Introduction to 3D printing
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A brief introduction to 3D printing, its mechanisms, 3D printers
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Introduction to 3D printing
- 3. Introduction Applicatio ns Types 3DPrinters Conclusio n 1. What is 3D Printing? 2. How is the technology being used? 3. What are the challenges with 3D Printing? 4. Can this be a career option in today's’s fast changing industry scenario? Frequently Asked Questions?
- 6. Introductio Applicatio ns Types 3DPrinters Conclusio n Process of joining materials to make objects from 3D model data, usually layer upon layer i.e. additive manufacturing as opposed to subtractive manufacturing methodologies. Technical Definition
- 8. Introductio Applicatio ns Types 3DPrinters Conclusio n CAD Model Prototype from 3D Printing Quickly Produce Physical Prototypes from 3D CAD Data
- 13. Introductio Applicatio ns Types 3DPrinters Conclusio n 3D Printing Potent Areas 1. Health – Prosthetics especially 2. Education 3. Aerospace – SpaceX is buliding rockets 4. Textiles and Jewelry – Nike is suing on commercial scale 5. Bio-Technology 6. Food Industry
- 14. Introductio Applicatio ns Types 3DPrinters Conclusio n Based on 3D Printing Mechanism 1 Stereolithography (SLA) 2 Digital Light Processing (DLP) 3 Fused Deposition Modeling (FDM) 4 Selective Laser Sintering (SLS) 5 Selective Laser Melting (SLM) 6 Electronic Beam Melting (EBM) 7 Laminated Object Manufacturing (LOM) 8 Binder Jetting (BJ) 9 Materials Jetting (MJ)
- 15. Introductio Applicatio ns Types 3DPrinters Conclusio n 1. Stereo Lithography (SLA) Its done by converting liquid photopolymers (a special type of plastic) into solid 3D objects, one layer at a time. The plastic is first heated to turn it into a semi-liquid form, and then it hardens on contact. The printer constructs each of these layers using an ultra violet laser, directed by X and Y scanning mirrors. Just before each print cycle, a recoater blade moves across the surface to ensure each thin layer of resin spreads evenly across the object.
- 17. Introductio Applicatio ns Types 3DPrinters Conclusio n https://youtu.be/8a2xNaAkvLo Pros-Cons - i. SLA is a fast prototyping process. ii. High accuracy and precision. iii.Popular for its fine details and exactness. iv. It can take longer to trace the cross-section of an object when compared to DLP. v. SLA printing has become a favored economical choice for a wide variety of industries. vi. Some of these include automotive, medical, aerospace, entertainment, and also to create various consumer products.
- 18. Introductio Applicatio ns Types 3DPrinters Conclusio n 2. Digital Light Processing (DLP) Technology It’s similar to SLA (see above), given that it also works with photopolymers. The liquid plastic resin used by the printer goes into a translucent resin container. There is, however, one major difference between the two, which is the source of light. While SLA uses ultra violet light, DLP uses a more traditional light source, usually arc lamps. This process results in pretty impressive printing speeds. When there’s plenty of light, the resin is quick to harden (we’re talking seconds).
- 20. Introductio Applicatio ns Types 3DPrinters Conclusio n https://youtu.be/3p9xnjGKCT0 Pros and Cons: Compared to SLA 3D printing, DLP achieves quicker print times for most parts. The reason it’s faster is because it exposes entire layers at once. With SLA printing, a laser has to draw out each of these layers, and this takes time. It is robust and produces high resolution models every time. It’s also economical with the ability to use cheaper materials for even complex and detailed objects. This is something that not only reduces waste, but also keeps printing costs low.
- 21. Introductio Applicatio ns Types 3DPrinters Conclusio n 3. Fused Deposition Modeling (FDM) Technology It uses production grade thermal plastic materials. Before the FDM printing process begins, the user has to slice the 3D CAD data (the 3D model) into multiple layers using special software. The sliced CAD data goes to the printer which then builds the object layer at a time on the build platform. It does this simply by heating and then extruding the thermoplastic filament through the nozzle and onto the base. The printer can also extrude various support materials as well as the thermoplastic..
- 24. Introductio Applicatio ns Types 3DPrinters Conclusio n 4. Selective Laser Sintering (SLS) Technology It’s a 3D printing technique that uses high power CO2 lasers to fuse particles together. The laser sinters powdered metal materials (though it can utilize other materials too, like white nylon powder, ceramics and even glass). The build platform, or bed, lowers incrementally with each successive laser scan. It’s a process that repeats one layer at a time until it reaches the object’s height
- 27. Introductio Applicatio ns Types 3DPrinters Conclusio n This means the 3D objects don’t need other support structures during the build. SLS produces durable, high precision parts, and it can use a wide range of materials. It’s a perfect technology for fully-functional, end-use parts and prototypes. SLS is quite similar to SLA technology with regards to speed and quality. The main difference is with the materials, as SLS uses powdered substances, whereas SLA uses liquid resins. It’s this wide variety of available materials that makes SLA technology so popular for printing customized objects.
- 28. Introductio Applicatio ns Types 3DPrinters Conclusio n 5. Selective Laser Melting (SLM) Technology Like SLA (see above), SLM also uses a high-powered laser beam to form 3D parts. During the printing process, the laser beam melts and fuses various metallic powders together. The simple way to look at this is to break down the basic process like thus: Powdered material Heat Precision Layered Structure 3D Product
- 29. Introductio Applicatio ns Types 3DPrinters Conclusio n https://youtu.be/yiUUZxp7bLQ Also known as Direct Metal Laser Sintering (DMLS)
- 30. Introductio Applicatio ns Types 3DPrinters Conclusio n As the laser beam hits a thin layer of the material, it selectively joins or welds the particles together. After one complete print cycle, the printer adds a new layer of powered material to the previous one. The main difference between SLM and SLS is that SLM completely melts the powder, whereas SLS only partly melts it (sinters). In general, SLM end products tend to be stronger as they have fewer or no voids.
- 31. Introductio Applicatio ns Types 3DPrinters Conclusio n The aerospace industry uses SLM 3D printing in some of its pioneering projects. These are typically those which focus on precise, durable, lightweight parts. It’s a costly technology, SLM is quite widespread now among the aerospace and medical orthopedics industries.
- 32. Introductio Applicatio ns Types 3DPrinters Conclusio n 6. Electron Beam Melting (EBM) Technology Similar to SLM (see above), in that it uses a powder bed fusion technique. The difference between the two is the power source. The SLM approach above uses high-powered laser in a chamber of noble, or inert gas. EBM, on the other hand, uses a powerful electron beam in a vacuum. EBM’s main use is to 3D print metal parts. Its main characteristics are its ability to achieve complex geometries with freedom of design. EBM also produces parts that are incredibly strong and dense in their makeup.
- 34. Introductio Applicatio ns Types 3DPrinters Conclusio n Some of EBM’s other impressive features - Doesn’t need extra auxiliary equipment for the 3D printing process. Has increased efficiency using raw materials Lessens lead times resulting in parts getting to market faster. Can create fully functional, durable parts on demand for wide-ranging industries. The printing process starts like most others in that the user has to first create a 3D model, or computer-generated digital file.
- 35. Introductio Applicatio ns Types 3DPrinters Conclusio n 7. Laminated Object Manufacturing (LOM) Technology LOM is a rapid prototyping system that works by fusing or laminating layers of plastic or paper using both heat and pressure. A computer-controlled blade or laser cuts the object to the desired shape. Once each printed layer is complete, the platform moves down by about 1/16th of an inch, ready for the next layer. The printer then pulls a new sheet of material across the substrate where it’s adhered by a heated roller. This basic process continues over and over until the 3D part is complete.
- 37. Introductio Applicatio ns Types 3DPrinters Conclusio n 8. Binder Jetting (BJ) Technology Other names - Powder bed printing, Inkjet 3D printing, Drop-on-powder. Uses two types of materials to build objects: a powder-based material (usually gypsum) and a bonding agent. Bonding agent acts as a strong adhesive to attach (bond) the powder layers together. The printer nozzles extrude the binder in liquid form similar to a regular 2D inkjet printer. After completing each layer, the build plate lowers slightly to allow for the next one. This process repeats until the object reaches its required height.
- 39. Introductio Applicatio ns Types 3DPrinters Conclusio n 9. Material Jetting (MJ) Polyjet and Wax Casting Technology Also known as wax casting. It’s something jewelers have used for centuries. For jewelers who want to experiment with various casts— as most jewelers do—MJ is now their leading 3D technology. Once the 3D model (CAD file) is uploaded to the printer, it’s all automated now. The printer adds molten (heated) wax to the aluminum build platform in controlled layers. It achieves this using nozzles that sweep evenly across the build area.
- 40. Introductio Applicatio ns Types 3DPrinters Conclusio n As soon as the heated material lands on the build plate it begins to cool down and solidify (UV light helps to cure the layers). As the 3D part builds up, a gel-like material helps to support the printing process of more complex geometries. Like all support materials in 3D printing, it’s easy to remove it afterward, either by hand or by using powerful water jets. Once the part is complete you can use it right away, no further post-curing necessary.
- 42. Introductio Applicatio ns Types 3DPrinters Conclusio n Overview Over 3D Printing Technologies
- 44. Introductio Applicatio ns Types 3DPrinters Conclusio n Motherboard or Controller Board Motherboard works as the brain of the 3D printers. It directs the motion components as per the instructions sent from a computer and at the same time, interprets signals from the sensors.
- 45. Introductio Applicatio ns Types 3DPrinters Conclusio n Frame Frame helps keep all the other components of your 3D printer together at one place. It also maintains the stability of the entire machine. If your frame is robust, you will have a more durable 3D printer.
- 46. Introductio Applicatio ns Types 3DPrinters Conclusio n Filament/Print Material Filament is used for the FDM 3D printers. When getting a printer, one must take care of the compatibility with different filaments. Some can process only one kind of filaments, mostly PLA. And, others can work with multiple choices of filaments including PLA, ABS and many others.
- 47. Introductio Applicatio ns Types 3DPrinters Conclusio n Motion Controllers Motion controllers receive instructions from the mother board about the movement they must make, while they are the ones who perform the actual movements. Various parts together make motion controllers – belts, stepper motors, threaded rods, end stops,
- 48. Introductio Applicatio ns Types 3DPrinters Conclusio n Power Supply Unit (PSU) Power Supply Unit helps in supplying power for a smooth operation of 3D printer. It can be mounted on the frame. Or, it can also be available separately along with another controller box. PSU strength would decide what temperature your 3D printer is capable of working with. For advanced materials, one must choose the one with higher temperature range allowance.
- 49. Introductio Applicatio ns Types 3DPrinters Conclusio n Print Bed This is the component where the models are created. The filaments are deposited on the print bed, one layer at a time for building the entire object. A non heated print bed may be enough for PLA, however, for advanced filaments, heated beds are recommended. These helps in enhancing adhesion and stability for first layer of the print.
- 50. Introductio Applicatio ns Types 3DPrinters Conclusio n Extruder/Print Head It extrudes the filament and deposit it on the print bed.
- 51. Introductio Applicatio ns Types 3DPrinters Conclusio n The extruder can be categorized in two sections. One is called the cold end while the other is known as the hot end. The job of the cold end is to lock the filament while pushing it gradually downwards to the hot end. The hot end that has a nozzle attached to it at the end, maintains a high temperature greater than the melting point of the filament. The hot end melts the filament which is further deposited on the print bed. The extruder itself is made of different parts - Filament Drive Gear, Heat Sink, Heater Cartridge, Cooling Fan, Nozzle
- 52. Introductio Applicatio ns Types 3DPrinters Conclusio n Feeder System There are two most common feeder system used in 3D printers: Bowden feeder system and Direct feeder system. Learn about these two - https://youtu.be/FmQcd_3tPcg
- 53. Introductio Applicatio ns Types 3DPrinters Conclusio n Connectivity When it comes to connectivity with other device, 3D printers differ a lot. Some provide only the ethernet or USB port for connection. The interface can also help connect the mobile phone or laptop through Wi-Fi connection to your 3D printer. For a standalone experience, many 3D printers also come with SD card slots. These slots are used for file transfer while the printer works without a need for any other device.
- 54. Introductio Applicatio ns Types 3DPrinters Conclusio n User Interface The majority of the 3D printer has a mounted interface. However, some models come with separate controller box including the LCD interface. Even the budget ones, comes with an LCD user interface.
- 55. Introductio Applicatio ns Types 3DPrinters Conclusio n Selection of a 3D Printer 321 Material Plastics Metals Bio-Materials etc. Production Volume Size Complexity Budget Type of Industry
- 56. Introductio Applicatio ns Types 3Dprinters Conclusio n The list of 3D printing technologies and processes continues to grow as 3D printing is always changing. The 3D printing industry continues to innovate its hardware as well as the materials and processes to create objects or parts. Depending on many factors such as budget, design or function, choosing the appropriate 3D printing process as well as the right material is important. 3D printing can create many different 3D printed objects that were previously only fabricated through mass manufacturing methods.
- 57. Introductio Applicatio ns Types 3Dprinters Conclusion An online 3D printing service like Sculpteo exists due to the complexity, time and skills required for the printing and Finishing steps. This complexity may hinder people from using this wonderful technology, but at Sculpteo we apply our knowledge to serve anyone willing to try 3D printing, as we want to broaden access to additive manufacturing technology. One of the vital component of evolving ‘Industrial Revolution 4.0’