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1.Introduction
3Dimensions printing is a method of converting a virtual 3D model into a physical object.
3D printing is a category of rapid prototyping technology. 3D printers typically work by printing
successive layers on top of the previous to build up a three dimensional object.
The past decade has witnessed the emergence of new manufacturing technologies that
build parts on a layer-by-layer basis. Using these technologies, manufacturing time for parts of
virtually any compleity is reduced considerably. !n other words, it is rapid. "apid #rototyping
Technologies and "apid $anufacturing offer great potential for producing models and uni%ue
parts for manufacturing industry.
& few years ago, to get some prototyping work done for a product or design you are
working on, you are re%uired to spend a lot of man-hours just to come up with the model. Those
hours will be spent creating miniature parts of your design using wood and then gluing all those
parts together painstakingly. #rototyping is, at the very least, time-consuming and etremely
tedious.
These days, however, you can take the tediousness and the time investment out of yourprototyping tasks through rapid prototyping or 3d printing. 3D printing is a revolutionary method
for creating 3D models with the use of inkjet technology. $any engineers have even dubbed 3D
printing as the process of creating something out of nothing. Thus, the reliability of products can
be increased' investment of time and money is less risky. (ot everything that is thinkable today
is already workable or available at a reasonable price, but this technology is fast evolving and the
better the challenges, the better for this developing process.
The term "apid prototyping )"#* refers to a class of technologies that can automatically
construct physical models from +omputer-&ided Design )+&D* data.
!t is a free form fabrication techni%ue by which a total object of prescribed shape, dimension and
finish can be directly generated from the +&D based geometrical model stored in a computer,
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with little human intervention. "apid prototyping is an additive process, combining layers of
paper, wa, or plastic to create a solid object. !n contrast, most machining processes )milling,
drilling, grinding, etc.* are subtractive processes that remove material from a solid block. "#s
additive nature allows it to create objects with complicated internal features that cannot be
manufactured by other means.
!n addition to prototypes, "# techni%ues can also be used to make tooling )referred to as rapid
tooling* and even production-%uality parts )rapid manufacturing*. or small production runs and
complicated objects, rapid prototyping is often the best manufacturing process available. /f
course, rapid is a relative term. $ost prototypes re%uire from three to seventy-two hours to
build, depending on the si0e and compleity of the object. This may seem slow, but it is much
faster than the weeks or months re%uired to make a prototype by traditional means such as
machining. These dramatic time savings allow manufacturers to bring products to market faster
and more cheaply.
3D PRINTING: MAKING THE DIGITAL REAL
!magine a future in which a device connected to a computer can print a solid object. & future in
which we can have tangible goods as well as intangible services delivered to our desktops or
highstreet shops over the !nternet. &nd a future in which the everyday atomi0ation of virtual
objects into hard reality has turned the mass pre-production and stock-holding of a wide range of
goods and spare parts into no more than an historical legacy.
1uch a future may sound like it is being plucked from the worlds of 1tar Trek. 2owever, whilst
transporter devices that can instantaneously deliver us to remote locations may remain a fantasy,
3D printers capable of outputting physical objects have been in development for over two
decades. hat4s more, several 3D printers are already on the market. &vailable from companiesincluding ortus, 3D 1ystems,1olid 1cape, 5+orp, and Desktop actory,these ama0ing devices
produce solid, 3D objects from computer data in roughly the same way that 6D printers take our
digital images and output hardcopy photos.
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The Desktop actorycurrently sells a 3D printer for 7899:. This can print models up to a five-
inch cube in si0e with consumables costing around 7; per cubic inch. 2owever, prices for most
3D printers tend to start in the ten-to-twenty thousand pound bracket and spiral upwards.
<hough some desktop models are on the market, most 3D printers are usually fairly bulky and
often floor-standing.
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2. Rapid Prototyping Tc!ni"u#
"apid prototyping is the fabrication of parts from +&D data sources. 1everal rapid
prototyping methods have been created to produce objects of comple geometries in a relatively
short amount of time. These systems are beneficial to engineers by allowing them to better
understand the products that they are designing and by providing them with a way to create a
visual aid to communicate with others. "apid prototyping allows design challenges to be
determined earlier in the design process, saving time and money. The technology of rapid
prototyping is easy to access and simple to understand.
2.1 $tro %it!ograp!y
#atented in ;9 laser traces out the first layer, solidifying the models cross section while
leaving ecess areas li%uid. (et, an elevator incrementally lowers the platform into the li%uid
polymer. & sweeper re-coats the solidified layer with li%uid, and the laser traces the second layer
atop the first. This process is repeated until the prototype is complete. &fterwards, the solid part
is removed from the vat and rinsed clean of ecess li%uid. 1upports are broken off and the model
is then placed in an ultraviolet oven for complete curing. ?ecause it was the first techni%ue,
stereolithography is regarded as a benchmark by which other technologies are judged. @arly
stereolithography prototypes were fairly brittle and prone to curing-induced warpage and
distortion, but recent modifications have largely corrected these problems.
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ig 6.;A1tereo lithography
2.2 La&inatd '()ct Manu*acturing
!n this techni%ue, developed by 2elisys of Torrance, +&, layers of adhesive-coated sheet
material are bonded together to form a prototype.. &s shown in the figure below.
ig6.6A 1chematic diagram of laminated object manufacturing.
& feederBcollector mechanism advances the sheet over the build platform, where a base
has been constructed from paper and double-sided foam tape. (et, a heated roller applies
pressure to bond the paper to the base. & focused laser cuts the outline of the first layer into the
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paper and then cross-hatches the ecess area )the negative space in the prototype*. +ross-
hatching breaks up the etra material, making it easier to remove during post-processing. During
the build, the ecess material provides ecellent support for overhangs and thin-walled sections.
&fter the first layer is cut, the platform lowers out of the way and fresh material is advanced. The
platform rises to slightly below the previous height, the roller bonds the second layer to the first,
and the laser cuts the second layer. This process is repeated as needed to build the part, which
will have a wood-like teture. ?ecause the models are made of paper, they must be sealed and
finished with paint or varnish to prevent moisture damage.
2elisys developed several new sheet materials, including plastic, water-repellent paper,
and ceramic and metal powder tapes. The powder tapes produce a green part that must be
sintered for maimum strength. &s of 6CC;, 2elisys is no longer in business.
2.3 $%cti+ La#r $intring
Developed by +arl Deckard for his masters thesis at the University of Teas, selective laser
sintering was patented in ;9
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ig 6.3A 1chematic diagram of selective laser sintering.
2., -u#d Dpo#ition Mod%ing
!n this techni%ue, filaments of heated thermoplastic are etruded from a tip that moves in
the -y plane. ike a baker decorating a cake, the controlled etrusion head deposits very thin
beads of material onto the build platform to form the first layer.
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ig6.8A schematic diagram of fused deposition modeling.
The platform is maintained at a lower temperature, so that the thermoplastic %uickly
hardens. &fter the platform lowers, the etrusion head deposits a second layer upon the first.
1upports are built along the way, fastened to the part either with a second, weaker material or
with a perforated junction.
2. E%ctron (a& &%ting)E/M*
!t is a type of additive manufacturing for metal parts. !t is often classified as a rapid
manufacturingmethod. The technology manufactures parts by melting metal powder layer per
layer with an electron beam in a high vacuum. Unlike some metal sinteringtechni%ues, the parts
are fully dense, void-free, and etremely strong.
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This solid freeform fabricationmethod produces fully dense metal parts directly from
metal powder with characteristics of the target material. The @?$ machine reads data from a 3D
+&D model and lays down successive layers of powdered material. These layers are melted
together utili0ing a computer controlled electron beam. !n this way it builds up the parts. The
process takes place under vacuum, which makes it suited to manufacture parts in reactive
materials with a high affinity for oygen.
ig6.8A @lectron beam melting
The melted material is from a pure alloy in powder form of the final material to be
fabricated )no filler*. or that reason the electron beam technology doesn4t re%uire additional
thermal treatment to obtain the full mechanical properties of the parts. That aspect allows
classification of @?$ with 1$where competing technologies like 11 and D$1 re%uire
thermal treatment after fabrication. +omparatively to 11 and D$1, @?$ has a generally
superior build rate because of its higher energy density and scanning method. $inimum layer
thicknessA C.C: mm. Tolerance capabilityA FB- C.8 mm.
2.0 3D Printing
!nk-Get #rinting refers to an entire class of machines that employ ink-jet technology. The
first was 3D #rinting )3D#*, developed at $!T and licensed to 1oligen +orporation, @trude
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2one, and others. The 5+orp 3D printer, produced by 5 +orporation of ?urlington, $& is an
eample of this technology. &s shown in igure =a, parts are built upon a platform situated in a
bin full of powder material. &n ink-jet printing head selectively deposits or prints a binder fluid
to fuse the powder together in the desired areas. Unbound powder remains to support the part.
The platform is lowered, more powder added and leveled, and the process repeated. hen
finished, the part is then removed from the unbound powder, and ecess unbound powder is
blown off. inished parts can be infiltrated with wa, +& glue, or other sealants to improve
durability and surface finish. Typical layer thicknesses are on the order of C.; mm. This process
is very fast, and produces parts with a slightly grainy surface. 5+orp uses two different materials,
a starch based powder )not as strong, but can be burned out, for investment casting applications*
and a ceramic powder. $achines with 8 color printing capability are available.
3D 1ystems version of the ink-jet based system is called the Thermo-Get or $ulti-Get
#rinter. !t uses a linear array of print heads to rapidly produce thermoplastic models )igure =d*.
!f the part is narrow enough, the print head can deposit an entire layer in one pass. /therwise, the
head makes several passes.
ig 6.=A 3D #rinting
3. T! /a#ic Proc## o* 3D Printing
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<hough several rapid prototyping techni%ues eist, all employ the same basic five-step process.
The steps areA
;. +reate a +&D model of the design
6. +onvert the +&D model to 1T format
3. 1lice the 1T file into thin cross-sectional layers
8. +onstruct the model one layer atop another
:. +lean and finish the model
AD Mod% ration:
irst, the object to be built is modeled using a +omputer-&ided Design )+&D* software package.
1olid modelers, such as #roB@(H!(@@", tend to represent 3-D objects more accurately than
wire-frame modelers such as &uto+&D, and will therefore yield better results. The designer can
use a pre-eisting +&D file or may wish to create one epressly for prototyping purposes. This
process is identical for all of the "# build techni%ues.
on+r#ion to $TL -or&at:
The various +&D packages use a number of different algorithms to represent solid objects. To
establish consistency, the 1T )stereolithography, the first "# techni%ue* format has been
adopted as the standard of the rapid prototyping industry. The second step, therefore, is to
convert the +&D file into 1T format. This format represents a three-dimensional surface as an
assembly of planar triangles, like the facets of a cut jewel. =The file contains the coordinates of
the vertices and the direction of the outward normal of each triangle. ?ecause 1T files useplanar elements, they cannot represent curved surfaces eactly. !ncreasing the number of
triangles improves the approimation, but at the cost of bigger file si0e. arge, complicated files
re%uire more time to pre-process and build, so the designer must balance accuracy with
manageability to produce a useful 1T file. 1ince the 1T format is universal, this process is
identical for all of the "# build techni%ues.
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$%ic t! $TL -i%:
!n the third step, a pre-processing program prepares the 1T file to be built. 1everal programs
are available, and most allow the user to adjust the si0e, location and orientation of the model.
?uild orientation is important for several reasons. irst, properties of rapid prototypes vary from
one coordinate direction to another. or eample, prototypes are usually weaker and less accurate
in the 0 )vertical* direction than in the -y plane. !n addition, part orientation partially determines
the amount of time re%uired to build the model. #lacing the shortest dimension in the 0 direction
reduces the number of layers, thereby shortening build time. The pre-processing software slices
the 1T model into a number of layers from C.C; mm to C.I mm thick, depending on the build
techni%ue. The program may also generate an auiliary structure to support the model during the
build. 1upports are useful for delicate features such as overhangs, internal cavities, and thin-walled sections. @ach "# machine manufacturer supplies their own proprietary pre-processing
software.
ig 3.;A- 1lice the 1T ile
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Layr (y Layr on#truction:
The fourth step is the actual construction of the part. Using one of several techni%ues )described
in the net section* "# machines build one layer at a time from polymers, paper, or powdered
metal. $ost machines are fairly autonomous, needing little human intervention.
ig 3.6 ayer by ayer +onstruction
%an and -ini#!:
The final step is post-processing. This involves removing the prototype from the machine and
detaching any supports. 1ome photosensitive materials need to be fully cured before use.
#rototypes may also re%uire minor cleaning and surface treatment. 1anding, sealing, andBor
painting the model will improve its appearance and durability.
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3D printing >s con+ntiona% tc!no%ogi#
3D# does notJand will notJreplace completely conventional technologies such (+ and
high-speed milling, or even hand-made parts. "ather, one should regard 3D# as one more option
in the toolkit for manufacturing parts. igure depicts a rough comparison between 3D# and
milling regarding the costs and time of manufacturing one part as a function of part
compleity;C. !t is assumed, evidently, that the part can be manufactured by either technology
such that the material and tolerance re%uirements are met.
ig:.;A 3D# vs. conventional machining
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2. Action -igur#
?lood @lves and band mates can both be brought to life using 3D printers. These two
were created using 5corp. machines which apply glue ink and powder in fine layers slowly
creating a replicaof one of your characters. igure #rintsallows you to create characters from
arcraft, "ock bandand 1poreprinting services are coming soon. &numberof othersitesallow
you to pull data from 1econd ife and your own 3D programs.
3. %ry
Gewelry makers were some of the first to use 3D printing in their manufacturing process,
however they do not use metal printers, but rather ones that use wa. !n a process called
Kinvestment castingL a piece of jewelry is sculpted or printed out of wa. #laster is then poured
on either side. $olten metal is poured onto the wa which melts out leaving a metal version of
your wa sculpt in its place in the plaster. This piece is then finished and polished by a jeweler.
$any independent jewelers have been using high tech printers in their businesses and an
innovative company called #aragon ake has combined this process with web based design tools
to offer an infinite inventory to the masses of jewelry stores.
,. Prototyp#
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#rototypinginproduct developmentis currently the biggest use of 3D printing technology.These
machines allow designers and engineers to test out ideasfor dimensional products cheaply before
committing to epensive tooling and manufacturing processes.
. Mod%#
1ales folks lives get much easier when you can have models like thisof your product printed up
for show and tell.
0. Mdicin
3D orld of arcraft characters are cool, but these tools have the power to help save lives.
1urgeons are using 3d printers to print body parts for reference before complicated surgeries.
/ther 3D printersare used to createbone graftsfor patients who have suffered traumatic injuries.
ooking further in the future scientist are working on #"!(T!(Hreplacement organs. #ersonal
abrication indeedM
http://www.objet.com/Misc/Groups_of_Pages/CaseStudies/Logitech/tabid/375/Default.aspxhttp://zcorp.com/Solutions/Rapid-Prototypes---CAD/Concept-Models/spage.aspxhttp://www.objet.com/Misc/Pages/CaseStudies/DesignworksWindsor/tabid/513/Default.aspxhttp://www.time-compression.com/x/guideArchiveCategoryArticlesList.html?bid=4&browse=phttp://www.capinc.com/pages/products/dimension3dprinter.cfmhttp://www.thinglab.co.uk/http://www.aecbytes.com/newsletter/2008/issue_34-images/fig7small.jpghttp://www.businessweek.com/technology/content/oct2008/tc2008103_077223.htmhttp://www3.interscience.wiley.com/journal/112671997/abstract?CRETRY=1&SRETRY=0http://www.pinktentacle.com/2007/08/artificial-bones-made-with-3d-inkjet-printers/http://abcnews.go.com/Technology/story?id=1603783&page=1http://www.technologyreview.com/biotech/17913/http://www.time.com/time/health/article/0,8599,1679115,00.htmlhttp://replicatorinc.com/blog/wp-content/uploads/2008/10/a_3d_med.jpghttp://replicatorinc.com/blog/wp-content/uploads/2008/10/a_3d_models.jpghttp://www.objet.com/Misc/Groups_of_Pages/CaseStudies/Logitech/tabid/375/Default.aspxhttp://zcorp.com/Solutions/Rapid-Prototypes---CAD/Concept-Models/spage.aspxhttp://www.objet.com/Misc/Pages/CaseStudies/DesignworksWindsor/tabid/513/Default.aspxhttp://www.time-compression.com/x/guideArchiveCategoryArticlesList.html?bid=4&browse=phttp://www.capinc.com/pages/products/dimension3dprinter.cfmhttp://www.thinglab.co.uk/http://www.aecbytes.com/newsletter/2008/issue_34-images/fig7small.jpghttp://www.businessweek.com/technology/content/oct2008/tc2008103_077223.htmhttp://www3.interscience.wiley.com/journal/112671997/abstract?CRETRY=1&SRETRY=0http://www.pinktentacle.com/2007/08/artificial-bones-made-with-3d-inkjet-printers/http://abcnews.go.com/Technology/story?id=1603783&page=1http://www.technologyreview.com/biotech/17913/http://www.time.com/time/health/article/0,8599,1679115,00.html8/11/2019 39051714 Rapid Prototyping 3d Printing
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4. ri& $cn Rcon#truction
3D printing can save lives, bring /rcs to life, and solve crimes. 3D printingBscanningis used in
forensics in real life and as a prop for dramatic effect in this clip from +1!.
Ad+antag# o* 3D Printing
The most successful companies have adopted 3D printing as a critical part of the iterative design
process toA
1. Incra# Inno+ation
#rint prototypes in hours, obtain feedback, refine designs and repeat the cycle until
designs are perfect.
2. I&pro+ o&&unication
2old a full color, realistic 3D model in your hands to impart infinitely more information
than a computer image.
+reate physical 3D models %uickly, easily and affordably for a wide variety of
applications.
3. $pd Ti& to Mar5t
+ompress design cycles by 3D printing multiple prototypes on demand, right in your
office.
,. Rduc D+%op&nt o#t#
+ut traditional prototyping and tooling costs.
!dentify design errors earlier.
"educe travel to production facilities.
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Di#ad+antag# o* 3D Printing
<hough three-dimensional printing has many advantages, it also has a few disadvantages that
come with itA
+urrent 3D printing materials for investment casting tend to yield sporadically rough
surfaces.
1ometimes encourages informal design methods which may cause more problems to fi.
!t may not be suitable for large si0ed applications.
The user may have very high epectations about theprototypes performance and it mightfail in the eact replication of the real product or systems.
3-D printers are still epensive.
<hough 3-D printers have the potential of creating many jobs and opportunities, they
might also put certain jobs at risk )for eample, you can make your toys at home so toy
stores and toy makers might go out of business*.
3D# parts have a ribbed and little rough appearance due to layering beads of plastic.
ould be a slow process for large build volume parts.
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T! -utur o* 3D Printing
irstly lets clarify what is meant by 3D printing, well in a nut shell it is a way of fabricating
objects designed on computer
, for eample if you designed a mug using computer aided design
, within a few hours you could have the real thing sitting in front of you.
!t is possible to watch your very creations come to life in true 1tar Trek fashion, before your
very eyes. To go into more detail, currently printers are fairly slow, limited and not tremendously
precise. & home 3D printer will typically set up back about ten thousand pounds, but this is
cheap considering the first commercially available printers cost at least ten times that amount.
3D printers presently are capable of fabricating objects using silicon and certain types of metal,
other substances that have been tested are plaster, play-doh and even chocolateM
& home 3D printer is about the si0e of a $icrowave and connects directly to a desktop
computer running softwarethat controls its operation. !t then creates objects layer-by-layer by
s%uee0ing material from a mechanically-controlled syringe. Unfortunately printers are somewhat
limited in the sense they still produce a fairly rough end product and the time scale it takes to
print an object is considerable.
Despite all the technical implications, there are huge possibilities for the future of 3D printing.
&ll ground breaking technologystarts somewhere, for eample in the case of the#+,mainframeshad eisted for years, but personal computing only took off in the late seventies. & cheap self-
assembly computer called the <air
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There are a number of different 3D printers available on the market today, all with slightly
different advantages, disadvantages, %uirks and features. 1ome interesting projects include an
open source 3D printer which has successfully been used to fabricate better parts to replace
eisting parts on the printer itself. The ultimate goal of 3d printers is to perfectly replicate
themselves, allowing much more cost effective manufacturing.
The future for 3D printing seems very promising, it is the fastest growing part of the rapid-
prototyping industry with revenues this year epected to be approimately a billion U1 dollars.
$any industries are showing huge amounts of interest and are seem great potential in different
applications where they could utili0e three dimensional printing. The U1 army have
eperimented using rapid prototyping to create parts for broken tanks, guns and other hardware
in combat situations. ?usinesses believe a rapid prototyping machine could prove invaluable in
showing factories how to assemble parts remotely, for eample in +hina. @ven (&1& has
re%uested a high resolution machine to manufacture crucial parts in space.
!n conclusion what is stopping you being part of a truly revolutionary technology, which could
become one of the major breakthroughs of the twenty first centuryN 3D printing has merely been
science fiction until recently, where it is now most certainly science fact. hat can we epect to
see in the not so far away futureN ell one ultimate goal is printable organic parts, for eample
replacement organs, identical skin grafts and even limbs, to combat victims of illness, disease
and war.
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