3D MANUFACTURING

A Project Report

FOUNDATION FOR ORGANISATIONAL RESEARCH AND

EDUCATION NEW DELHI

Academic Session 2019-20

Submitted To: Submitted By:

Prof. Somayya Vaibhav Baheti
Madakam 281173
 TABLE OF CONTENT

 Introduction

 Need of the study

 Objective

 Methodology

 General Principles:

 Applications

 Advantages

 Disadvantages

 Conclusion

 Reference
1. Introduction:
3-D printing, 3-D manufacturing or additive manufacturing is a process for
making a 3-D object of any shape from a 3-D model or other electronic data
sources through a additive processes in which successive layers of material are
laid under computer controls. Hideo Kodama of Nayoga Municipal Industrial
Research Institute is generally regarded to have print the first solid object from a
digital design. However, the credit for the first 3-D printer generally goes to
Charles Hull, who in 1984 designed same while working for the company he
founded, 3-D Systems Corp. Charles a Hull was a pioneer of the solid imaging
process known as stereo lithography and the STL (stereo lithographic) file format
which is still the most widely used format used today in 3-D printing. The same
person started the rapid-prototyping that was concurrent comercially with his
development of 3-D printing. Photopolymers were used initially which were
heated by ultraviolet light to achieve the melting and solidification effect. Since
1984, when the first 3-D printer was design and realized by Charles W. Hull from
3-D Systems Corporation, the technology has evolved and these machines have
become more and more useful, while their price have reduced, thus becoming
more affordable.

Nowadays, rapid prototyping has a wide range of applications in various fields

of human activity: research, engineering, medical, military, construction,
architecture, fashiontech, education, computer industry and many more. In 1990,
the plastic extrusion technology most widely associated with the term "3-D
printing" was invented by Stratasys by the name Fused deposition modeling or
FDM. After the start of the 21st century, there has been a large growth in the
sales of 3-D printing machines and their price has been dropped gradually.

Manufacturing processes are not new to this world. Process or sequence of

preparing any useful product is known as manufacturing process. Since human
invented the wheel, Manufacturing processes have gradually become more
complex and there was need to transform these complex processes into simple
process. 3-D printing is one such technology which can make 3-D products and
copy of products with great ease with reduction in material use by reducing
wastage which eventually saves capital and improves efficiency of manufacturing
processes.

Other terms that had been used as AM synonyms included desktop

manufacturing, rapid-manufacturing, and agile tooling ondemand manufacturing.
The 2010s were the first decade in which metal end use parts such as engine
brackets and large nuts would be grown in job production rather than compulsory
being machined from plate or stock..

2. Need of the study:

Manufacturing processes are continuously changing and reformation in the way

world uses its manufacturing technologies was long overdue. In the recent years, 3-
D printing has developed significantly and performs crucial roles in many
applications, with the most important being in manufacturing, medicine,
architecture, automotive, custom art and design.

3-D printing processes are finally catching up to their full potential, and are
currently being used in manufacturing and medical industries, as well as by
sociocultural sectors which facilitate 3-D printing for commercial purposes.
There has been lot of hype in the previous years when referring to the possibilities
that we can achieve by adopting 3-D printing as one of the main manufacturing
technology.

For a long time, the issue with 3-D printing was that it has demanded very high
entry costs, which does not allow profitable implementation to mass-manufacturers
when compared to standard processes. However, recent market trends spotted have
found that this is finally changing. As the market for 3-D printing has shown some
of the quickest growth within the manufacturing industry in recent years there is
need to focus on this technology which may reform the manufacturing processes in
time to come.

3. Objective

3-D printing is widely used in this world so it’s great time to study the 3-d
manufacturing processes, the main purpose of this project is to study about the
advancement in 3-D manufacturing in recent times and to also know about the
basics of 3-D manufacturing.

The main objectives are:

1) To get familiar with the term 3-D manufacturing, 3-D printing and 3-D
modeling.
2) To know how 3-D manufacturing processes works and how this technology
is being used in this world.
3) To know about the different applications of 3-D printing and 3-D modeling
4) To know how it is different from conventional manufacturing
 5) To know how different systems and departments are collaborated into
single system by the help of IT infrastructure and made 3-D modeling and
manufacturing platform easy to work.

4. Methodology

This study is a systematic literature review 10 latest research papers from

International Journals. We conducted our review in five stages: define, search,
select, analyse and present work. This guideline contributes to theoretical
process and has adequate flexibility for literature review. Furthermore, this
guideline enables researchers to apply thematic content analysis to identify key
themes in a single field of study.

Many methodologies are used in different paper such as

1) Quantitative analysis

2) Qualitative analysis

3) Observational

4) Article studies

5) Hypothesis

All of these were used to achieve different type of results and fulfil different

objectives.
5. General Principles

Modeling:

3-D printable models can be created with the help of CAD design software or via a
3-D scanner. The manual modeling process of preparing geometric data for 3-D
computer graphics is similar to method of sculpting. 3-D modeling is a process of
collecting and analyzing the data on the shape and appearance. Based on this data,
3-D model of the scanned object can be produced. Both manual and automatic
creations of 3-D printed model are very difficult for average consumers. That is
why several market-places have emerged over the last years among the world. The
most popular are Shape ways, Thing verse, My Mini Factory, and Threading.

Printing:

Before printing a 3-D models from any .STL file, it must be processed by a piece
of software called a slicer which converts the 3-D model into a series of thin
multiple layers over layer and produces a G code file from some .STL file which
contains instructions. There are several open sources slicer programs. The 3-D
printer follows the G code instructions to put down successive layers of liquid,
powder, or sheet materials to build a model from a series of cross-sections of a
model. These layers, virtual cross sections which correspond from the CAD
model, are joined or fused to create the final shape of a model. The main
advantage of using this technique is it’s ability to create almost any geometric
shape. Construction of a model with existing methods can take anywhere from
several hours to days, which depends on the method used and the size and
complexity of this model.
Finishing:

Although the printer produced resolution is sufficient for most of the applications,
printing a slightly oversize version of the object in standard resolution and then
removing material with a higher resolution process can gain better precision. As
with the 3D printer or other machines Press Release. The International
Manufacturing Technologies showed additive manufacturing techniques are
capable of using multiple materials in the course of constructing parts.
Applications:

Aeronautical Sector:
The Aeronautical industries pushes the limits of geometric design complexity;
the evolution and consistent improvement in the aircrafts demand that the parts
become more efficient and accurate even if the size of the vessels become
smaller. This is why design optimization is essential to the progression of any
kind of industry. Optimizing a design can be challenging when using
traditional manufacturing processes and that is why most technicians have
turned to 3-D Printing.

Automobile Sector:
Automobile design has become very easy since the development of CAD
softwares like AutoCAD, Solidworks, Ansys and Catia.
These softwares have facilated of designing and simulation of automobile with
high quality rendering and high precision and information with 0 tolerances.

3-D model in
Solidworks
 Model after
Fabrication

Pharmaceutical Sector:

To support new product development for the medical and dental industries the
3-D technology is utilized to make patterns for the downstream metal casting
of dental crowns and also in the manufacturing of the tools over which plastic
is being vaccum formed to make aligners for dental. In various body organ
prototypes designing also this is used.
 Fig. Design of jaws with the help of 3-D printing

Jewellery Sector:
For the jewellery sector, 3-D printing has proved to be of huge advantage. There is
a great deal of interest and uptake based on how 3-D printing can, and will,
contribute to the further development in this industry. Now from the new design
freedoms enabled by 3-D CAD and 3-D printing, through improving traditional
processes for jewelry production all the way to direct 3-D printed production
eliminating many of the traditional steps and saving resources.

BIM- Construction sector:

With a vision to make construction management easy 3-D printing offers a

relatively fast, easy and economically viable method of producing detailed models
directly from 3-D CAD, BIM or other digital data that BIM architects use. BIM is
Building Information Modeling which is used to create 3-D models of buildings
before construction and then various services like HVAC, MEP, Firefighting are
collaborated into one system to make construction more easy and fast.
• LOD Specifications

• 3-D Models of building with walk in views

• Software: Revit and Navisworks

• Architecture design

• MEP, HVAC, Electrical, Firefighting services all in one system

• Clash coordination among different services of building

• Site installation

ADVANTAGES
• Time-to-Market: 3-D printing allows ideas and products to develop faster. Being
able to print a concept on the same day it was designed shrinks a
development process from what might have been months to a number of
days, helping companies have a competitive advantage.

• Cost reduction: Prototyping injection moulding tools and production runs are
expensive hence not cost effective. The 3-D printing process allows the
creation of parts or tools through additive manufacturing at rates much
lower than traditional machining cost.

• Mitigating Risk: Being able to verify any design before investing in any
expensive moulding tool is worth its weight in 3-D printed prototyping. It is
far cheaper to 3-D print a test prototype than to re-design or make changes in
any existing mould.
• Feedback mechanism: With a prototype, we can also test the market by
unveiling it at any tradeshow, showing it to potential buyers or raising
capital by pre-selling it. Getting buyers responses for the product before it
actually gears up for production is a valuable way to verify if the product
has market potential or not.

• Get the Feel: The one thing we can't get a picture or any virtual prototype on
the computer screen is in the way that something feels in your hand. If we
want the ergonomics and fit of a product are just right, we must actually take
it hold it then use it and test it.

• Personalize It: With standard mass production, all the parts come off the
assembly line are mostly the same. With 3-D printing, one can personalize
and customize any part to uniquely fit their needs, which allows for custom
fits in the various industries and helps set people to elaborate their idea in
the new world.

DISADVANTAGES

• Intellectual property issues: The ease with which the replicas of any
product can be created using 3-D technology raises issues over intellectual
property rights. Blue prints availability for free can make businesses ru for
money and can hinder the rights.

• Limitations of the raw material: 3-D printers can work with a lot of raw
materials. But this is insignificant when compared with the enormous range of
raw materials which can be used in traditional manufacturing. More research is
required to develop methods to enable 3-D printed products to be more durable.

• Limitations of size: Very large objects are still not feasible when built
using 3-D printers hence this technology is currently limited by size constraints.

• Cost of printers: Feasibility of buying a 3D printer is still not there due to

high cost but with advancement in technology the prices will get reduced and
technology will become more affordable. Also, printers that can manufacture in
colour are costlier than printers of monochrome objects.

• Fewer Manufacturing Jobs: As with all the newer technologies,

manufacturing jobs will gradually decrease and this disadvantage can have large
impact to the economies of this world specially on India that have low cost
labors abundance.

.
6. CONCLUSION

Introduction part is about the concept and brief history of 3-D printing, in the next
section we have depicted the 3-D-printing and the processes used in 3-D-printing
in today’s world. Then we discussed the objective of the project. In the next
section, we have highlighted the main advantages and disadvantages of the 3-D
printing technology. We also discussed the applications of 3-D manufacturing
applications and we can conclude that the 3-D printing technology's importance
and social impact increase gradually day by day and influence the human's life, the
economy, and modern society by creating a new platform of IT infrastructure and
will collaborate various disciplines into a single platform.
3D printing have the ability to make a big jump in the prefered manufacturing
processes and with it’s applications increasing continuously in various industries
and with more number of IT systems and infrastructures this technology can be
collaborated with other technologies like Internet of things and cloud computing to
give newer and more vivid apllications.
The advancement in this technology are overdue, said that the potential of this
technology to replace conventional manufacturing processes can not be
understated as it has huge advantages over other manufacturing processes.
REFERENCE:

1. A Review paper on 3D-Printing Aspects and Various Processes Used in the

3D-Printing

2. Swarm Economics: How 3D Manufacturing Will Change the Shape of the

Global Economy

3. A Review of Metal Additive Manufacturing Technologies

4. BIM-Based Digital Fabrication Process for a Free-Form Building Project in

South Korea

5. 3D Food Printing: A Taste of the Future

6. 3D Printing & Service Learning: Social Manufacturing as a Vehicle for

Developing Social Awareness

7. Design and Manufacturing of a 3D Printer for Teaching and Research

8. Three-dimensional printing in cardiology: Current applications and future

challenges

9. Research and Development of 3D Modeling

10. Review of Building Information Modeling (BIM) Application in

Construction Industry

11. V.B.BHANDARI, Design of machine elements, Mc Graw Hill Education

India Pvt. Ltd.

12. https://en.wikipedia.org/wiki/3D_modeling

13. https://en.wikipedia.org/wiki/3D_printer