: 3D-Micromac AG and EOS Gmbh Micro Laser Sintering technology (MLS)
- 26. Bio-Medical Custom implants Custom prosthetics
- 27. Bio-Medical Printing organs Printing muscle
- 28. Fashion Printed Dresses and shoes
- 29. Architecture Printing organic structures (out of moon dust) Printing entire structures
- 30. Atomic Level Manipulation of individual atoms
- 31. Multi-material Creating parts out of many materials including metal
- 32. 4D Printing Parts that change over time (the 4th dimension)
- 33. Home Based Manufacturing Download, print, use, share No more going to the store to buy items Manufacture right in your own home Order a replacement part and print at home Lots of development into multi-material printers
- 34. Questions?
- 35. 3D Printed Guns Don’t believe everything you read Single shot only More likely to blow your hand off Much safer ways to create guns than 3D printing
Notas del editor
- 99.9% of all 3D printers work on the same principle. Take an existing 3D model and export to a compatible file type (de facto standard is .STL) Slice that file type into a number of layers using additional software Print first 2D slice Increment height a certain amount Print next layer Repeat until last layer is finished All the different types of 3D printers use these steps. Some methods print the final material directly, others combine two technologies to create a solid material. Depending on the method, some require additional supports added to the original 3D model in order to print correctly. Others require a layer material to be deposited before a layer can be printed. Overall though, the steps are all the same.
- Just a few of the main technologies companies are developing, each having various pros/cons.
- Chuck Hull invented Stereolithography known as SLA (Resin/Laser based printing) as well as and the STL file format and started 3D Systems in 1986. SLS - US Patent 4863538
- In 1989, Stratasys was founded and created the Fused Deposition Modeling method known as FDM (Extruder based printing) and by 2007 supplied 44% of the world market in additive fabrication machines. Zprinting - Patent # 5204055 The 1990's saw primarily only corporations and Universities using 3D printers because the cheapest ones available cost at least $20,000. The main companies supplying 3D printers were 3D Systems, Stratasys, and Z-Corp.
- By the mid 2000's, more powerful personal computers, and easier to use 3D modelling allowed 3D printing to enter the home/hobbyist market. These hobbyist machines took cues from the large machines these corporations created and made them smaller, cheaper, and more readily available. The first one of these home based systems was RepRap in 2005. http://en.wikipedia.org/wiki/File:Reprap_Darwin.jpg What made RepRap so popular, is the approach of open source. The design, software, and hardware were all made open to anyone who wanted to use, modify, or copy. This spawned a number of various projects such as the MakerBot Industries Thing-O-Matic, Ultimaker, Shapercube, Mosaic, Prusa and Huxley 3D printers as well as many many more (new ones appear all the time and it's now hard to keep track). All of which are based on the FDM method and quality varies greatly. Kits have cost anywhere from $500-$2000, and have seen improvements in speed, accuracy, and capabilities. New machines are now able to print in two colors or use water soluble support material. One new FDM project, the MakiBox, has created a kit which can be assembled in a few hours and costs only $300 (mine is on it's way).
- Recently, other players have come up to offer custom 3D printer services online. This is where you upload your 3D model, tell them what method you want to use, and they provide a quote, and quick turn around on your part. Two of the biggest companies that offer these services are Ponoko and Shapeways. Not only can you have your designs made, but you can sell those designs for others to buy, where you get a commission on the parts you designed that others want to have printed.
- In terms of big players in the field, it really has stayed with those who started it. 3D Systems (with Chuck Hull as Executive VP and CTO) has purchased just about every type of 3D printing technology available from small hobbyist companies (like BotMill), to some of the other competing founding technologies like Z-Corp. 3D Systems has FDM, SLA, SLS, SLM (Direct Metal), and ZPrinting. Stratasys has remained dominant in the FDM field purchasing other FDM companies (uPrint, FORTUS, RedEye On Demand, Dimension Printing) while also producing very large envelop printers with the largest one being 36" x 24" x 36". 3D Systems owns Zcorp Stratasys owns Objet and MakerBot and Thingiverse
- Also known as Laminated Object Manufacturing (LOM). The individual layers of the part start from solid sheets of material which have the final shape cut out of them, with each layer bonded to the next one with some type of adhesive. http://www.youtube.com/watch?feature=player_detailpage&v=ZJk8O6y6fpM#t=14(1min) Matrix video start at 14s Model 1 video start right away and skip through http://www.mcortechnologies.com/resources/gallery/gallery-videos/ Advantages Cheap stock material $0.21/Cu. In. One of the lowest price per cubic inch for large parts Parts are easily recyclable Disadvantages Build size dependant on paper size Difficult to remove support material Cutters wear out and can cause bad prints
- Start video at 57s http://www.youtube.com/watch?feature=player_detailpage&v=kf-zLPuW844#t=57 Advantages Cheap machine cost Flexible and transparent parts Materials get used up at same rate Relatively cheap material $1.34/Cu.In Disadvantages Build size is dependent on PVC roll A lot of waste material for small parts Non-recyclable Difficult to remove support material Cutters wear out and can cause bad prints
- In Powder based printing, the final part is created from some sort of powder. This powder can be anything including; sugar sand starch gypsum cement (U.S. Gypsum HYDROPERM) plastic glass ceramic powdered aluminum powdered titanium The type of powder determines the type of print head needed to make it become solid. This is done either chemically or thermally. For thermal fusion, the melting point of the powder determines the level of power needed for the printer. In order to print the first slice, a even layer of powder needs to be deposited onto the print bed. Then the powder becomes fused in the desired pattern using the appropriate method. The print bed lowers a certain amount, a new layer of powder is put down, and the process is repeated. Sintering methods consist of using heat to melt a material to form a solid. This heat source could come from a jet of hot air, concentrated solar, lasers, or electron beams. In the pursuit of creating large cheap objects, CandyFab was created. Using cheap granulated sugar and a jet of hot air, CandyFab has gone through several iterations to create large edible prints, each one becoming larger and more automated. The largest build envelope was 24" x 13.5" x 9". The resolution is limited not by the gain size of the sugar, but more by the air-flow rate of their hot air jet. They have not pursued using a high powered laser since it would be quite expensive and contrary to the overall desire to make this a low cost machine. http://www.flickr.com/photos/oskay/sets/72157594553416374/
- In trying to find even cheaper materials and power sources, this project http://www.markuskayser.com/ ( (Skip to 2:26 then to 4:30) uses a large fresnel lens to concentrate solar energy onto a bed of sand to create prints. Resolution is quite low, but so are the operating costs! Exact specs are not available.
- http://www.youtube.com/watch?v=SVkUwqzjGJY Using a CO2 laser and various plastics, the sPro 230 HS from 3D Systems is the largest available at 22" x 22" x 30" with Z-resolution between 0.003"-0.006" and build speed of 300 cu. in. / hr. Advantages Extremely fast build speed Material properties of finished part close to injection molded parts Powders can be extremely cheap ($1.50/cu.in) Disadvantages Expensive machine cost up to $485,000
- http://www.youtube.com/watch?v=1YgEOsZ8iJg#t=22 Advantages Parts made from metal Extremely fine resolution Disadvantages Very expensive machine cost ($600-700k) Expensive material cost Expensive consumables such as Argon at 70 L/hr Huge power consumption around 2.5kW
- Systems using a liquid ink-jet type of print head prints a binder onto a powdered layer. This layer will react with the binder due to a chemical reaction with the powder. Binders can range from a simple water/alcohol mixture, to specific resins which react with an activated powder mixture. http://www.youtube.com/watch?v=u7h09dTVkdw http://www.youtube.com/watch?v=7QP73uTJApw#t=171 Advantages Full color prints Overall consumable cost can be low Disadvantages Low material strength without wicking (can use CA – super glue to add strength) Can be messy $60,000 for best machine out there
- http://www.youtube.com/watch?v=SgrGhJ5u5oM Advantages Can cast directly into printed part Very large parts Disadvantages High machine cost $1.5-1.9 million Needs a large area for operation
- Key is the special UV cured resin. Printers differ only in the way the resin is cured. One advantage that powder and cutter based technologies have over resin and FDM is that there is no need for support material. Resin and FDM require supports to be printed along side the final part. This is needed, otherwise you could print overhangs in air or liquid and they would fall down. http://www.youtube.com/watch?v=iceiNb_1E0I http://www.youtube.com/watch?v=keybWPgrjbc Advantages Very large parts High level of accuracy Parts could weigh up to 330 lbs! Disadvantages High material cost Can be a very slow process Material cost is high at $5/cu.in Resin can be toxic and need special handling Parts need to be post cured to achieve final stability Parts could change shape over time or change color depending on resin
- http://www.youtube.com/watch?feature=player_detailpage&v=pbjcfplk8Ig#t=77s Advantages Can print very fine resolution Can print in different materials at the same time Can print in color Can create hybrid (digital) materials Disadvantages High material cost High machine cost Fairly high amount of waste due to purging the heads before each layer
- Recycled plastic from refrigerator http://www.youtube.com/watch?v=FvRTHynk9KA http://www.youtube.com/watch?v=KlDDKb3_Dog Advantages -Materials are stable -A number of colors -Materials are common -Lots of new plastics available including engineering plastics -Most common type of printer in DIY world Disadvantages -Finer details increase the print time -Requires hot bay temperature which uses lots of power in order to prevent part curling for ABS
- http://www.youtube.com/watch?v=TyOgDlUWfFE http://www.youtube.com/watch?v=EfbhdZKPHro
- Print through either a syringe or a pump (progressive cavity pump) or through sintering
- The meat is turkey which was done in honor of US Thanksgiving http://fabbaloo.com/blog/2014/1/7/developments-in-3d-food-printing.html http://www.tctmagazine.com/ces-news/worlds-first-kitchen-ready-chefjet-3d-printer-launched-by-3/
- http://www.youtube.com/watch?v=euZivv8ySyA General move towards cheaper machines, cheaper materials Material costs $2/kg vs. $8.80/kg from Stratasys Free software and hardware designs are available Majority are FDM based, but some are SLA or powder Close to 100 kits are available, most are in the $1000 range, but some cost as low as $100 (Peachy Printer - SLA) to $300 (http://makibox.com/ - FFF) which is the one I’m waiting on. http://pinterest.com/finklean/diy-3d-printers/
- http://www.youtube.com/watch?v=5y0j191H0kY http://hackadaycom.files.wordpress.com/2012/03/bridge.jpg
- http://www.aleixdesign.com/blog/2010/09/15/3-d-printing/ http://www.aleixdesign.com/blog/2010/09/15/3-d-printing/ http://www.gizmag.com/first-3d-printed-lower-jaw-implant/21383/
- http://www.explainingthefuture.com/bioprinting.html http://www.youtube.com/watch?v=bzyXKl9sW70 http://regenovo.com/english/index.aspx# http://www.youtube.com/watch?v=g2ZTWHsO8l0&feature=player_embedded http://www.technologyreview.com/demo/426985/printing-muscle/ http://singularityhub.com/2011/03/15/growing-human-organs-%E2%80%94-dr-anthony-atala-blows-the-minds-of-a-ted-audience/
- http://3dprintingindustry.com/2014/01/07/australian-architects-take-home-top-prize-3d-printing-fashion-contest/
- http://www.youtube.com/watch?v=CEA2HaFqsVQ&feature=related http://www.esa.int/Highlights/Lunar_3D_printing
- http://www.youtube.com/watch?v=zqyZ9bFl_qg http://www.youtube.com/watch?v=oSCX78-8-q0
- http://www.nueveojos.com/portfolio/full-printed/?lang=en
- http://area51machinedesign.com/3d-printing/
- http://fabbaloo.com/blog/2014/1/3/solid-concepts-printed-metal-gun-on-sale.html 1911DMLS will run you $11,900 http://fabbaloo.com/blog/2013/5/10/a-word-on-3d-printed-gun-safety.html http://www.youtube.com/watch?v=ZL7y3YNUbiY http://www.youtube.com/watch?v=zxe_zMJj5m0 http://www.youtube.com/watch?v=d7cn1YIm3nU http://www.gadgetreview.com/2013/05/another-3d-gun-has-been-printed.html http://www.digitaltrends.com/cool-tech/forget-3d-printed-guns-dude-makes-working-firearms-stuff-can-buy-airport-terminals/