Workshop Practice

3-d Printing

Submitted by -

SE20UECE013
B.V.S. Pranav
A4

Part (i) :

3-d Printing Introduction :

3-d printing refers to a new class of manufacturing methods that quickly

produce physical prototypes from 3D cad data.

3-d printing models :

3-d printing machines :

3D Printing Types :

Polymer 3D Printing

•FDM (Fused Deposition Modeling)

•SLA (Stereolithography)
•SLS (Selective Laser Sintering)

Metal 3D Printing

•DMLS (Direct Metal Laser Sintering)

•EBM (Electron Beam Melting)
FDM (Fused Deposition Modeling) :

Fused Deposit Modeling (FDM) is a common desktop 3D printing technology

for plastic parts.

❖ The FDM printer works by extruding the plastic filament layer by layer
onto the build platform.

❖ The plastic hardens as soon as it flows from the nose and ligaments to
the bottom layer. Once one layer is built, the platform shrinks, and the
extraction nozzle deposits another layer.

❖ It is an expensive and quick method to create physical models.

❖ There are a few examples of when FDM was used for functional testing,
but the technology was limited by the relatively rough surface finishes
and lack of strength.

❖ A wide variety of materials are available, including ABS, polyamide,

polycarbonate, polyethylene, polypropylene, and investment casting
wax.

Diagram :
Stereolithography (SLA) :

Stereolithography (SLA) is an original industrial 3D printing process.

❖ SLA printers excel at producing components with a high level of detail,

smooth surface finishes, and tight endurance.

❖ It uses a low-power, high-focus UV laser to detect successive

cross-sections of a three-dimensional object in the vat of a liquid
photosensitive polymer.

❖ When the laser layer is detected, the polymer solidifies and excess areas
remain fluid. When one layer is finished, a leveling blade is moved
across the surface to smooth it out before the next layer is deposited.

❖ A distance equal to the thickness of the platform layer (usually

0.003-0.002 inches) is reduced and the next layer is formed on top of the
previously finished layers.

Diagram :
Selective Laser Sintering :

The basic concept of SLS is similar to SLA. It uses a moving laser beam to
detect and select dry polymer and/or metallic alloys in successive
cross-sections of a three-dimensional component.

❖ The powder is deposited on top of each solid layer and sealed. This
powder layer is rolled from a bin to the platform before being built.

❖ This powder is held at a high temperature so that it mixes easily with the
laser.

❖ SLS allows a wide range of materials, including nylon, glass-filled nylon,

Somos (rubber-like), Truform (investment casting), and the metal alloy
discussed earlier.

Diagram :
Direct Metal Laser Sintering :

❖ The DMLS process can be done by two different methods, powder deposition,
and powder bed, which differ in the way each layer of powder is applied.

❖ In the dry deposition method, the metal powder is in a hopper, which melts the
powder and deposits a thin layer on the build platform. In the powder bed
method (shown in the next slide), the powder dispenser piston increases the
power supply, and then a recuperator arm distributes the powder layer over the
powder bed.

❖ A laser then sinters a layer of dry metal. In both methods, after building one
layer the build piston lowers the build platform and the next layer of powder is
applied.

❖ The powder deposition method offers the advantage of using more than one
material, each in its hopper. The powder bed method is limited to just one
material but provides rapid build-up speed.

❖ Material options currently offered are Alloy Steel, Stainless Steel, Tool Steel,
Aluminum, Bronze, Cobalt-Chrome, and Titanium.

Diagram :
Electron Beam Melting :

❖ The material is layered in a vacuum chamber.

❖ It uses the energy source of the electron beam generated by the electron
beam cannon to melt the metal powder.

❖ The powder is removed from the pellets and expanded using a rake on a
platform, the entire dry bed is heated to 700-900 to C using an electron
beam.

❖ The electron beam melts in the current layer, cross-sections, according

to the CAD model.

Diagram :
Materials Options for 3D Printing :

Metallic materials :

Plain Carbon Steel, Tool Steel, Stainless steel, Aluminium, Copper, Titanium,
Bronze, Nickel Alumides

Polymers and Polymeric Composites :

ABS, Nylon (Polyamide), Polycarbonate, PP, Epoxies, Glass-filled polyamide,

Windform, Polystyrene, Polyester, Polyphenylesulfone

Others

Sand, Ceramics, Elastomers, Tungsten, Wax, Starch, Plaster

Bio-Compatible Materials

Polycaprolactone (PCL), polypropylene-tricalcium phosphate, (PP-TCP),

PCL-hydroxyapatite (HA), polyetheretherketone-hydroxyapatite, (PEEK-HA),
tetra calcium phosphate (TTCP), beta-tricalcium phosphate (TCP), Polymethyl
methacrylate (PMMA)
 Part ( ii )

Aim: To print a given part using a 3D printer.

Printer Used :

● Ultimaker 2+

● Build Volume:
223 x 220 x 205 mm

● Materials :
• PLA
•ABS
•Nylon, etc

● Technology:

● FDM
Procedure :

❖ Create a 3D component in modeling software

❖ Save the part drawing in .stl format

❖ Prepare a printer loaded with the desired material.

❖ Transfer the file to Ultimaker Cura software

❖ Select the printer in the software.

❖ Set the parameters in the software.

❖ Slice the piece for printing.

❖ Note the printing time

❖ Save the file to the SD card or print directly using the USB connection to
the printer.

❖ And the final product is ready

Conclusion :

In this workshop, I learned about what is 3d printing, what are the types of 3d
printing, and the advantages it and I understood that 3d printing is one of the
great innovation which helps to make the world better.

Result :

In this workshop, we had successfully printed CUBE of 20 mm sides with ABS

(Acrylonitrile butadiene styrene) material using 3d printer.