complete documentation of 3D printing

1. A
TECHNICAL SEMINAR
ON
“3D PRINTING”
Submitted in partial fulfillment of requirements
For the award of the Degree of
BACHELOR OF TECHNOLOGY
IN
ELECTRONICS & COMMUNICATION ENGINEERING
By
B.VINEETHA (11RQ1A0486)
Under the Guidance of
Prof. Mr. MD. MUSTAQ AHMED
[ M.Tech.]
Asst. Professor
DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGINEERING
MINA INSTITUTE OF ENGINEERING & TECHNOLOGY FOR WOMEN
(Approved by AICTE, New Delhi, Affiliated to JNTUH, Hyderabad)
Ramachandragudam, Miryalaguda-Nalgonda (Dist), T.G.
2015

2. DEPARTMENT OF ELECTRONICS & COMMUNICATION ENGINEERING
MINA INSTITUTE OF ENGINEERING & TECHNOLOGY FOR WOMEN
(Approved by AICTE, New Delhi, Affiliated to JNTUH, Hyderabad)
Ramachandragudam, Miryalaguda-Nalgonda (Dist), T.G.
2015
CERTIFICATE
This is to certify that the technical seminar entitled “3D PRINTING”
submitted by B.VINEETHA (11RQ1A0486) in partial fulfillment for the award of
the Degree of Bachelor of Technology in Electronics & Communication
Engineering from Jawaharlal Nehru Technological University, Hyderabad. This is a
bonafide work done by her under my guidance and supervision.
The results presented in this project have been verified and are found to be
satisfactory. The results embodied in this project have not been submitted to any other
University or Institute for the award of any other Degree or Diploma.
Internal Guide Head of the Department
Prof. Mr. MD. MUSTAQ AHMED Prof. Mr. MD. MUSTAQ AHMED
[ M.Tech.] [ M.Tech.]
Asst. Professor Asst. Professor
External Examiner Principal
Mr. PANDURANGA REDDY

3. ACKNOWLEDGEMENT
The satisfaction that accompanies the successful completion of any task would be
incomplete without the mention of the people who made it possible and whose
constant guidance and encouragement crown all the efforts success.
I thank our guide Prof. Mr. MD. MUSTAQ AHMED, Asst. professor,
Department of Electronics & Communication Engineering for his support in
completion of our Project.
I wish to express my sincere thanks to Prof. Mr. MUSTAQ AHMED, HOD
of Electronics & Communication Engineering and also to our Principal Mr.
PANDURANGA REDDY for providing the facilities to complete the Project.
Last but not least, I express my heartful thanks to all my staff, parents and
friends for their constant support, encouragement and valuable contribution in the
completion of this Project.
B.VINEETHA 11RQ1A0486

4. ABSTRACT
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 are quickly
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.
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.

5. INDEX
S.NO CONTENTS PAGE NO
LIST OF FIGURES i
1. INTRODUCTION 1
1.1 INTRODUCTION TO 3D PRINTING 1
1.2 HISTORY OF 3D PRINTING 3
2. WORKING PRINCIPLE 4
2.1 ALGORITHM 6
3. METHODS OF 3D PRINTING 8
3.1 STEREO LITHOGRAPHY 8
3.2 SELECTIVE LASER SINTERING(SLS) 9
3.3 FUSED DEPOSITION MODELING(FDM) 10
3.4 INK-JET 3D PRINTING 10
4. PRINT HEAD 11
4.1 DROP-ON-DEMAND(DOD) 11
4.2 CONTINUOUS INK-JET(CJ) 12
5. FEATURES 13
5.1 3D PRINTING CAPABILITIES 13
5.1.1 3D SAVES TIME & COST 13
5.2 ADVANTAGES 14
5.3 POTENTIAL NEW BUSINESSES 14
6. APPLICATIONS 15
6.1 FASHIONABLE PLASTER 15
6.2 ARTIFICIAL ARMS FOR DISABLED 16
6.3 BIONIC EAR 17
6.4 REPLACE ORGANS 18
6.5 OPPURTUNITIES OF APPLICATIONS 19
7. CONCLUSION 21
8. REFERENCES 21

6. LIST OF FIGURES
1. TYPICAL 3D PRINTER 1
2. DIGITAL DATA 2
3. FATHER OF 3D PRINTING 3
4. BASIC WORKING MODEL 4
5. MANUFACTURING A MODEL WITH 3D PRINTER 5
6. PROTOTYOE CAR 6
7. ALGORITHM OD 3D PRINTING 6
8. WORLD’S FIRST 3D PRINTED PLANE TAKES FLIGHT 7
9. STEREO LITHOGRAPHY 8
10. SELECTIVE LASER SINTERING 9
11. FUSED DEPOSITION MODELING 10
12. DROP ON DEMAND 11
13. CONTINUOUS INK JET 12
14. 3D PRINTERS 14
15. FASHIONABLE PLASTER 15
16. ARTIFICIAL ARMS FOR DISABLED 16
17. BIONIC EAR 17
18. VARIETY OF APPLICATIONS 19

7. 1. INTRODUCTION
1.1 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 are quickly
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.
Fig 1.1: Typical 3D Printer

8. 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.
Fig 1.2 Digital data

9. 1.2 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.
Fig 1.3 Father of 3D printing
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.

10. 2. WORKING PRINCIPLE
This is the basic working principle of 3D printing.
Modeling Printing Finishing
Fig 2.1 Basic working model
The general principles of 3-D printing are:
1. Modeling:
 A person creates a 3D image of an item using a computer-aided design (CAD)
software program.
 Additive manufacturing takes virtual blueprints from computer aided
design (CAD) or animation modeling software and "slices" them into digital
cross-sections for the machine to successively use as a guideline for printing.
2. Printing:
 The CAD information is sent to the printer.
 To perform a print, the machine reads the design and lays down successive
layers of liquid, powder, 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 together or automatically fused to create the
final shape. The primary advantage of this technique is its ability to create
almost any shape or geometric feature.

11. 3. Finishing:
 The printer forms the item by depositing the material in layers—starting from
the bottom layer—onto a platform. In some cases light or lasers are used to
harden the material.
 To perform a print, the machine reads the design and lays down successive
layers of liquid, powder, 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 together or automatically fused to create the
final shape. The primary advantage of this technique is its ability to create
almost any shape or geometric feature.
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 shape of the model,
binding it to first layer.
 3D printing builds 3D objects layer by layer.
 100-200 layers per inch.
Fig 2.2: Manufacturing a model with 3-D printer.

12. Fig 2.3 Prototype car
2.1 ALGORITHM:
The algorithm used in the 3D printing is as follows:
Fig 2.4 Algorithm of 3D printing
The flow of work can be easily understood with the help of the algorithm. The 3-D
prototype of a desired object is created in three basic steps and these steps are:
 Pre-Process.
 3-D Printing.
 Post-Printing.

13. 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.
Fig 2.5 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.

14. 3. METHODS OF 3-D PRINTING
The different methods of 3-D printing are:
 Stereo lithography.
 Selective laser sintering (SLS).
 Fused deposition modeling (FDM).
 Ink-Jet 3D printing.
3.1STEREO LITHOGRAPHY:
Stereo lithography is a process for creating three-dimensional objects using a
computer-controlled laser to build the required structure, layer by layer. It does this by
using a resin known as liquid photopolymer that hardens when in contact with the air.
Fig 3.1 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

15. 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.
3.2 SELECTIVE LASER SINTERING (SLS):
Selective laser sintering (SLS) is an additive manufacturing technique that
uses a high power laser to fuse small particles of plastic, metal (direct metal laser
sintering),ceramic or glass powders into a mass that has a desired 3-dimensional
shape.
Fig 3.2 Selective Laser Sintering
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.

16. 3.3 FUSED DEPOSITION MODELING (FDM):
Commonly used for modeling, prototyping, and production applications.Here
a hot thermoplastic is extruded from a temperature-controlled print head to produce
fairly robust objects to a high degree of accuracy.
Fig 3.3 Fused Deposition Modeling
Here a hot thermoplastic is extruded from a temperature-controlled print
head to produce fairly robust objects to a high degree of accuracy.
3.4 INK-JET 3-D PRINTING:
It creates the model one layer at a time by spreading a layer of powder and ink
jet printing binder in the cross-section of the part. It is the most widely used 3-D
Printing technology these days.

17. 4. PRINT HEAD
Industrial inkjet printing essentially means using inkjet technology as a
printing or deposition process in manufacturing or on production lines.
There are 2-types of print head for the generation of liquid drops.
1. Drop-On-Demand (DOD).
2. Continuous-Jet (CJ)
4.1 Drop-On-Demand (DOD):
Drop on Demand (DOD) is a broad classification of inkjet printing technology
where drops are ejected from the print head only when required. The drops are formed
by the creation of a pressure pulse within the print head.
Fig 4.1 Drop-on-Demand

18. 4.2 CONTINUOUS INK-JET (CJ):
A pump directs fluid from a reservoir to one or more small nozzles, which eject a
continuous stream of drops at high frequency (in the range of roughly 50 kHz to 175
kHz) using a vibrating piezoelectric crystal.
Fig 4.2: Continuous Ink-Jet (CJ)

19. 5. FEATURES
5.1 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.
5.1.1 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.

20. 5.2 ADVANTAGES
These are some of the advantages of 3D printing technology:
 Print movable parts.
 Print items in remote locations.
 Ability to send items over internet and print out at home.
 Plastic used is strong.
5.3 POTENTIALNEW BUSINESSES
 Printing shops.
 Printing Leasing.
 3-d Printing solutions for self service.
 Online printing services.
Fig 5.1 3D Printers

21. 6. APPLICATIONS
These are some of the applications of 3D printing technology:
6.1 FASHIONABLE PLASTER:
This 3D-printed cast to help repair broken bones may be the future of medical
orthopedic casts. 3D-printed casts also bring out the positive potential of this
emerging technology.
Fig 6.1 Fashionable Plaster

22. 6.2ARTIFICIAL ARMS FOR DISABLED:
Richard Van As, a South African carpenter, assembles a Robohand and fits it to
Liam Dippenaar. Liam was born without fingers on his right hand. Makerbot provided
them with the 3D printing technology that they used to print the parts for the
Robohand.
Fig 6.2 Artificial arms for disabled

23. 6.3BIONIC EAR:
Scientists, including an Indian-origin researcher, have created a 3D-printed
bionic ear that can "hear" radio frequencies far beyond the range of normal human
capability. Using off-the-shelf printing tools, the scientists at Princeton University
explored 3D printing of cells and nano particles, creating the bionic ear.
Fig 6.3 Bionic ear

24. 6.4 REPLACE ORGANS:
Surgeon Dr. Anthony Atala demonstrated during TED an early-stage
experiment that could someday solve the organ-donor problem: a 3D printer that uses
living cells to print out a transplantable kidney.
Fig 6.4 Replace organs

25. 6.5 OPPURTUNITIES OF APPLICATIONS:
 Unique back cover.
 Printing your own spectacle.
 Design & Use instead of Buy & Use.
Fig 6.5 Variety of applications

26. Fig 6.6 Variety of Applications

27. 7. CONCLUSION
Nothing communicates ideas faster than a three-dimensional part or model.
With a 3D printer you can bring CAD files and design ideas to life – right from your
desktop. Test form, fit and function – and as many design variations as you like –
with functional parts.
8. REFERENCES
 Wikihow available at: https://m.wikihow.com
 Lisa Harouni 3D printing entrepreneur available at:
https://www.ted.com/talks/lisa_harouni_a_primer_on_3d_printing
 Avi Reichental what next in 3d printing available
at:https://www.ted.com/talks/avi_reichental_what_s_next_in_3d_printing
 Bastian Schaefer a 3d printed jumbo jet available
at:http://www.ted.com/talks/bastian_schaefer_a_3d_printed_jumbo_jet?langua
ge=en
 Anthony atala printing a human kidney available
at:https://www.ted.com/talks/anthony_atala_printing_a_human_kidney
 http://www.explainingthefuture.com/3dprinting.html
 http://en.wikipedia.org/wiki/3D_printing
 http://www.mahalo.com/3d-printers/
 http://net.educause.edu/ir/library/pdf/DEC0702.pdf
 http://www.inventioncity.com/intro-to-3-d-printing.html
 http://desktop3dprinters.net/773374/3d-printing-technologies