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A short review on 3D printing methods, process parameters and materials

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Contents lists available at ScienceDirect

Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

A short review on 3D printing methods, process parameters

and materials
M. Manoj Prabhakar a, A.K. Saravanan b, A. Haiter Lenin c, I. Jerin leno d, K. Mayandi a,
P. Sethu Ramalingam b,⇑
a
Kalasalingam Academy of Research and Education, Krishnankoil, Tamilnadu, India
b
Rajalakshmi Institute of Technology, Chennai, Tamilnadu, India
c
Wollo University, Kombolcha Institute of Technology, Kombolcha, Ethiopia
d
St. John the Baptist University, Central African Republic

a r t i c l e i n f o a b s t r a c t

Article history: Additive producing technological innovation features an important effect on today’s advanced world due
Received 7 October 2020 to the way it can manufacture exceptionally complicated geometrics. Actual 3D-printed plastic compo-
Accepted 11 October 2020 nents have limited capacity uses because of naturally poor mechanical and anisotropic qualities. For flex-
Available online xxxx
ibility and use, its functionalities have been enhanced by the accession of fillers. 3D printing has
advantages, which include personalized geometry, minimum slopes, low priced, along with also simplic-
Keywords: ity of substance modification. A general introduction is given on AM techniques mainly fused deposition
3D printing
modeling (FDM), Powder-liquid 3D printing (PLP), selective laser sintering (SLS), stereolithography (SLA),
Methods
Parameters
digital light processing (DLP), and Electron beam melting. This work investigates the effect of input
Polymers parameters like filament diameter, extruder temperature, feed rate, raster angle, characteristic of work-
ing material, nozzle angle, and distance between parallel faces on output parameters. Some approaches
are suggested to maximize these parameters. It is believed a summary of the approaches produced would
help compare their major characteristics and their benefits and limitations to help choose one of the most
acceptable approaches for a specific application.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Mechanical, Electronics and Computer Engineering 2020: Materials Science.

1. Introduction accuracy [4]. Fabricating is currently assisting businesses that are

3D printing is one of the Additive manufacturing processes and
also called a rapid prototyping process. A method of transforma-
tion of computerized models into three-dimensional [1]. The sub-
stances normally used are plastics, concrete, ceramics, etc., From
the 1980 s, efforts were made to build up additive manufacturing
methods. After many decades, Charles Hull devised stereo-
lithography [2,3]. The practice of AM technique begins using a
CAD (Computer-Aided Design) version of some necessary product
or arrangement developed in software. The meshed CAD version
has changed too. STL fed and file into the 3D printing system at
the kind of g codes for the production. It is a layer by a coating
development, which reduces the material clogs and provides high
⇑ Corresponding author.
E-mail address: sethu1412@gmail.com (P. Sethu Ramalingam).
different. In automotive and aerospace market, it empowers to fab-
ricate lightweight areas such as mobile [5] parts that comprise
angle and cavities to handle excess weight It is at ease to simulate
arrangements and also to review their feasibility and performance
[6] 3D printing assists in creating types for development and idea
[7]. In recent times medical field has used of technologies in penis
printing and tissue production [8] and tooth and synthetic bones
growing [9] But 3D printing continues to be restricted to design
prototype modelling and designing as a result of poor lands of
absolute plastic stuff since they absence load and strength bare-
ness their applications are restricted by these shortcomings of
polymers Fig. 1.
When selecting a material to print a certain portion, careful
attention is needed. While many commercially available polymers
are available, only one polymer is included and gives it the
necessary properties for a specific application. Also, one individual

https://doi.org/10.1016/j.matpr.2020.10.225
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Mechanical, Electronics and Computer Engineering 2020:
Materials Science.

Please cite this article as: M. Manoj Prabhakar, A.K. Saravanan, A. Haiter Lenin et al., A short review on 3D printing methods, process parameters and mate-
rials, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.10.225
M. Manoj Prabhakar, A.K. Saravanan, A. Haiter Lenin et al.
Fig. 1. General system of additive processes.
polymer available on the market cannot be printed with a single
AM technique [10]. The filament selection determined by the pro-
duct and the needs of customers. These are used for the manufac-
turing of bottles, tools, containers, tablets, computers, machines,
cables, electronics and transport components [11]. It, therefore,
makes sense to focus on the creation of 3D-printed materials that
allow for fast production. Polymers are large molecules or macro-
molecules, which consist of several small units repeatedly. They
contain a wide variety of artificial and natural resources containing
thermoplastic, elastomeric and thermosetting polymers [12]. The
polymer has many unique physical characteristics compared to
small molecular compounds, including strength, durability and vis-
coelasticity, due to repetitive sub-units – polymer chains – that can
be easily transferred, allowing deformation under external forces
[13].
Polymer systems are usually often granted manufacturers
attention due to their unique features such as ease-of-use, light-
weight, low cost, long service life and sometimes ductile efficiency
[14–16] However, polymers have considerably less modulus and
strength relative to metals and ceramics, which have always out-
weighed the latter’s singular features [17,18]. Many decades ago,
researchers found a new way to remove polymeric systems’ prob-
lems, by reinforcing the secondary inclusions of metal, ceramic and
polymer in the form of fibre, whisks, platelets or particles [19]. The
integration of these inputs into a host polymer matrix renders it a
composite, that provides enhanced material properties used for
challenging engineering applications—commonly known as com-
posites of the polymer matrix [20].
Over the past 20 years, additive production technologies (AM)
of functional parts and products have become extremely legiti-
mate. Some standard thermoplastic products, including polyamide
(PA). Poly(lactic) acid (PLA) [21], Acrylonitrile butadiene styrene
(ABS) [22], polycarbonate (PC) [9], as well as some thermosetting
products in AM printing process. The polymer materials, mostly
epoxy resins, cannot be preferred for 3D printing since proper heat
or ultraviolet radiation treatment was required [23].
2. Types of additive manufacturing technology
2.1. Fused filament fabrication (FFF) or fused deposition modeling
(FDM)
An utmost popular and cheapest forms of 3D production
method in the globe are Filament Extrusion devices. Often they
are also called Fused Filament Fabrication or FFF. How it functions
is a filament spool has been packed into the 3D machine and then
fed right directly into the extrusion headset to some printer’s noz-
zle. This printer’s nozzle is warmed to the necessary temperature
and also the motor lets it meltdown and pushes throughout the
2
Materials Today: Proceedings xxx (xxxx) xxx
nozzle that the filament. The extrusion nozzle goes along side sta-
ted coordinates putting the blackened material on to the plate
solidify and to refresh. If the sheet has been removed, the printer
sets another sheet. This cross-section printing cycle is repeated,
creating layer after layer until the object is fully developed
[24–26].
2.2. Stereolithography
SLA is traditionally the first 3D printing system in the world.
Chuck Hull devised stereolithography in 1986, which filed a tech-
nology patent and founded 3D printers to commercialize the tech-
nology. An SLA system uses galvanometers, with one located in the
X-axis and one in the Y-axis. Such galvos rapidly aim at a laser
beam through a resin vat that selectively cures and solidifies the
cross-section within this construction area and creates it layer by
layer. Most SLA methods cure parts using a dense-state laser
[27,28].
2.3. VAT photopolymerization
Vat Polymerization is a three-dimension process for printing a
photopolymer resin in a vat with a light source selectively. Two
more popular types of vat polymerization are SLA (Stereolithogra-
phy) and DLP (Digital Light Processing). The distinction in the light
origin utilized to heal the resin would involve these 3D printing
technologies. They are compared together with all the strategy
SLA printers utilize a point laser [29,30].
2.4. Masked stereolithography
The stereo brightens the UV light through an LCD screen which
shows that the slice of a layer for a mask and employs a LED array.
The digitally rendered LCD picture mask is made of square pixels
like OLP. The LCD photomask pixel size determines the granularity
of a display. The Differentiation between DLP and MSLA is How
MSLA Utilizes Lots of Countless different emitters Instead of One
Purpose emitter light source Such as a laser diode or DLP light bulb.
MSLA can reach Print times that were faster in contrast under
specific conditions to SLA similar to DLP. It is because there is an
entire layer shown, rather than the region. With LCD units cost,
MSLA is the ideal technology for the budget resin printer segment
[31].
2.5. Digital light processing
For DLP, this form of 3D printing technique is identical to SLA. A
major change is that DLP uses a digital light projector that simulta-
neous (or several flashes for large parts) flashes a single picture of
M. Manoj Prabhakar, A.K. Saravanan, A. Haiter Lenin et al. Materials Today: Proceedings xxx (xxxx) xxx

every sheet. The picture on each sheet is a digital screen, and thus a the high temperatures, DMLS / SLM components have a warping
layer is made up of small rectangular blocks called voxels. In con- chance [37].
trast with SLA, DLP can attain faster print times. It is because a
whole layer is revealed at once instead of using a laser to trace
the intersectional field. Light is projected to the resin with a Digital 3. 3D printing Machine parameters
Micromirror Device (DMD) on the Light Emitting Diode (LED)
screen or a UV light source (lamp). A DMD is a range of micro- The precision, efficiency and properties of the manufactured
speakers that controls the light projected on the structure surface additive depend heavily on its process parameters. There are there-
and generates the light pattern [32]. fore also fundamental studies into different process parameters
which should be included in every attempt to build functionally
reliable parts from the FDM process. The FDM printing process
2.6. Selective laser sintering
depends on several specified and briefly mentioned parameters.
These can be classified into three macro classes for simplicity:
Selective laser sintering (SLS) can be an additive producing
1. Geometry based 2. Process-based. 3. Structural based
(AM) strategy which employs a laser cutter. In contrast, the ability
parameters.
resource to sinter powdered content (an average of nylon or poly-
amide), organizing the laser mechanically in things from a distance
1. Geometry based Parameters
characterized through a 3D version, binding the cloth jointly to
generate a great arrangement. It is comparable to Selective laser
cutting; both the two are instantiations of precisely exactly the 3.1. Nozzle size
exact very exact idea; however, disagree from technical particulars
[33]. Selective laser melting (SLM) runs on the comparable idea; The nozzle is the element that extrudes the filament to create
however, also in SLM, the materials are completely pumped the component on a 3D printer. Nozzle varies from 10 mm to
instead of sintered, making it possible for various possessions. 100 mm in diameter. In most cases, the usual nozzle size is
SLS (in addition to one other cited AM methods) can be a rather 0.4 mm because the print speed and precision are well balanced.
new technology which far has chiefly been useful for speedy proto-
typing as well as also for low-volume manufacturing of element
3.2. Filament size
areas. Generation functions are enlarging while the commercializa-
tion of how AM tech enhances [34].
The 3D filament is a thermoplastic feedstock for the 3D printer
manufacturing of fused deposition materials. Various filaments
2.7. Material Jetting with different characteristics require different printing tempera-
tures are available. The filaments are offered in 2 routine diameters
Material Jetting (MJ) operates on a traditional inkjet printer in have been 1.75 mm and also 2.85 mm. Frequently the 2.85 mm fil-
the same method. The printer head throws an enormous variety ament is usually called the ‘‘3 mm” filament Fig. 2.
of photopolymer droplets; after which they are cured/fixed in an
infra-rouge (UV) atmosphere. When one layer has been processed 2. Process-based Parameters
and deposited, the development stage has been reduced to one-
layer depth, and the procedure of constructing three-dimensional
structures is repeated. MJ Is Different in other kinds Mend or depo- 3.3. Melting temperature
sition build material Instead of working with a Purpose out machi-
nes that are stick to some course that outlines the component of a The melting temperature is defined as the extruder exiting tem-
coat Deposition build material at a rapid vogue. The benefit of rust perature of the molten material.
is the fact that MJ printers in one line can fabricate items without
impact. Provided that the distance within each build lineup is opti-
3.4. Bed temperature
mized, and also as models have been arranged [35].
Heated beds are essential for 3D printing. While not all printers
2.8. Electron beam melting (EBM) have them, those that always have to be set to a certain tempera-
ture. For example, the best range is 55° C to 70° C.
A beam moves inducing solidification and melting on a particu-
lar location that is cross-sectional. These regions are designed up to
develop a good thing. In comparison to DMLS, along with SLM 3.5. Printing speed
kinds of 3D printing technology, EBM features an exceptional build
rate as a result of its energy density [36]. Print speed is the key level setting for 3d printing technologies.
As the name implies, print speed determines how quickly the prin-
ter’s motors move. It includes the X- and Y-axis control electric
2.9. Selective laser melting (SLM)
motors and the extruder motor.

DMLS and SLM generate objects in a similar manner to SLS. SLS

is an important component of our design and creation cycle. The
principal distinction is that these 3D printing techniques are used
in metal parts manufacturing. SLM uses a laser to melt the metal
powder in its entirety and form a homogenous component. Its
leads to a part that does not produce an alloy but has a single melt-
ing temperature. In comparison to SLS, structurally assisted pro-
cesses of DMLS and SLM limit any possibilities of distortion
(despite the physical support provided to the surrounding pow-
der). Because of the residual stress-induced during printing by
3
3. Structural based parameters
3.6. Layer thickness
With any successive addition of the additive manufacturing or
3D printing process material. The height of the layer is the vertical
resolution of the z-axis and is one of the important technical fea-
tures of a 3D printer. In designing a project using additives, the
three dimensions of the X, Y, and Z axis are dealt.
M. Manoj Prabhakar, A.K. Saravanan, A. Haiter Lenin et al.
Fig. 2. Classification flow chart of 3D Printing Machine Parameters.
3.7. Infill geometry
Infill geometry is also referred to as a pattern that was infill. To
this infill, pattern refers in 3 D printing. The image was printed
within by structure. The pattern of infilling for an object in differ-
ent proportions and forms can be described using slice software.
Patterns affect printing time, weight, print speed, object strength
and mechanical properties. Generally, there are four types of infill
patterns, 1) triangular, 2) rectangular, 3) hexagonal or honeycomb
and 4) wiggle.
3.8. Infill density
The quantity of material occupying the inner part of the piece.
The amount of content will usually be adjusted by rolling programs
from 0 percent (hollow part) to 100 percent (total solid part).
3.9. Raster angle
The raster angle refers to the angle between the nozzle direc-
tion and the X axis of the FDM printer board. Raster angles
between two consecutive layers differ by 90°. The raster angle
affects the shape precision and mechanical efficiency of the sample
being printed.
3.10. Raster gap
The distance between the two adjacent filaments deposited in
the same layer is the air gap. The number of contours is the number
of filaments positioned at the outer edge.
4
Materials Today: Proceedings xxx (xxxx) xxx
4. Polymers in 3D Printing
The phrase ‘‘Polymer” consists of two Greek words ’Poly’ which
suggests numerous quite a few and ’Mer’ this means components
In fundamental provisions a plastic is really actually just a long
chain molecule that’s consists with a high numbers of all most
replicating models of indistinguishable arrangement These indis-
tinguishable constructions we know as an component composed
of at least two atoms combine with each other to produce a
lengthy string Fig. 3.
3.11. Classification of polymers
As Polymers are often created or identified and are a lot of num-
ber with behaviors, they are sometimes categorized in a variety of
manners. Listed below are a few Methods by that polymers are
classified by us:
3.12. Poly lactic acid (PLA)
Poly(lactic acid), PLA, can be just a biodegradable, biocompatible
and compostable polyester based on renewable resources like corn,
corn, cane molasses and beet sugar levels. It’s an excellent future as
an environmentally friendly. Thermo plastic with the assistance
with the polymer industries are going to have the ability to close
the carbon cycle, and their dependence on funds will soon undoubt-
edly likely probably be decreased.Acid is oligomer zed to create an
oligomer and also dimerized to create the lactide monomer that is
cyclic. The high molecular weight polylactide is created of lactide
monomer by ring opening polymerization (ROP). Tin and aluminum
alkoxides are all catalysts for the procedure for lactides [38].
M. Manoj Prabhakar, A.K. Saravanan, A. Haiter Lenin et al.
Fig. 3. . Classification flow chart of Polymers.
PLA is found in 3D printing utilizing the FDM. PLA can be uti-
lized in 3D printing together with the FDM fused deposition mod-
eling technologies along with combined with ABS (Acrylonitrile
Butadiene Styrene) this substance is among those conventional
substances with this particular technology There’s often an Inclina-
tion to compare those plastic stuff as they would be both choices
designed for customer printers’ PLA plastic substance is simple to
use [39]. PLA has 178° C and 65° C of melting and glass transition
temperatures respectively. PLA is not the thermal-resistant mate-
rial, but it is especially suitable for decorative items that do not
have mechanical restrictions. PLA plastics have many benefits,
which is why this material is the most commonly used plastic
for 3D desktop printers [40]. PLA filaments come in many colors
and types that are ideal for many different applications. This plastic
material Is Particularly efficient. It will come from the form of cable
and hauled onto the printing tray right into drops [41]. This mate-
rial contracts less than ABS, which gives it geometric equilibrium,
when cooling. As this material may be useful for rapid prototyping,
PLA may be helpful for the product development. Nevertheless, the
main applications for this material include figurines, toys, nonfunc-
tional prototypes, etc.
3.13. Acrylonitrile butadiene styrene (ABS)
ABS is made by Acrylonitrile Styrene and butadiene polymers
because its name implies, it’s a substance This material that is
familiar because, It’s easy to use with a desktop 3D printer, but it
has some great stuff possessions. ABS has a thermo plastic and
amorphous polymer. It is employed for injection molding since
it’s low of cost and also utilized by manufactures due to insulation
properties and the impact resistance. ABS Was Created by Poly-
merizing styrene, acrylonitrile and butadiene. The acrylonitrile is
of 15 to 35 percent, butadiene of 5 to 30 percent and styrene of
40 to 60 percent [42]. It is bind to earn ABS strong. The rubbery
imparts strength into acrylonitrile along with the substance adds
resistance to heat and Ecological degradation. ABS has good impact
5
Materials Today: Proceedings xxx (xxxx) xxx
strength and is light weight; nevertheless, nonetheless, it really is
abrasion resistant and inexpensive. Furthermore, ABS polymers
defy a great deal of chemical formulations. The glass transition
temperatures of ABS vinyl had 105 °C (221°F), making it perfect
for use within relatively safe machines that are easy to function
(the protection of household machines is equally important) [43].
However, this very low melting point makes ABS easy to server
through the injection molding process, or with 3D printers. The
Appeal of production that is additive Technique is its worth.
Because of the lapse of certain patents associated with FDM tech-
nology the price of 3D has decreased [44]. Entry level printers cost
between several hundred. Along with the chemical resistance and
mechanical Possessions, can be fire retardant and ABS cloth has a
surface quality. The Material color is white, however the oxidation
of this polymers may result in a Yellowing coloration. It is easy to
paint and glue vinyl Solutions Imprinted offering chances of per-
sonalization, with ABS fabric [45].
3.14. Thermoplastic Polyurethane:
Thermoplastic polyurethane (TPU) can be a elastomer that’s
fully Thermo plastic. Like most of elastomers, TPU is melt-
processable and also elastic. It might be processed on compression,
blow and injection molding equipment in addition to extrusion. It
might be solution-coated or even vacuum-formed and is suited to a
vast array of manufacturing methodologies. TPU may be colored
through many of procedures. But more than every elastomer,
TPU could offer a range of land mixes making it a very flexible
material [46]. That is because TPU is really actually just a seg-
mented block copolymer made from soft and hard sections. The
segment could be aromatic or aliphatic. While aliphatic TPU’s
derive from isocyanates such as h-12 MDI aromatic TPU’s derive
from isocyanates like MDI. They turned into the block when these
isocyanates are along with diols. Normally it’s aromatic, however a
segment that is hard is utilized if clarity and color retention in sun
vulnerability is important [47]. The segment can be considered
M. Manoj Prabhakar, A.K. Saravanan, A. Haiter Lenin et al.
described as a polyester or polyether type, based upon the applica-
tion form. Whilst hydrocarbon and petroleum immunity require a
TPU By way of instance surroundings call for a TPU. For usefulness,
the ratio weight and also compound type of these soft and hard
sections might be varied.
3.15. Polybutylene terephthalate
Research more about Poly-Ethylene terephathalate (PET) and
also learn what causes it to be a suitable choice in lots of software.
Learn about its own vital properties, the way its combinations are
made along together with different thermoplastics and thermosets,
processing requirements and of course, benefits which make PET
like No. inch recyclable plastic worldwide. PET is one of those plas-
tics that are an equally significant part one’s activity. It’s a signifi-
cant business plastic having application which range from
packaging, textiles, pictures, molded parts such as automotive,
electronics. . . and also a lot more. It’s possible to come across this
plastic personally as pop jar container or plain water jar [48].
Polyethylene terephthalate (PET or PETE) is really just a general
purpose thermoplastic polymer that belongs to your polyester
family of all polymers. Polyester resins have been famous for their
mix of properties like stability in addition to mechanical, thermal
resistance. Recycled PET might be converted into sheets for pack-
aging, cloths, fibers and automotive pieces. PET ranges that are
available consist of un-reinforced to glass reinforced, flame retar-
dant and flow substances for heating resistance and or engineering
tools that normally require greater durability. Addition of carcino-
gens such as glass fibers, including CNTs etc., help improve impact
strength, surface finish, reduce warpage and many other advan-
tages. PET is semi-crystalline, colorless and elastic resin from its
own normal condition. Determined by how it’s processed, then it
could be semi rigid to stiff [49].
3.16. Nylon
Nylon’s first success came within women’s sleeves together
with it has usage, in roughly 1940. These certainly were also a
major hit, however they eventually become so hard to comprehend
such as principles and parachutes. However, before parachutes or
lace, the ny-lon product was a vest using bristles. In the beginning,
DuPont (producer of advertisement nylon 6,6) had trouble finding
out how to use it to get. Markets started all over the area, once it
caught, however. Nylon has excellent properties for use in fishing
line plus trimmer lineup, also it’s useful for several ‘‘vinyl” screws
along with push-in connectors. If you look you’ll locate nylons in
your house as well as at cars. Nylon can be utilized in clothing such
as wind breakers, also (ahem. . .) lingerie, but also in different
regions, in the shape of a thermoplastic. [35]
The expression ny-lon points towards a family known as poly-
amides. There are two methods for making nylon for applications
that are fibre. From the first strategy, the molecules which contain
of a contaminated group (COOH) on every ending react with mole-
cules which feature amine (NH2) bands at each end. The conse-
quent ny-lon receives a name on the basis of the amount of
carbon atoms which different two amines along with 2 contami-
nated collections. Nylon 6,6 is utilized as fibers generated from
hexamethylene diamine and adipic acid [50,51].
3.17. Polycarbonate
Polycarbonate (PC) alloys are a certainly translucent amorphous
thermoplastic. Even though they’re made commercially offered in
various colors (maybe see-through as well as not), the raw stuff
allows for your inner transmission of lighting virtually at precisely
exactly the exact same capacity as a glass. Poly-carbonate
6
Materials Today: Proceedings xxx (xxxx) xxx
polymers are utilised to make an assortment of substances and
are especially useful when impact transparency or resistance are
a commodity Poly carbonate has excellent heat resistance and will
be put together without material degradation that is significant
with fire retardant substances [52,53].
4. Conclusion
The Majority of the problems faced by AM methods are course
of action dependent. FDM has become easily simple to manage
most often seen and inexpensive 3D procedure. Throughout coat-
ing sediment and FDM extrusion, the practice of emptiness devel-
opment is notable due to heating and heating. It also results in
anisotropic Constructions and Declines in mechanical Possessions.
In the heating mix, 3D printing procedures such as SLM and SLA,
the healing of metals or powder has been achieved layer by coat-
ing. The horizontal and vertical led throughout healing possessions
could vary on account of this variant of the temperature gradient. It
may create a behavior that is anisotropic inside the area. Other
processes possess topics of qualities and also rate throughout fab-
rication. Of capacities, its usage has significantly really increased
despite these various drawbacks and challenges. In the task, the
investigators are currently attempting to enhance 3D printing pro-
cesses to cut back the limits compared with conventional manufac-
turing procedures. In the last couple of years, with all the evolution
of plastic composites, the researchers have the independence to
test and get a grip on performance and the attributes of services
and products associated with the use and opened a new field.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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