A

Mini-Project Report
On

Additive Manufacturing
Titled

3D Printing on AION 500

Submitted by
1. Sanchit Nevatia (B224/70031115043)
2. Kartik Pareek (B225/70031115045)
3. Dhruv Patel (B226/70031115046)
4. Leo Puthussery (B228/70031115051)

Guided by
Dr. Rushikesh Dandhagwhal
 Contents
1. Introduction

2. Theory

2.1 Additive Manufacturing

2.2 FDM type Additive manufacturing technique

2.3 About AION 500

2.4 Software used

2.5 Material used

2.6 About file formats

3. Procedure

4. Conclusion
 1. INTRODUCTION

What is Additive Manufacturing?

 Additive Manufacturing (AM) is an appropriate name to describe the technologies that

build 3D objects by adding layer-upon-layer of material, whether the material is
plastic, metal, concrete or one day…..human tissue.

 Common to AM technologies is the use of a computer, 3D modeling software

(Computer Aided Design or CAD), machine equipment and layering material. Once a
CAD sketch is produced, the AM equipment reads in data from the CAD file and lays
downs or adds successive layers of liquid, powder, sheet material or other, in a layer-
upon-layer fashion to fabricate a 3D object.

 The term AM encompasses many technologies including subsets like 3D Printing,

Rapid Prototyping (RP), Direct Digital Manufacturing (DDM), layered manufacturing
and additive fabrication.

2. THEORY

2.1 Solid Based Additive Manufacturing

 Solid-based rapid prototyping systems are very different from the liquid-based photo-
curing systems.
 They are also different from one another, though some of them do use the laser in the
prototyping process.
 The basic common feature among these systems is that they all utilize solids (in one
form or another) as the primary medium to create the prototype.
 Fused deposition modeling (FDM)
 Laminated Object Manufacturing system (LOM)
 3D printing and Deposition Milling
 Multi-jet modeling system
 Selective Adhesive and Hot Pass (SAHP)

2.2 Fused Deposition Modelling

Stratasys Inc. was founded in 1989 and has developed most of the company’s products based
on the Fused Deposition Modeling (FDM) technology. The technology was first developed
by Scott Cramp in 1988 and the patent was awarded in the U.S. in 1992. FDM uses the
extrusion process to build 3D models. Stratasys introduced its first rapid prototyping machine,
the 3D modeler® in early 1992 and started shipping the units later that year.
Principle
  The principle of the FDM is based on surface chemistry, thermal energy, and layer
manufacturing technology.
 The material in filament (spool) form is melted in a specially designed head, which
extrudes on the model. As it is extruded, it is cooled and thus solidifies to form the model.
 The model is built layer by layer, like the other RP systems.

Parameters which affect performance and functionalities of the system are material
column strength, material flexural modulus, material viscosity, positioning accuracy,
road widths, deposition speed, volumetric flow rate, tip diameter, envelope temperature,
and part geometry.

2.3 About AION 500:

The revolutionary AION 500 is a high performance, massive size 3D printer that offers a
professional-level build volume at an affordable price point. Armed with our patented AFPM
(Advanced Fusion Plastic Modeling) technology, the printer renders a stronger and durable
output. With multiple connectivity options and sensors, it is one of the most advanced 3D
printers available in India. Offering a large build size, ultra-fast print speeds, and unmatched
precision, the AION 500 is designed for versatility.
AION 500 is a fully enclosed industrial grade 3D printer and assures a consistently high print
quality and repeatability. It features, the Quick Load functionality for changing and loading
filaments easily, anti-clogging filament sensors and a super-slicer that makes sure there’s no
time lost when the print is initiated - making it highly efficient and productive. The machine is
easy to use allowing the user to alternate between quick-&- easy to professional-grade printing
smoothly.
2.4 Software used:

Solidworks:

SolidWorks is a solid modeller, and utilizes a parametric feature-based approach which was
initially developed by PTC (Creo/Pro-Engineer) to create models and assemblies. The software
is written on Parasolid-kernel. Parameters refer to constraints whose values determine the
shape or geometry of the model or assembly. Parameters can be either numeric parameters,
such as line lengths or circle diameters, or geometric parameters, such as tangent, parallel,
concentric, horizontal or vertical, etc. Numeric parameters can be associated with each other
through the use of relations, which allows them to capture design intent. Features refer to the
building blocks of the part. They are the shapes and operations that construct the part. Shape-
based features typically begin with a 2D or 3D sketch of shapes such as bosses, holes, slots,
etc. This shape is then extruded or cut to add or remove material from the part. Operation-based
features are not sketch-based, and include features such as fillets, chamfers, shells, applying
draft to the faces of a part, etc. Building a model in SolidWorks usually starts with a 2D sketch
(although 3D sketches are available for power users). The sketch consists of geometry such as
points, lines, arcs, conics (except the hyperbola), and splines. Dimensions are added to the
sketch to define the size and location of the geometry. Relations are used to define attributes
such as tangency, parallelism, perpendicularity, and concentricity. The parametric nature of
SolidWorks means that the dimensions and relations drive the geometry, not the other way
around. The dimensions in the sketch can be controlled independently, or by relationships to
other parameters inside or outside of the sketch.

Netfabb-

Autodesk Netfabb is the next generation of industrial-strength 3D printing software for.

Windows. It allows for extensive customization of supports, mesh repair, and overall
workflow, to optimize your production process. Netfabb's native file format is
FABBPROJECT. It contains your parts, slices, lattice bodies, loaded modules to create
supports, to repair, or to manipulate meshes, for example, as well as machine workspaces. It
also stores information about visibility and grouping. To get part data into and out of Netfabb,
it reads and writes a large number of mesh file formats such as 3MF and STL. CAD formats
such as IGS, STEP, and CATPART may be loaded and saved. Slice data are loaded and saved
in formats such as CLI, SLC, XML as well as stacks of SVG, PNG and DXF images. Additional
loading and saving is available for simulation results, Lua scripts, scripts for support generation
or repair, and other functions. Access to most file functions happens through the File menu.
Where applicable, you can also use context menus and drag-and-drop to work with files. Some
functions will have their own file loading and saving dialogs.

KISSlicer:

KISSlicer has come a long way from the initial command line release. Targeting precision and
focusing on the technical aspects of 3D printing has kept KISSlicer adding features and options
to keep up with a wide variety of printer types, print styles, and mesh topologies, all while
gracefully handling new and more demanding materials.That is why KISSlicer 1.6 is armed
with a series of Profile Wizards designed to get you printing, from scratch, in a matter of
minutes. Once the basics are in place, KISSlicer offers a Tuning Wizard to precisely tune
material settings in a single print. Now you will only need to keep a bin of Marvin or Benchy
prints around if you really want to.

Next-Gen features like the adaptive ("Stepover-Controlled") layer heights, numerically

modelled dynamic plastic deposition ("Preload"), extruder priorities (for handling overlapping
meshes), varying Styles per object ("Lock Paths"), loop stitching ("Fractional Loops") to better
bond to the infill, loop-modifying seam hiding ("Join-Loop"), and others combine to generate
beautiful and precise G-code paths for technically demanding prints.
KISSlicer's new profile handling makes it easy to share a specific profile with a friend, archive
all settings used in a print in a Project File, or carefully monitor and manage your settings with
a version control system of your choice. Most Recently Used profiles are also linked with each
Printer profile, so you can easily switch between multiple printers, slice and print.

2.5 Material used:

ABS P500:

 ABS P500 is a high impact strength material well suited for the medical, pharmaceutical
and food packaging industries. Parts manufactured with ABS P500 material are bio-
compatible and can be gamma or ETO sterilized.
 This material can be used for products that come in contact with skin, food and medications.
 It is 25 to 65 percent stronger than standard ABS, making it ideal for concept modelling,
functional prototyping, manufacturing tools and end use parts.
 With significantly stronger layer bonding than ABS and greater tensile, impact and flexural
strength, ABS-P500 parts are stronger, smoother and have better feature detail.
 PROPERTIES VALUES

Specific Gravity 1.02

Impact Strength (Izod) (J/m) 533.787

Tensile Strength (MPa) 46

Tensile Elongation (%) 30

Tensile modulus (MPa) 2300

Flexural Strength (MPa) 74

Injection Pressure (MPa) 66.327-106.868

Melt Temperature (oC) 222.22-225

2.6 About File Formats:

SLDPRT file:
SLDPRT is a file extension for an image file used with SolidWorks CAD software. SLDPRT
stands for Solid works Part file. SLDPRT files contain a 3-D object or “part” that can be
combined with other “parts” to create a single assembly file. SLDPRT files can be opened and
edited with SolidWorks CAD software. SLDPRT files can also be viewed with Adobe Acrobat
3D or Acrobat Pro 9.

STL FILE:
STL (an abbreviation of "stereolithiography") is a file format native to the stereolithiography
CAD software created by 3D Systems. STL has several after-the-fact acronyms such as
"Standard Triangle Language" and "Standard Tessellation Language". This file format is
supported by many other software packages; it is widely used for rapid prototyping, 3D printing
and computer-aided manufacturing. STL files describe only the surface geometry of a three-
dimensional object without any representation of colour, texture or other common CAD model
attributes. The STL format specifies both ASCII and binary representations. Binary files are
more common, since they are more compact.
An STL file describes a raw, unstructured triangulated surface by the unit normal and vertices
(ordered by the right-hand rule) of the triangles using a three-dimensional Cartesian coordinate
system. In the original specification, all STL coordinates were required to be positive numbers,
but this restriction is no longer enforced and negative coordinates are commonly encountered
in STL files today. STL files contain no scale information, and the units are arbitrary.
3. PROCEDURE