Engineering knowledge series

3D PRINTING
——RAPID PROTOTYPING

Industrial center of UJS: S. Huang (Sophia)

Artificial heart
First Industrial Revolution

The first industrial revolution

began in Britain in the 18th
century, with the mechanism
of the textile industry

Second Industrial Revolution

The second industrial
revolution came in the early
20th century, when Henry
Ford mastered the moving
assembly line and ushered in
the age of mass production.
One of the Next Industrial Revolution
open-cellular lattice
structures for
osseointegrative and
isoelastic bone implant

Typical 3D printing process

free form surfaces

network / lattice
structures
How Can 3D Printing Change the World
The Wonder of 3D Printing
White area: ground-glass infection 3D printed model of new
coronavirus pulmonary infection

nCoV

3D printing technology can materialize the

structural features of viruses and assist in
the analysis of the evolution of physical
models in the field of emergent medicine

Mpro crystal
structure

Internal cross
complex structure
The Wonder of 3D Printing
The world's first April, 2019
3d-printed heart

The heart can contract,

but it is not yet capable
of pumping blood
The heart, which measures
just 2.5cm in length and is
about the size of a rabbit's
heart, has complete cells,
blood vessels and a heart
cavity, said Israeli scientist
David dewell
The Wonder of 3D Printing
McDonald's wants a 3D printer in
every restaurant so they can print
Happy plastic/metal toys!

“Always working” cartoon

Teaching Objectives
p Principle of 3D Printing
p Categories of 3D Printing
p Typical equipments of 3D Printing 3D Printer

p Applification of 3D Printing

3DP Product
What is 3D Printing?
3D printing is a form of Additive Manufacturing, process of joining
material to make an object from 3Dmodel Data, layer-by-layer process.

AM

Slicing+Layered manufacturing STL approximation

Basic Principle of 3D Printing
• 3Dprinting is produced by adding materials rather than
removing materials.

• A part is firstly modelled by a geometric modeller such

as a solid modeller and then is mathematically sliced into
series of parallel cross-section pieces. For each piece,
the curing or binding paths are generated.

• These cutting or binding paths directly used to instruct

the machine for producing the part by solidifying or
binding a line of material.

• After a layer is built, a new layer is built on the previous

one in the same way. Thus, the model is built layer by
layer from the bottom to top.
Basic Principle of 3D Printing

Virtual
Model

3D CAD design STL approximation Slicing

Actual
Model

3DP product Layered manufacturing

Prepare Control Instructions for 3D Printing

CAD model is converted into a

computerized format that
Crank approximates its surfaces by
facets (triangles or polygons)

Geometric modeling Tessellation

Slicing the Model to Layers

Conversion of a solid model of an object into Slice and layered

layers (only one layer is shown) processing of statue
Advantages of 3D Printing
p Produces physical prototypes in short
time (within minutes, hours or days
rather than weeks).
p These prototypes are frequently used
to quickly test the product's look,
dimension, and feel. Rapid prototyping
usually can result in plastic/metal
objects.
p Provides the proof of concept
p Shows users how the final system would look like
p Reduces development costs
p Increases system development speed and quality
p Assists to identify any problems with early designs
p Refines the potential risks with product delivery
Typical example of 3D Printing
A C

B D
Why is Rapid Prototyping Important?

p Product designers want to have a physical model of a

new part or product design rather than just a
computer model or line drawing
p Creating a prototype is an integral step in design
Ø A virtual prototype (a CAD model of the part) may not
be sufficient for the designer to visualize the part
adequately
Ø Using 3D Printing to make the prototype, designer
can see and feel the part and assess its merits and
shortcomings
Categories of 3D Printing
To substantially shorten the time for developing patterns,
moulds and prototypes, some manufacturing enterprises have
started to use RP for complex patterns making and component
prototyping. over the past few years, a variey of new rapid
manufacuring technologies have emerged. The most common
five are:

p Laminated Object Manufacturing (LOM)

p Fused Deposition Modeling (FDM)
p Stereolithography (SLA)
p Selective Laser Sintering (SLS)
Training 1: Laminated Object Manufacturing (LOM)

p Starting material is solid

p Solid physical model made by stacking layers of
sheet stock, each an outline of the cross-sectional
shape of a CAD model that is sliced into layers
p Starting sheet stock includes paper, plastic, metals, or
fiber-reinforced materials
p The sheet is usually supplied with adhesive backing
as rolls that are spooled between two reels
p After cutting, excess material in the layer remains in
place to support the part during building
Laminated Object Manufacturing (LOM)

Schematic diagram of LOM

Solido SD300Pro 3D Printer
p The SD300Pro 3D Printer is an office friendly, desktop printer
that allows you to quickly create solid, plastic, 3D objects
from 3D CAD drawings. SD300Pro models can be sanded,
spray painted, painted or any other similar finish with
negligible distortion.

p SD300Pro 3D models can be used in all phases of design,

from concept modeling to functional testing and assembly
verification. For example, a model can be used as a tool to
communicate design intent, to verify the fit of a new or
existing component part or to create a rugged, plastic
prototype of a new invention.
SD300Pro 3D Printer
Main Parts and Operating Panel

The finished model

SD300Pro 3D Printer Operating Step

Modeling Coat PVC foil Layered cutting

Coat unglued liquid Remove support Complete

Improve product designs and prototypes
• When making a product design and prototype, designers and
engineers should bear in mind the lessons of user experience. This is
often applied to software design, but it is just as relevant to new
product development and manufacturing processes. It’s the key to
creating great products that are easy to use and satisfy the
customer’s rational and emotional expectations.
• What makes for a great user experience?
• Usability
• Desirability
• Acceptability
• Emotional Satisfaction
It’s important to understand how these ideas work together to create
great user experience and therefore a great product.
SD300 Success Case:Equipment Shell

Layered manufacturing, pasting, polishing and painting

SD300 Success Case:Creative Chair
SD300 Success Case:Fold Bicycle

The toughness and strength can effectively simulate the bicycle aluminum alloy
stent
The engineer install the brake, chair cushion, chain, pedal, etc for the bicycle。A
fully realized function of bicycle can be completed in less than 5 days. A zero defect
of bicycle design using LOM technology immediately available with the company
and customer's recognition, and preparations for mass production immediately.
Assembly Production -From Design to Product

In order to reduce the processing height, divided the whole assembly componet into
several parts, and then processing at the same time, followed by post-processing
and assembling
Test the Design at Any Time
Physical test instead of virtual test
Solid Test Instesd of Virtual Test
Personal Custom Parts - Critical Components

Respirator for the girl with respiratory disease

Wonderful Presentation Tool

Design drawings 3D model

Building demonstration by SD300 (LOM)
Shell of SD300
Training 2: Fused Deposition Manufaturing (FDM)

FDM based on deposition of extruded thermoplastic material, a spool of

thermoplastic filament feeds into a heated FDM extrusion head. The
movement of FDM head is controlled by computer.
Inside the flying extrusion head, the filament is melted into liquid by a
resistant heater. The head traces an exact outline of each cross-section
layer of the part. AS the head moves horizontally in X and Y axes, the
thermoplastic material is extruded out of a nozzle by precision pump. The
material solidifies in 1/10 second as it is directed onto the workplace.
After one layer is finished, the extrusion head moves up a programmed
distance in Z direction for building the next layer. Each layer is bonded to
the previous layer through thermal heating.
Fused Deposition Manufaturing (FDM)

Schematic Diagram of FDM

Typical Application of FDM

The car door handle: Prototype and injection component

Typical Application of FDM

The turbine shell: to test the structure and appearance design

Typical FDM Printer 3D printer

Yinhua FDM Printer 1

Yinhua FDM Printer 2
Objet 30Pro 3D
Assemble of Typical FDM Printer

Desktop FDM Printer

Important Parameters: Printing Velocity and Temperature
Typical Applicationof FDM
Cure injured duck Artificial blood vessels

Cure injured tortoise Artificial heart

Cure injured girl Delicious food

Cure injured man Buildings

Heart valve Jaws Cartilage tissue

Typical Applicationof FDM
——Local Motors
The world's first 3D printing electric car
Local Motors is an American motor vehicle manufacturing company focused on low-volume
manufacturing of open-source motor vehicle designs using multiple microfactories. Local Motors'
web site is a community focusing on engine vehicle innovation. The content is created by the
users of the community who discuss designing, engineering and building innovative engine
vehicles. Members contribute with their own ideas and projects which are discussed with the
community. Due to the co-design of the vehicles with contributions from the community's
worldwide members, the firm has reduced the time and cost of the development of their engine
vehicles.
Local Motors in collaboration with Cincinnati Incorporated and Oak Ridge National Laboratory
manufactured Strati, the world's first 3D printed electric car. The printing took 44 hours to
complete, and was witnessed by a live audience at the 2014 International Manufacturing
Technology Show, Chicago. Production was hoped for 2015.
In 2016 the company plans to sell 3D printed cars called LM3D Swim for $35,000. The materials
used are 80 percent ABS plastic and 20 percent carbon fiber. The car consists of 50 individual
parts, far less than a traditional vehicle (which is manufactured with roughly 30,000 parts).
Training 3: Stereolithography (SLA)
p Starting material is liquid photosensitive resin

p RP process for fabricating a solid plastic part out of a

photosensitive liquid polymer using a directed laser
beam to solidify the polymer

p Part fabrication is accomplished as a series of layers,

each layer is added onto the previous layer to gradually
build the 3D geometry
Stereolithography (SLA)

Schematic Diagram of SLA

Stereolithography (SLA)

Stereolithography: (1) at the start of the process, in which the initial

layer is added to the platform; and (2) after several layers have
been added so that the part geometry gradually takes form
Typical Application of SLA

Water saving device

The vacuum cleaner

Micro dropper
Turbine
Typical Application of SLA

Typical componets manufactured by SLA 7000

Auro-350 production of
throttle valve components
( b y Yi n h u a c o m p a n y i n
Beijing)
Continous Liquid 3D Printing

Viedo of CLIP
Continous Liquid 3D Printing
p In what may be one of the biggest stories we have covered this year, a new company,
Carbon3D has just emerged out of stealth mode, unveiling an entirely new
breakthrough 3D printing process, which is between 25 and 100 times faster than
what is available on the market today.
p Continuous Liquid Interface Production technology (CLIP) works by harnessing the
power of light and oxygen to cure a photosensitive resin. Sounds an awful lot like
Stereolithography (SLA) technology, doesn’t it? While Instead of printing an object
layer-by-layer, this new process harnesses light as a way to cure the resin, and
oxygen as an inhibiting agent, to print in true 3-dimensional fashion.
p Current 3D printing technology has failed to deliver on its promise to revolutionize
manufacturing, CLIP technology offers the game-changing speed, consistent
mechanical properties and choice of materials required for complex commercial
quality parts
p By bringing oxygen into the equation, CLIP removes the layering effect, it relies on a
special transparent and permeable window which allows both light and oxygen to get
through. Think of it as a large contact lens. The machine then is able to control the
exact amount of oxygen and when that oxygen is permitted into the resin pool. The
machine will then produce a series of cross sectional images using UV light in a
fashion similar to playing a movie.
Continous Liquid 3D Printing

Additive manufacturing processes such as 3D printing use time consuming, stepwise layer by
layer approaches to object fabrication. We demonstrate the continuous generation of
monolithic polymeric parts up to tens of centimeters in size with feature resolution below 100
micrometers. Continuous liquid interface production is achieved with an oxygen-permeable
window below the ultraviolet image projection plane,which creates a“deadzone”(persistent
liquid interface) where photopolymerization is inhibited between the window and the
polymerizing part. We delineate critical control parameters and show that complex solid parts
can be drawn out of the resin at rates of hundreds of millimeters per hour. These print speeds
allow parts to be produced in minutes instead of hours.
Continous Liquid 3D Printing

Compare CLIP against commercial printer in each technology category

Carbon’s CEO & Co-Founder to Present Opening Keynote at Inside 3D Printing

NewYork Recently

The Revolution Arrives: Carbon Releases M1 Commercial 3D Printer with CLIP

Technology & New Resins

NewPro3D, the Fastest 3D Printer in the World, Just Printed a Full-Sized Skull in
Minutes Not Hours
Training 4: Selective laser sintering(SLS)

• In many respects SLS is similar to SLA except that the

laser is used to sinter and fuse powder rather than
photocure a polymeric liquid.

• The first step is to prepare the "STL" files as described

earlier. Inside the SLS machine, a thin layer of fusible
powder is laid down and heated to just below its melting
point by infrared heating panels at the side of the
chamber. Then a laser sinters and fuses the disired
pattern of the first slice of the object in the powder. Next,
the first fused slice descends the roller spreads out
another layer of powder, and the process repeats.
Selective laser sintering(SLS)
In comparison with SLA, this process can rely on the supporting
strength of the unfused powder around the partially fused object,
this allows the creation of rather delicated, lacelike objects.
Nevertheless hand finishing is still needed to improve inevitable
stair-stepping. Also, SLS parts have a rough, grainy appearance
from the sintering process, and it is often preferable to hand
smooth the surface.

Another difficulty is maintaining the temperature of the powder

at a few degrees below melting. This is done with the infrared
panels, but maintaining an even temperature over a large mass
of powder requires long periods of stabilization before sintering
by the laser can be started.
Principle of Selective laser sintering(SLS)

Schematic Diagram of SLS

Typical Appliction of SLS

SLS combined with high speed Complex cooling

milling to manufacture a mold waterway

Dies processed by EOS Company

Typical Appliction of SLS

Gear box parts Steel impeller Injection mold

Typical Appliction of SLS

Sand mold Ceramic part Polymer vase

Typical Appliction of SLS

SLS technology in the EADS-ST company: typical

applications of the liquid rocket engine
Typical Appliction of SLS

Metal mold Plastic mold Sand mold

Typical Appliction of SLS

Dress design and manufacture

Typical Appliction of SLS

Metal pistol Human body metal jaw bone implants

Chain design and manufacture

Inkjet 3D Printing

Three dimensional printing: (1) powder layer is deposited, (2) inkjet

printing of areas that will become the part, and (3) piston is
lowered for next layer (key: v = motion).
Special application: ceramic molds for the metal casting and powder-
metal tooling for injection molding dies
Typical Application of 3D Printing

Cartoon character modelling of Warcraft

3D Printing is valued by 3 factors

Evolution in manufacturing processes by laser technology

Challenges of todays and future markets of 3D Printing
3D Printing markets and fields of competence

Project and cooperation partners

New approaches for lightweight design
New approaches for lightweight design
3D printed bionic Concept Car by EDAG
Integration conformal cooling and pneumatic ejectors
into tooling inserts

advantages of conformal cooling

n reduction of cycle time
n reduction of part distortion
n near-net-shape manufacturing

advantages of pneumatic ejectors

n no mechanical moving components
n uniform ejection pressure
n prevention of plagiarism
Lead time reduction for spare-parts by 3D manufacturing

Conventional: 96 weeks
production
production of Pintle Pin
mill run & raw material delivery (70 weeks) of forging
(18 weeks)
(8 weeks)

Reduction of lead time through LAM production: 22 weeks

preparation production
production of Pintle Pin
& of ALM part
(18 weeks)
raw material (3 weeks)

ALM allows:
n largely reduced lead-time and no NRC (machine set up) for cast / forging blank
n shapeless powder material can be formed into any “cast / forging” blank
n “easy” storage of base material
– less raw material needed through “(Near)-Net-Shape” manufacturing
– recycling of powder material from previous jobs
4D printing- Shape Change over Time
p Through a collaboration between Stratasys, Autodesk and MIT’s Self-Assembly
Lab, a new process is being developed, coined 4D Printing, which demonstrates a
radical shift in rapid-prototyping. 4D Printing entails multi-material prints provided by
the Connex Technology with the capability to transform from one shape to another,
directly off the print-bed. This revolutionary technique offers a streamlined path from
idea to reality with full functionality built directly into the materials. Imagine robotics-
like behavior without the reliance on complex electro-mechanical devices!

p In order to take advantage of this new technology from idea conception to reality we
have collaborated with Autodesk Research on their developments for a new software,
called Cyborg, a design platform spanning applications from the nano-scale to the
human-scale. This software allows for simulated self-assembly and programmable
materials as well as optimization for design constraints and joint folding. The aim is
to tightly couple this new cross-disciplinary and cross-scalar design tool with the real-
world material transformation of 4D printing. The tightly coupled software and
hardware tools will eliminate the traditional paradigms of 1. simulating then building
or 2. building then adjusting the simulation. This coupled workflow will be
unprecedented in the simulation adjusting physical performance and materials
promoting new simulated possibilities.
4D printing- Shape Change over Time

Multi-Material Shape Change: MIT 2013 Self-Folding Strand into 3D Cube

Self-Folding surface 4D Cube Self-Folding Truncated Octahedron

The Emergence of 4D Printing

TED TALKS1 6 Axis 3D Printer

TED TALKS2 Full Color 3D Printer

Summary
p SLA emerges as the most commercially accepted of the
newer rapid prototyping technologies.
p SLS emerges as a very useful, commercially accepted
alternative to SLA for overhanging structures needing
support and for stronger materials that can be sintered
rather than photocured.
p FDM is an excellent choice for an in-house machine that
can be used by an industrial design team for an iterative
series of prototypes.
p LOM is excellent for large components.
p Machining and casting remain central to the rapid
prototyping field, especially for high-strength prototypes and
longer batch runs of several prototypes.
Summary
p The accuracy of processes such as SLA and SLS is improving as
time goes by. These processes are being more and more in the
creation of the original, first master for casting and for plastic
injection molding. As consumer products such as stereos, phones,
personal digital assistant(PDAS) and computers begin to look more
aerodynamic, there is a need to create molds that have unusual
curves and reentrant shapes, these are easy to create in RP,
especially in comparison with machining.

p It has nonetheless been emphasized that RP's accuracy is poor in

comparison with machining. Overhanging structures may be hard to
support during fabrication, and there are problems with component
warping during curing. While simple shapes might have accuracies
of 25 to 75 microns, the range for complex shapes might be as high
as 125 to 375 micrions.
Summary
• While the strength of RP parts is today less than machined parts, new
trends are closing the gap. The FDM parts made by the stratasy machine
can be formed in near full strength ABS and similar polymers. some
researchers have increased the strength of photopolymers by fiber
reinforcement. Also, research on a process called laser engineered net
shaping(LENS) is permitting direct fabrication of high-strength metal molds.
This and similar projects are modified versions of DTM company's SLS
process.

• Rapid prototyping dramatically accelerates time to market.

• Psychologically, it focuses the attention of the members of the

design team in a "learning organization".

• Physically, it reduces the time necessary to make a full production

die from hardened steel and launch into mass production.
Training Report Requirements

pMake an overview of the principle of 3D printing.

pList the main category of 3D printing.
pDraw the principle diagram of typical rapid prototyping (LOM ,
FDM, SLA, SLS).
pDescribe the continous liquid interface production and 4D
printing technology briefly.
pDescribe the challenges of todays and future markets of 3D
Printing.