20MEE10 - ADDITIVE MANUFACTURING (Professional Elective-II)

UNIT-III

Pre-processing in AM

Pre-processing in additive manufacturing, also known as 3D printing, refers to a set of activities

and steps that are carried out before the actual printing process. These steps are crucial for
preparing the digital design files and optimizing them for successful fabrication. Pre-processing
ensures that the additive manufacturing process can accurately and reliably produce the desired
object with the desired properties. Here are some key aspects of pre-processing in additive
manufacturing:

1. Design preparation: Pre-processing begins with the creation or acquisition of a digital

3D model of the object to be printed. This model is often created using computer-aided
design (CAD) software. The design may need to be adjusted and optimized for additive
manufacturing, taking into account factors such as manufacturability, support
structures, material properties, and printing limitations.

2. Orientation and support structure generation: The digital model needs to be properly
oriented for printing to achieve the desired results. Orientation affects factors like
surface finish, strength, and the need for support structures. Support structures are
temporary structures that provide stability to overhanging or delicate parts during the
printing process. Pre-processing software can automatically generate support structures
or allow manual placement and editing of supports.

3. Slicing: Slicing is the process of dividing the 3D model into a series of 2D layers, which
the 3D printer can understand. The slicing software generates a set of instructions, often
in the form of G-code, that guide the printer on how to move and deposit the material
layer by layer. Parameters such as layer thickness, infill density, printing speed, and
temperature may be specified during the slicing process.

4. Material selection and preparation: Different additive manufacturing processes use

various materials, including polymers, metals, ceramics, and composites. Pre-
processing involves selecting the appropriate material for the desired application and
ensuring it is compatible with the specific 3D printer being used. Material properties,
 such as melting temperature, viscosity, and shrinkage, need to be considered during pre-
processing.

5. Calibration and machine setup: Before initiating the printing process, it is essential to
calibrate the 3D printer and ensure it is properly configured. This may involve verifying
the printer's accuracy, levelling the build platform, checking extruder temperature, and
confirming the availability of sufficient printing material. Machine setup also includes
considerations such as bed adhesion methods (e.g., tapes, adhesives) and adjusting
printing parameters to achieve the desired print quality.

6. File conversion and transfer: Once the digital design has been prepared and optimized,
it needs to be converted into a format compatible with the specific 3D printer. The file
format conversion may involve converting the design into STL (Standard Tessellation
Language) or another printer-specific format. The converted file is then transferred to
the printer via direct connection, USB, SD card, or network.

Overall, pre-processing in additive manufacturing involves a series of steps to ensure the digital
design is properly prepared, optimized, and converted into a format that the 3D printer can
understand. By paying attention to design considerations, material selection, slicing, and
machine setup, pre-processing helps maximize the chances of successful fabrication and obtain
high-quality 3D-printed objects.

STL Format

In additive manufacturing, an STL file is a widely used file format for representing 3D models.
The acronym "STL" stands for "Standard Tessellation Language" or "Standard Triangle
Language." It is a mesh-based file format that represents the geometry of a 3D object using a
collection of interconnected triangles.

Here are some key features and characteristics of STL files:

1. Triangle representation: An STL file breaks down the surface of a 3D object into a series
of triangles, also known as facets or polygons. These triangles are defined by their
vertices, which specify the X, Y, and Z coordinates of each corner.
 2. Simplified geometry: STL files represent the surface geometry of an object and do not
capture attributes such as color, texture, or internal structure. The file format focuses
solely on the shape and topology of the model.

3. Binary or ASCII format: STL files can be saved in either binary or ASCII (text) format.
Binary files are more compact and efficient, while ASCII files are human-readable but
larger in size.

4. Triangular mesh quality: The quality of an STL file depends on the density and
distribution of the triangles. A higher triangle count generally results in a smoother and
more detailed surface representation. However, excessively large files can lead to
increased processing and printing times.

5. Facet normal vectors: Each triangle in an STL file typically includes a normal vector,
which indicates the direction perpendicular to the triangle's surface. These vectors are
used to determine the orientation of the triangles during the printing process.

STL files are commonly used in additive manufacturing because they provide a universal
format that can be read by most 3D printing software and machines. They serve as a bridge
between the 3D design created in CAD software and the slicing software that prepares the
model for printing.

It's worth noting that while STL files are widely used, they have certain limitations. For
example, they do not store information about the object's colour, material properties, or internal
structure. More advanced file formats, such as AMF (Additive Manufacturing File Format) or
3MF (3D Manufacturing Format), have been developed to address some of these limitations
and offer additional capabilities for additive manufacturing.

STL (Standard Tessellation Language) is a file format commonly used in additive

manufacturing, also known as 3D printing. It represents the surface geometry of a 3D object
using a collection of interconnected triangles. The STL file format is widely supported by
various 3D modeling software, slicing software, and 3D printers. Here's a more detailed
explanation of the STL file format in additive manufacturing:

1. Triangle representation: An STL file breaks down the surface of a 3D object into a series
of triangles, also called facets or polygons. Each triangle is defined by three vertices,
which specify the X, Y, and Z coordinates of each corner. These vertices form a mesh
that approximates the shape of the object.
 2. Triangle normal vectors: Each triangle in an STL file has a normal vector associated
with it. The normal vector represents the direction perpendicular to the surface of the
triangle. It helps define the orientation of the triangle during the printing process,
ensuring that the correct side of the surface is facing outward.

3. File format variants: There are two variants of the STL file format: ASCII and binary.
ASCII STL files are human-readable text files that store the coordinates and normal
vectors of the triangles as ASCII characters. Binary STL files, on the other hand, use a
binary format that is more compact and efficient for storing large and complex 3D
models.

4. Simplified geometry: STL files focus solely on the surface geometry of a 3D object and
do not capture attributes such as color, texture, or internal structure. The file format
represents a simplified version of the object's geometry, breaking it down into flat
triangles.

5. Units and scaling: STL files do not inherently specify the units of measurement. The
size of the object in an STL file is relative and needs to be interpreted correctly by the
software and printer. It is crucial to establish the correct scale or convert units when
importing an STL file into a 3D modeling or slicing software.

6. Mesh quality: The quality of an STL file is determined by the density and distribution
of triangles. A higher triangle count generally results in a smoother and more detailed
surface representation. However, extremely dense meshes can significantly increase file
size and processing requirements.

STL files serve as a bridge between the 3D design created in CAD software and the slicing
software used to prepare the model for 3D printing. The slicing software converts the STL file
into a format specific to the 3D printer, such as G-code, which provides instructions for the
printer to deposit material layer by layer.

While STL files are widely used in additive manufacturing, they have certain limitations. They
do not store information about colour, material properties, or internal structure. To address these
limitations, other file formats such as AMF (Additive Manufacturing File Format) and 3MF
(3D Manufacturing Format) have been developed, which offer more comprehensive
capabilities for representing 3D models in additive manufacturing.
STL File Problems

While STL files are widely used in additive manufacturing, they can present certain challenges
and issues. Here are some of the common problems associated with STL files used in additive
manufacturing:

1. Insufficient resolution: STL files represent 3D objects using a mesh of triangles. If the
resolution of the mesh is too low, the resulting printed object may have a visibly faceted
or coarse surface. Increasing the resolution by adding more triangles can help improve
the visual quality of the print, but it also leads to larger file sizes and longer processing
times.

2. Non-manifold geometry: Non-manifold geometry refers to errors or inconsistencies in

the surface representation of the 3D model. It can include issues such as intersecting or
overlapping triangles, holes, gaps, or self-intersecting surfaces. Non-manifold
geometry can cause difficulties during slicing or lead to printing errors, resulting in
incomplete or distorted prints.

3. Incomplete or open meshes: An incomplete or open mesh occurs when the surface of
the 3D model has missing or unclosed triangles. These gaps in the mesh can result in
printing artifacts, such as holes or incomplete surfaces, as the slicing software and 3D
printer struggle to interpret and print the incomplete geometry.

4. Thin or fragile structures: STL files may not accurately represent thin or delicate
structures in the 3D model. This can lead to challenges during the printing process, as
these structures may be prone to warping, breakage, or collapse. It is important to
validate and reinforce such structures before printing, especially when using certain
additive manufacturing processes.

5. File size and complexity: As the complexity and level of detail in the 3D model
increase, so does the file size of the corresponding STL file. Very large STL files can
be challenging to handle and process, requiring significant computational resources and
potentially causing software or hardware limitations.

6. Lack of colour and texture information: STL files do not store information about colour,
texture, or other visual attributes. While this may not be a concern for some
applications, it limits the ability to accurately represent multi-coloured or textured
objects using STL files alone.
To mitigate these problems, it is essential to use robust 3D modeling software that can generate
high-quality and valid STL files. Additionally, performing pre-processing steps, such as mesh
repair, optimizing the resolution, and validating the geometry, can help address many of these
issues before the STL file is sent for printing.

STL file Repairs

STL file repairs in additive manufacturing refer to the process of correcting and resolving issues
present in the geometry of the 3D model represented by an STL file. These repairs aim to fix
errors, ensure the model is manifold and watertight, and make it suitable for successful 3D
printing. Here are some common techniques and tools used for STL file repairs:

1. Automated repair software: Several software tools are available specifically designed
for automatically identifying and fixing common issues in STL files. These tools can
detect and repair problems such as non-manifold geometry, self-intersections, gaps, and
open meshes. They employ algorithms to analyze the geometry and automatically make
corrective modifications to ensure the model is printable.

2. Manifold conversion: Manifold conversion tools are used to transform non-manifold

models into manifold ones. Non-manifold geometry includes elements like intersecting
or overlapping triangles, holes, or gaps in the mesh. Manifold conversion algorithms
resolve these issues by closing gaps, removing intersecting or overlapping triangles,
and ensuring a continuous and connected surface.

3. Mesh refinement: Mesh refinement techniques aim to increase the resolution or

smoothness of the STL file's geometry. These tools add more triangles to areas of the
mesh that require additional detail or smoother surfaces. Mesh refinement helps
improve the visual quality of the printed object and ensures fine features and complex
shapes are accurately represented.

4. Hole filling: If an STL file contains holes or gaps in the mesh, hole-filling algorithms
can be used to automatically close these gaps. These algorithms analyze the geometry
and create new triangles to bridge the gaps, resulting in a watertight and complete
surface representation.
 5. Simplification and decimation: In some cases, an STL file may have an excessively
high triangle count, leading to large file sizes or increased processing requirements.
Simplification or decimation algorithms can be used to reduce the number of triangles
while preserving the overall shape and important features of the model. This process
helps optimize the file size and computational efficiency while still maintaining the
desired level of detail.

6. Manual repairs: In certain cases, manual repairs may be required to address specific
issues in an STL file. Skilled designers or engineers can use 3D modeling software to
manually edit the geometry, close gaps, fix self-intersections, or perform other
necessary modifications. Manual repairs offer greater control and customization but can
be time-consuming and require expertise in 3D modeling.

STL file repairs are an important part of the pre-processing stage in additive manufacturing.
By resolving issues and ensuring the integrity of the 3D model, these repairs help improve the
printability, accuracy, and overall quality of the final 3D-printed object.
Post Processing of AM

Post-processing in additive manufacturing refers to the series of steps and techniques

performed after the 3D printing process is completed. It involves treating, refining, and
enhancing the printed object to achieve the desired final properties, aesthetics, and
functionality. Post-processing plays a critical role in additive manufacturing to improve surface
finish, mechanical properties, dimensional accuracy, and overall quality. Here are some
common post-processing techniques used in additive manufacturing:

1. Support removal: Many 3D printing processes use support structures to provide

stability for overhanging or complex features during printing. Post-processing involves
removing these support structures, typically by cutting, breaking, or dissolving them.
The removal process may require manual work, such as sanding or filing, to smooth
any rough areas left behind.

2. Surface finishing: Post-processing techniques are employed to improve the surface

quality and aesthetics of 3D-printed objects. This can include sanding, polishing, or
grinding to remove layer lines, surface imperfections, or roughness. Chemical
treatments, such as vapor smoothing or chemical baths, can be used to enhance the
surface finish by dissolving or fusing the outer layer of the printed object.

3. Part cleaning: After printing, the 3D-printed object may require cleaning to remove any
residual support material, debris, or uncured resin. Cleaning techniques can include
washing with water, solvents, or ultrasonic baths. This step ensures the final object is
free from any contaminants that could affect its appearance or functionality.

4. Heat treatment: Certain additive manufacturing processes, such as metal 3D printing,

benefit from heat treatment to improve the mechanical properties of the printed object.
Heat treatment involves subjecting the object to controlled heating and cooling cycles
to modify its microstructure, relieve stresses, enhance strength, or achieve specific
material properties.

5. Surface coloring or painting: Post-processing can involve applying color or paint to the
3D-printed object to enhance its appearance or to match specific design requirements.
Coloring techniques can include spray painting, airbrushing, or dyeing. It allows for
customization, branding, or achieving specific visual effects.
 6. Assembly and integration: In some cases, post-processing may involve assembling
multiple 3D-printed parts together or integrating printed components with non-printed
elements to create a functional object or system. This can include mechanical fastening,
adhesive bonding, or other joining techniques.

7. Quality inspection and testing: Post-processing may include quality control measures
to ensure the printed object meets the desired specifications. Inspection techniques such
as dimensional measurement, surface analysis, or non-destructive testing may be
employed to verify dimensional accuracy, surface quality, or structural integrity.

It is important to note that the specific post-processing steps and techniques required for
additive manufacturing can vary depending on the material, 3D printing technology, and the
desired properties and application of the final object. Post-processing adds value to the additive
manufacturing process by refining the printed objects, improving their aesthetics, functionality,
and performance, and enabling them to meet specific requirements for different industries and
applications.

Post Processing Steps Involved in Support Material Removal

Support material removal is a crucial post-processing step in additive manufacturing,

particularly for processes that utilize support structures to facilitate the printing of complex or
overhanging features. The following are the typical steps involved in support material removal:

1. Identification: Identify the areas of the 3D-printed object where support structures were
used during the printing process. These areas are typically determined based on the
design geometry and the requirements of the specific additive manufacturing process.

2. Accessibility: Assess the accessibility of the support structures. Determine if the

supports can be easily reached and removed or if they are embedded within intricate or
hard-to-reach areas of the printed object.

3. Manual removal: Begin the removal process by manually breaking or cutting away the
larger support structures using appropriate tools such as pliers, wire cutters, or flush
cutters. Care should be taken not to damage or deform the printed object while
removing the supports.
 4. Mechanical assistance: For support structures that are difficult to remove manually,
mechanical assistance can be employed. This may involve the use of sanding tools,
milling machines, or other mechanical tools to carefully remove the supports.

5. Dissolvable supports: In some cases, the support material used in additive

manufacturing processes is soluble in a specific solvent. If dissolvable supports were
used, immerse the printed object in the appropriate solvent to dissolve and remove the
supports. Examples of dissolvable support materials include PVA (polyvinyl alcohol)
and certain types of soluble filaments.

6. Cleaning: After the support structures are removed, clean the printed object to remove
any residue or debris left behind. This can be done by washing the object with water,
using a brush or compressed air to remove loose particles, or utilizing other cleaning
methods appropriate for the specific material.

7. Surface finishing: Once the support material is completely removed and the object is
cleaned, perform any necessary surface finishing techniques to smooth out the surface
and remove any remaining imperfections. This may involve sanding, polishing, or
chemical treatments to achieve the desired surface quality.

It is important to follow the manufacturer's guidelines and recommendations for support

material removal specific to the additive manufacturing technology and materials used.
Additionally, proper safety precautions should be taken during support removal, such as
wearing protective equipment and ensuring proper ventilation when working with solvents or
using mechanical tools.

Post Processing Steps Involved in Surface Texture Improvement

Surface texture improvement is an important post-processing step in additive manufacturing to

enhance the appearance and smoothness of the printed object's surface. The specific steps
involved in surface texture improvement can vary depending on the material and additive
manufacturing process used. Here are some common post-processing steps for surface texture
improvement:
 1. Removal of support structures: If support structures were used during the printing
process, the first step is to remove them. This step typically involves manual removal
or dissolving the supports, as discussed earlier.

2. Sanding and filing: Begin the surface texture improvement process by using sandpaper
or abrasive tools to smooth out any visible layer lines, rough surfaces, or imperfections.
Start with a coarser grit sandpaper and gradually move to finer grits for a smoother
finish. Filing can be employed to target specific areas or details that require additional
refinement.

3. Chemical treatments: Chemical treatments can be used to further enhance the surface
texture of the printed object. Vapor smoothing is a technique where the object is
exposed to a solvent vapor, such as acetone for ABS prints, which melts and fuses the
surface layers, resulting in a smoother appearance. It is important to follow proper
safety precautions when working with chemicals and ensure compatibility with the
printed material.

4. Surface coating or painting: Applying a surface coating or paint can help improve the
surface texture and aesthetics of the printed object. This can include using primers, clear
coats, or paint to achieve a desired finish or to add color and protection. Various
techniques such as spraying, brushing, or dipping can be employed depending on the
desired outcome.

5. Polishing and buffing: Polishing compounds and buffing wheels can be used to achieve
a high-gloss or reflective finish on the printed object. This step involves using a
polishing compound and a rotary tool to buff the surface, removing any remaining
imperfections and enhancing the shine and smoothness.

6. Surface treatment or finishing processes: Depending on the specific requirements of the

printed object, additional surface treatments or finishing processes may be employed.
These can include techniques such as electroplating, anodizing, or powder coating to
improve surface hardness, corrosion resistance, or other desired properties.

It is important to note that the post-processing steps for surface texture improvement may vary
based on the specific additive manufacturing technology and the material used. It is
recommended to refer to material and process-specific guidelines and consult with experts or
manufacturers for the best practices and recommendations for achieving the desired surface
texture and finish.

Post Processing Steps Involved in Accuracy Improvement

Accuracy improvement is a critical post-processing step in additive manufacturing to enhance

the dimensional accuracy and precision of the printed object. Here are some common post-
processing steps involved in accuracy improvement:

1. Dimensional measurement: Start by measuring the printed object's dimensions using

precision measuring tools such as calipers, micrometers, or coordinate measuring
machines (CMMs). Compare the measurements to the intended design specifications to
identify any deviations or inaccuracies.

2. Calibration and machine optimization: Ensure that the 3D printer is properly calibrated
and optimized for accurate printing. This includes checking and adjusting parameters
such as nozzle alignment, bed leveling, temperature settings, and print speed. Regular
calibration and maintenance of the 3D printer help ensure accurate and consistent
results.

3. Design optimization: Review the design of the printed object to identify any areas that
may be prone to dimensional inaccuracies. Modifying the design to optimize features,
tolerances, or support structures can help improve accuracy during the printing process.
This step is often performed during the design stage but can also be addressed in the
post-processing phase if necessary.

4. Slicing parameters adjustment: Adjust the slicing parameters in the slicing software to
optimize the printing process for better accuracy. This includes settings such as layer
height, infill density, print speed, and cooling. Fine-tuning these parameters can help
reduce dimensional errors and improve overall accuracy.

5. Support structure removal: Ensure that support structures are carefully removed, as
their removal can sometimes lead to minor distortions or inconsistencies in the printed
object. Take care not to apply excessive force during support removal to minimize any
potential deformation.
 6. Surface refinement: Refine the surface of the printed object using post-processing
techniques such as sanding, filing, or chemical treatments. This step helps remove any
imperfections or irregularities on the surface that may affect dimensional accuracy.

7. Post-curing (for resin-based printing): If the additive manufacturing process involves

resin-based printing, post-curing the printed object can help improve its dimensional
stability and accuracy. Follow the manufacturer's recommendations for the specific
resin material used to ensure proper post-curing procedures.

8. Iterative improvement: If any dimensional inaccuracies are identified, iterate the

process by making necessary adjustments to the design, printer settings, or post-
processing techniques. Analyze the cause of the inaccuracies and implement corrective
actions to continually improve the accuracy of future prints.

Regular quality control checks and continuous improvement efforts throughout the additive
manufacturing process are essential for achieving higher accuracy. It is important to refer to
the specific guidelines and recommendations provided by the material and printer
manufacturers for accurate printing and post-processing techniques specific to the additive
manufacturing technology and materials used.

Post Processing Steps Involved in Aesthetics Improvement

Aesthetics improvement is an important post-processing step in additive manufacturing to

enhance the visual appeal and aesthetics of the printed object. Here are some common post-
processing steps involved in aesthetics improvement:

1. Support removal: Begin by removing any support structures used during the printing
process. This step ensures that the printed object's surface is clean and ready for further
aesthetic enhancements.

2. Surface finishing: Utilize various techniques to improve the surface finish and texture
of the printed object. This can include sanding, filing, or using abrasive tools to smooth
out any visible layer lines, rough areas, or imperfections. Start with a coarse grit
sandpaper and gradually move to finer grits for a smoother finish.

3. Chemical treatments: Chemical treatments can be employed to enhance the appearance

and surface quality of the printed object. Vapor smoothing is a technique that involves
 exposing the object to a solvent vapor, such as acetone for ABS prints, which melts and
fuses the outer layer, resulting in a smoother and more refined finish. However, it is
important to follow proper safety precautions and ensure compatibility with the printed
material.

4. Painting and coloring: Applying paint or color can significantly enhance the aesthetics
of the printed object. This can include spray painting, airbrushing, or hand-painting
techniques. Select paints or pigments that are compatible with the material used for
printing. Applying multiple layers of paint, adding texture, or incorporating gradients
can further enhance the visual appeal.

5. Surface coating: Consider applying a protective coating or clear varnish to the printed
object to provide a glossy finish and protection against wear, UV exposure, or moisture.
There are various types of clear coatings available, such as epoxy resin, polyurethane,
or lacquer, depending on the specific requirements and material compatibility.

6. Surface texturing or embossing: Add texture or patterns to the surface of the printed
object to enhance its aesthetics. This can be achieved through techniques like
sandblasting, laser etching, or adding texture with specialized tools or molds. Texturing
can create unique visual effects and add a tactile element to the printed object.

7. Assembly and integration: If the printed object consists of multiple parts or

components, proper assembly and integration can enhance its aesthetics and
functionality. Ensure precise alignment and secure attachment of parts using
appropriate techniques such as adhesives, mechanical fasteners, or welding.

8. Branding and labeling: Consider incorporating branding elements, logos, or labels onto
the printed object using techniques such as engraving, embossing, or applying decals.
This step can add a professional and personalized touch to the final product.

9. Packaging and presentation: Pay attention to the packaging and presentation of the
printed object. Use suitable packaging materials and consider including custom labels,
documentation, or user instructions to enhance the overall aesthetic experience for the
end-user.

Each of these post-processing steps can be tailored based on the specific requirements, design,
and intended use of the printed object. It is important to experiment, iterate, and refer to
material-specific guidelines or consult with experts to achieve the desired aesthetics and visual
appeal in additive manufacturing.

Post Processing Steps Involved in Preparation for use as a Pattern

Preparing a 3D-printed object for use as a pattern involves post-processing steps that are
specific to the application of the pattern. Here are some common post-processing steps
involved in preparing a 3D-printed object for use as a pattern in additive manufacturing:

1. Support removal: Begin by removing any support structures used during the printing
process. Carefully break or cut away the supports, taking care not to damage the pattern.
Sanding or filing may be required to smooth any rough areas left behind.

2. Surface refinement: Refine the surface of the pattern to ensure it meets the required
specifications. This may involve sanding, filing, or using abrasive tools to remove any
visible layer lines, rough areas, or imperfections. Achieving a smooth and uniform
surface is essential for accurate pattern reproduction.

3. Dimensional accuracy verification: Measure the dimensions of the pattern using

precision measuring tools such as calipers or micrometers. Compare the measurements
to the intended design specifications to ensure the pattern has been printed accurately.
Make any necessary adjustments or modifications if deviations are found.

4. Fit and alignment checks: If the pattern is intended for use in an assembly or for creating
a mold, verify its fit and alignment with other components or tooling. Ensure that the
pattern aligns correctly with mating surfaces or fits within the desired tolerances. Make
any necessary adjustments to ensure proper fit and alignment.

5. Surface coating or sealing (optional): Depending on the application, it may be necessary

to apply a surface coating or sealant to the pattern. This can be done to enhance its
durability, increase resistance to wear or corrosion, or provide a specific texture or
finish. Consider using appropriate coatings or sealants compatible with the material
used for printing.

6. Documentation and labeling: Properly document the pattern, including relevant

information such as part numbers, revision numbers, or any special instructions or
 notes. Labeling the pattern can help with identification and traceability, especially if
multiple patterns are being used simultaneously.

7. Storage and protection: Store the pattern in a suitable location or packaging to protect
it from damage or contamination. Consider using protective covers, cases, or boxes to
prevent dust, moisture, or other external factors from affecting the pattern's integrity.
Store the pattern in a controlled environment if required to maintain dimensional
stability.

8. Pattern replication (if necessary): If the pattern is intended for mass production or
replication, consider using the printed pattern to create moulds or tooling for casting or
other manufacturing processes. This may involve creating silicone moulds, tooling
patterns, or master patterns for replication.

It is important to note that the specific post-processing steps for preparing a 3D-printed object
as a pattern can vary depending on the application, materials used, and desired quality
standards. It is recommended to refer to industry-specific guidelines, consult with experts, or
follow best practices for pattern preparation in additive manufacturing.

Post Processing Steps Involved in Property Enhancements using Nonthermal and

Thermal Techniques

In additive manufacturing, post-processing steps can be employed to enhance the properties of

3D-printed objects using non-thermal and thermal techniques. These techniques aim to
improve the mechanical, chemical, or physical properties of the printed parts. Here are some
common post-processing steps involved in property enhancements using non-thermal and
thermal techniques:

Non-Thermal Techniques:

1. Surface Finishing: Perform surface finishing operations such as sanding, filing, or

polishing to improve the surface quality and remove any visible layer lines or
roughness. This step enhances the aesthetics and can reduce stress concentrations on
the surface.

2. Chemical Treatments: Utilize chemical treatments to modify the surface properties of

the printed parts. Examples include:
 • Surface etching: Use chemical etchants to selectively remove a thin layer of
material, creating a textured or roughened surface that enhances adhesion or
promotes bonding in subsequent processes.

• Surface activation: Apply chemical agents or plasma treatment to modify the

surface chemistry, making it more receptive to coatings, adhesives, or other
treatments.

3. Coating and Plating: Apply coatings or platings to improve properties such as wear
resistance, corrosion resistance, or electrical conductivity. This can be achieved through
processes like electroplating, electroless plating, or physical vapor deposition (PVD).

4. Chemical Vapor Smoothing: Involves exposing the printed object to a chemical vapor,
such as acetone, to dissolve and smooth the surface, reducing the appearance of layer
lines and improving surface quality.

Thermal Techniques:

1. Annealing: Heat-treat the printed parts at a specific temperature to relieve internal

stresses, improve dimensional stability, and enhance mechanical properties. Annealing
can also refine the microstructure, resulting in increased strength and toughness.

2. Sintering: For certain materials like metal or ceramic powders, sintering can be
employed to bond the particles together, increasing density and strength. This process
involves subjecting the printed parts to elevated temperatures below their melting point.

3. Stress Relief: Heat the printed parts to a temperature below their melting point to relieve
residual stresses and improve dimensional stability. This is particularly important for
larger or complex geometries that are prone to warping or distortion.

4. Heat Treatment: Employ various heat treatment processes, such as tempering or

quenching, to modify the microstructure and enhance the mechanical properties of the
printed parts. Heat treatment can improve hardness, strength, and toughness based on
the specific material and desired properties.

5. Hot Isostatic Pressing (HIP): Involves subjecting the printed parts to high temperatures
and pressures in an inert gas environment to eliminate porosity and enhance density.
HIP can improve mechanical properties and ensure uniformity in the printed parts.
 6. Laser Surface Modification: Utilize laser-based techniques, such as laser polishing or
laser peening, to modify the surface of the printed parts. These techniques can improve
surface finish, hardness, and fatigue resistance by inducing controlled thermal or
mechanical effects.

It is important to note that the specific post-processing steps and techniques employed for
property enhancements may vary depending on the material used, the desired properties, and
the specific additive manufacturing process. Manufacturers and material suppliers often
provide guidelines and recommendations for post-processing techniques that are specific to
their materials and technologies.

AM Software’s

Additive manufacturing software plays a crucial role in the entire process of 3D printing. These
software tools enable users to create, prepare, and optimize digital models for additive
manufacturing. Here are a few key points about additive manufacturing software:

1. Design and Modeling: Additive manufacturing software provides powerful design and
modeling tools that allow users to create 3D models from scratch or modify existing
designs. These tools often include features for precise geometry manipulation,
parametric modeling, sculpting, and assembly design. Popular software in this category
includes Autodesk Fusion 360, SolidWorks, and Blender.

2. CAD File Preparation: Additive manufacturing software helps prepare the 3D models
for printing by converting them into machine-readable formats, such as STL (Standard
Tessellation Language) or AMF (Additive Manufacturing File Format). It ensures that
the models are watertight, free of errors, and suitable for the chosen 3D printing
technology. Software like Materialise Magics, Netfabb, and Simplify3D are commonly
used for CAD file preparation.

3. Slicing: Slicing software is essential for additive manufacturing as it breaks down the
3D model into thin layers and generates the instructions for the 3D printer to create
each layer. These tools define parameters like layer thickness, infill density, print speed,
and support structures. Popular slicing software includes Ultimaker Cura, PrusaSlicer,
and Slic3r.
 4. Simulation and Analysis: Additive manufacturing software often includes simulation
and analysis capabilities to optimize the printing process and predict the behavior of
the printed part. These tools can help identify potential issues such as warping,
distortion, or structural weaknesses before printing. Software like Ansys Additive Suite,
Simufact Additive, and MSC Apex Generative Design offer simulation and analysis
features.

5. Material and Process Optimization: Some software tools focus on optimizing the
material selection and printing process for specific applications. They consider factors
such as material properties, printing parameters, and post-processing requirements to
optimize the final part's performance. Examples include software from Autodesk
(Netfabb), Materialise (Build Processor), and EOS (EOSPRINT).

6. Workflow and Management: Additive manufacturing software also assists in managing

the overall workflow, from design to printing and post-processing. It can help with job
scheduling, tracking print progress, managing material and machine parameters, and
maintaining traceability. Software like Materialise Streamics, 3DPrinterOS, and AMFG
provide workflow management capabilities.

7. Connectivity and Integration: Many additive manufacturing software tools offer

connectivity features to enable seamless integration with 3D printers, data management
systems, and other software platforms. This allows for better data exchange,
automation, and control over the entire additive manufacturing process.

Additive manufacturing software continues to evolve rapidly, incorporating advanced features

such as generative design, artificial intelligence, and cloud-based collaboration. These tools
enhance the efficiency, accuracy, and productivity of additive manufacturing, empowering
users to create complex, high-quality parts. Selecting the appropriate software depends on the
specific requirements, budget, and compatibility with the chosen 3D printing technology.

Features of Additive Manufacturing Software like Materialise Magics

Materialise Magics is a widely used additive manufacturing software that offers a range of
features to facilitate the preparation and optimization of 3D models for 3D printing. Here are
some key features of Materialise Magics:
1. CAD File Repair: Materialise Magics provides advanced tools for automatically
identifying and repairing common issues in CAD files, such as gaps, overlapping
triangles, or non-manifold geometry. This feature ensures that the 3D models are
suitable for 3D printing without any errors or mesh imperfections.

2. STL Editing and Manipulation: Users can make precise modifications to the 3D models
using a variety of tools available in Materialise Magics. This includes capabilities like
mesh editing, cutting, hollowing, scaling, and mirroring. These tools allow users to
optimize the geometry and prepare the models for specific printing requirements.

3. Support Structure Generation: Materialise Magics enables the generation of support

structures that provide stability during the printing process and help prevent
deformations or failures. Users can define support parameters, such as density, pattern,
and placement, and the software automatically generates the required support
structures.

4. Orientation and Nesting: Optimizing the orientation and nesting of 3D models within
the build chamber can significantly affect print quality, material usage, and build time.
Materialise Magics offers tools for orienting and nesting multiple models efficiently,
maximizing the build volume and minimizing material waste.

5. Part Nesting and Batch Processing: For mass production or printing multiple parts
simultaneously, Materialise Magics allows users to nest multiple models within the
build chamber, optimizing space utilization and minimizing printing time. The software
also supports batch processing, enabling users to automate the preparation and
processing of a large number of models.

6. Analysis and Measurement: Materialise Magics includes measurement tools that allow
users to analyze and inspect the 3D models. These tools provide measurements such as
distances, angles, wall thickness, and surface deviations, ensuring that the models meet
the desired specifications and quality standards.

7. File Conversion and Format Support: Materialise Magics supports various file formats
and offers the capability to convert models into different formats, such as STL, AMF,
or 3MF, to ensure compatibility with different 3D printers and software platforms. It
also provides options for exporting models with specific settings optimized for different
additive manufacturing technologies.
 8. Reporting and Documentation: The software enables the generation of comprehensive
reports and documentation related to the preparation and processing of 3D models. This
includes information on part orientation, support structures, build time estimation, and
material usage. These reports are useful for tracking, analysis, and quality control
purposes.

9. Integration with Additive Manufacturing Ecosystem: Materialise Magics integrates

seamlessly with other software and hardware in the additive manufacturing ecosystem.
It supports connectivity with various 3D printers, data management systems, and
workflow automation tools, providing a streamlined and efficient additive
manufacturing workflow.

These features make Materialise Magics a powerful tool for preparing, optimizing, and
analyzing 3D models for additive manufacturing. It simplifies the process of converting digital
designs into printable models, ensuring high-quality results and maximizing the efficiency of
the 3D printing process.

Features of Additive Manufacturing Software like Mimics

Mimics is a popular additive manufacturing software developed by Materialise that specializes

in medical image processing and 3D modeling. It offers a range of features tailored to the needs
of the healthcare industry and enables the conversion of medical image data into printable 3D
models. Here are some key features of Mimics:

1. Medical Image Import: Mimics allows users to import medical image data from various
imaging modalities, such as CT scans, MRI scans, or 3D ultrasound. It supports a wide
range of image formats and provides tools for image calibration and alignment to ensure
accurate representation of the patient's anatomy.

2. Image Segmentation: One of the primary features of Mimics is its advanced image
segmentation capabilities. It provides intuitive tools for segmenting different
anatomical structures from medical images. Users can manually trace the regions of
interest or employ semi-automatic or automatic segmentation algorithms to extract the
desired structures.
 3. 3D Reconstruction: Mimics enables the conversion of segmented 2D medical images
into accurate and high-quality 3D models. It employs sophisticated algorithms to
reconstruct the anatomical structures in a three-dimensional space, capturing the details
and geometry of the patient's anatomy.

4. Surface Editing and Mesh Generation: Once the 3D models are reconstructed, Mimics
offers a variety of tools for refining and editing the surfaces. Users can manipulate the
model geometry, smooth surfaces, fill holes, remove artifacts, and enhance the overall
quality of the model. It also provides options for generating watertight and printable
mesh structures.

5. Virtual Planning and Simulation: Mimics supports virtual planning and simulation for
surgical procedures. Surgeons can use the software to virtually manipulate and analyze
the patient-specific 3D models, plan surgical interventions, simulate different scenarios,
and evaluate the potential outcomes.

6. Customization and Design: With Mimics, users can customize and design patient-
specific implants, prosthetics, or surgical guides. The software allows for modifying the
3D models, adding or subtracting structures, creating patient-specific anatomical
models, and designing custom-fit medical devices.

7. Export and Integration: Mimics supports the export of 3D models in various file
formats, including STL, AMF, and 3MF, making them compatible with different 3D
printers and additive manufacturing workflows. It also provides integration capabilities
with other software platforms, allowing seamless data exchange and interoperability.

8. FDA-Approved Medical Device Software: Mimics is an FDA-approved medical device

software, ensuring that it meets the rigorous regulatory requirements for medical image
processing and 3D printing applications in the healthcare industry.

Mimics is widely used in medical research, surgical planning, anatomical education, and
patient-specific treatment solutions. Its comprehensive features and user-friendly interface
make it a valuable tool for medical professionals and researchers working with medical
imaging data and additive manufacturing in the healthcare field.
Features of Additive Manufacturing Software like Solid Works

SolidWorks is a widely used computer-aided design (CAD) software that also offers powerful
additive manufacturing capabilities. Here are some key features of SolidWorks related to
additive manufacturing:

1. Design and Modeling: SolidWorks provides a robust set of tools for designing and
modeling 3D objects. Users can create complex geometries, parametric models, and
assemblies. The software supports various design techniques, such as sketching,
extruding, revolving, lofting, and sweeping, enabling users to create intricate parts for
additive manufacturing.

2. Integration with Additive Manufacturing Processes: SolidWorks seamlessly integrates

with different additive manufacturing processes. It supports a wide range of file
formats, including STL, AMF, and 3MF, commonly used for 3D printing. Users can
easily export their designs to these formats, ensuring compatibility with additive
manufacturing machines.

3. Design for Additive Manufacturing (DfAM) Tools: SolidWorks offers specific tools and
features to optimize designs for additive manufacturing. These tools include lattice
generation, thin wall analysis, part consolidation, and support structure generation.
Users can leverage these tools to enhance part performance, reduce material usage, and
improve the overall efficiency of the additive manufacturing process.

4. Simulation and Analysis: SolidWorks provides simulation capabilities to analyze and

validate the performance of additive manufactured parts. Users can perform structural
analysis, thermal analysis, and fluid flow simulations to ensure the part's functionality
and integrity. Simulation results help identify potential issues and optimize the design
before 3D printing.

5. Slicing and Print Preparation: SolidWorks supports slicing, which is the process of
dividing a 3D model into layers for additive manufacturing. Users can generate
toolpaths and define printing parameters, such as layer thickness, infill density, and
support structures. SolidWorks prepares the model for printing by generating the
necessary instructions for the 3D printer.

6. Collaboration and Documentation: SolidWorks facilitates collaboration among team

members working on additive manufacturing projects. It allows for easy sharing of
 design files, annotations, and markups. The software also provides documentation
capabilities, such as generating drawings, bill of materials (BOM), and manufacturing
instructions, ensuring clear communication throughout the additive manufacturing
workflow.

7. Material and Process Selection: SolidWorks includes extensive material libraries,

enabling users to select the appropriate materials for additive manufacturing
applications. It also provides information about material properties, compatibility with
different printing technologies, and post-processing requirements. This helps users
make informed decisions when choosing materials for their designs.

8. Workflow Management: SolidWorks offers tools for managing the additive

manufacturing workflow. Users can track design iterations, monitor project progress,
and manage file revisions. The software integrates with other product data management
(PDM) systems, ensuring smooth data flow and version control throughout the entire
process.

These features make SolidWorks a versatile software tool for additive manufacturing. It
combines design capabilities with dedicated additive manufacturing functionalities, allowing
users to create optimized, manufacturable 3D models for various additive manufacturing
processes.

Features of Additive Manufacturing Software like SolidView

Here are some general features commonly found in additive manufacturing software:

1. 3D Model Viewing: Additive manufacturing software allows users to open and view
3D models in various file formats, such as STL, OBJ, AMF, or 3MF. Users can rotate,
zoom, and pan the models to examine them from different angles and get a better
understanding of the geometry.

2. Model Analysis: These software tools provide analysis features to evaluate and inspect
the 3D models. Users can measure dimensions, distances, angles, and clearances within
the models. They can also perform advanced analyses, such as thickness analysis,
undercuts detection, or part comparison.
 3. Slicing and Toolpath Generation: Slicing is a critical step in additive manufacturing
where the 3D model is divided into layers, and toolpaths are generated for the 3D
printer. Additive manufacturing software allows users to define slicing parameters like
layer height, infill density, and support structures. It generates the toolpaths necessary
for the printer to build the part layer by layer.

4. File Conversion and Format Support: Additive manufacturing software often supports
file conversion between different formats, ensuring compatibility with various 3D
printers and software platforms. It allows users to import models in one format and
export them in the required format for printing.

5. Support Structure Generation: Some additive manufacturing software offers tools to

automatically generate support structures. These structures provide stability during the
printing process and help prevent deformations or failures. Users can customize support
parameters such as density, pattern, and placement to optimize the support generation
process.

6. Integration with Additive Manufacturing Ecosystem: Additive manufacturing software

can integrate with other software and hardware in the additive manufacturing
ecosystem. This includes connectivity with 3D printers, data management systems, and
workflow automation tools. Integration streamlines the data exchange, improves
efficiency, and facilitates a seamless additive manufacturing workflow.

7. Reporting and Documentation: Additive manufacturing software allows users to

generate reports and documentation related to the additive manufacturing process. This
includes information on print parameters, material usage, estimated print time, and
post-processing instructions. Reports and documentation help with quality control,
traceability, and process optimization.

Please note that the specific features may vary depending on the software tool you choose. It
is advisable to research and select a software that best suits your specific requirements and
integrates well with your additive manufacturing workflow.

Features of Additive Manufacturing Software like 3D Rhino

3D Rhino, also known as Rhinoceros or Rhino 3D, is a powerful CAD software widely used
in various industries, including additive manufacturing. While Rhino 3D is primarily a general-
purpose CAD software, it offers several features that are beneficial for additive manufacturing.
Here are some key features of Rhino 3D related to additive manufacturing:

1. NURBS Modeling: Rhino 3D uses Non-Uniform Rational B-Splines (NURBS) as its

primary modeling technique. NURBS modeling allows for the creation of smooth and
accurate geometry, which is essential for producing high-quality 3D printed objects.
NURBS surfaces and curves can be easily manipulated, edited, and combined to create
complex and organic shapes.

2. File Import and Export: Rhino 3D supports a wide range of file formats, including
common formats used in additive manufacturing such as STL, AMF, and 3MF. This
enables seamless import and export of 3D models, ensuring compatibility with various
3D printers and other additive manufacturing software.

3. Surface and Solid Modeling: Rhino 3D provides tools for both surface and solid
modeling, giving users flexibility in creating additive manufacturing designs. Users can
create and edit surfaces to define the outer shape of the object, and then convert them
into solid models for further manipulation and refinement.

4. Geometry Editing and Manipulation: Rhino 3D offers a comprehensive set of tools for
editing and manipulating geometry. Users can modify curves, surfaces, and solids,
allowing for precise adjustments to achieve the desired shape and form of the 3D model.
This capability is crucial for optimizing designs for additive manufacturing processes.

5. Boolean Operations: Rhino 3D supports boolean operations, which allow users to

combine, subtract, or intersect multiple solid objects. This feature is useful for creating
complex geometries and optimizing designs by combining or subtracting parts. Boolean
operations help prepare models for additive manufacturing by ensuring correct
geometry and solid structures.

6. Mesh Creation and Editing: Rhino 3D provides tools for creating, editing, and refining
meshes. This is particularly useful for additive manufacturing, as many 3D printers
work with mesh-based file formats like STL. Users can convert their NURBS models
into meshes and perform mesh editing operations to refine the geometry or reduce the
complexity of the model.
 7. Dimensioning and Annotation: Rhino 3D allows users to add dimensions, annotations,
and other textual information to the 3D models. This helps in communicating design
intent, documenting design features, and providing important instructions for the
additive manufacturing process.

8. Visualization and Rendering: Rhino 3D offers advanced visualization and rendering

capabilities, allowing users to create realistic images and visualizations of their additive
manufacturing designs. This helps in evaluating the aesthetics, surface finishes, and
overall appearance of the final printed objects.

9. Scripting and Automation: Rhino 3D supports scripting and automation through its
RhinoScript and PythonScript capabilities. This allows users to automate repetitive
tasks, customize workflows, and create scripts to streamline the additive manufacturing
process.

These features make Rhino 3D a versatile tool for additive manufacturing. Its combination of
powerful modeling capabilities, file format compatibility, and customization options provides
users with the necessary tools to design, optimize, and prepare models for 3D printing.