Additive-Manufacturing-(3D-Printing)

Addi ve Manufacturing (3D Prin ng)
SI.No Modules and Units Page No
Par cipant Handbook
Sector
Instrumenta on
Sub-Sector
Instrumenta on and
Automa on
Occupa on
Installa on and
Commissioning(Instrumenta on
and Automa on)
Reference ID: IAS/Q5602 Version-3.0
NSQF Level: 4
Addi ve Manufacturing
(3D Prin ng)
Scan this QR Code to access eBook
Par cipant Handbook
This book is sponsored by Instrumenta on, Instrumenta on, Automa on,

Surveillance & Communica on Sector Skill Council
Contact Details:
B-12, Sector1, Noida 201301, U ar Pradesh, India
Email: info@iascsectorskillcouncil.in
Website: www.iascsectorskillcouncil.in
Phone: 012 02424331
Under Crea ve Commons License: CC-BY-SA

A ribu on-ShareAlike: CC BY-SA
This license lets others remix, tweak, and build upon your work even for commercial purposes,
as long as they credit you and license their new crea ons under the iden cal terms. This license
is o en compared to "copyle " free and open-source so ware licenses. All new works based
on yours will carry the same license, so any deriva ves will also allow commercial use. This is
the license used by Wikipedia and is recommended for materials that would benefit from
incorpora ng content from Wikipedia and similarly licensed projects.
Disclaimer
The informa on contained herein has been obtained from sources reliable to Instrumenta on,
Automa on, Surveillance & Communica on Sector Skill Council. Instrumenta on,
Automa on, Surveillance & Communica on Sector Skill Council disclaims all warran es to the
accuracy, completeness or adequacy of such informa on. Instrumenta on, Automa on,
Surveillance & Communica on Sector Skill Council shall have no liability for errors, omissions,
or inadequacies, in the informa on contained herein, or for interpreta ons thereof. Every
effort has been made to trace the owners of the copyright material included in the book. The
publishers would be grateful for any omissions brought to their no ce for acknowledgements
in future edi ons of the book. No en ty in Instrumenta on, Automa on, Surveillance &
Communica on Sector Skill Council shall be responsible for any loss whatsoever, sustained by
any person who relies on this material. The material in this publica on is copyrighted. No parts
of this publica on may be reproduced, stored or distributed in any form or by any means either
on paper or electronic media, unless authorized by the Instrumenta on, Automa on,
Surveillance & Communica on Sector Skill Council.
Skilling is building a be er India.

If we have to move India towards
development then Skill Development
should be our mission.
Shri Narendra Modi

Prime Minister of India
iii
Par cipant Handbook
Certificate
is hereby issued by the

Instrumentation Automation Surveillance & Communication
Sector Skill Council
for
Complying to National Occupational Standards of

Job Role/Qualification Pack: Additive Manufacturing (3D Printing)
QP Nos IAS/Q5602 Level 4
Sd/-
Date of Issuance: Feb. 05th, 2023 Brajesh Kumar
Authorised Signatory
Valid up to : Feb. 05th, 2026
*Valid up to the next review date of the Qualification Pack or the
(IASC Sector Skill Council)
‘Valid up to’ date mentioned above (whichever is earlier)
iv
Acknowledgements
The Instrumenta on, Automa on, Surveillance & Communica on Sector Skill Council (IASC) would like
to thank all the individuals and organisa ons, who contributed, in various ways, to the prepara on of
this par cipant handbook. The handbook could not have been completed without their ac ve
contribu on. Special gra tude is extended to those who collaborated during the prepara on of the
different modules in the par cipant handbook. Wholehearted apprecia on is also extended to all who
provided peer review for these modules.
The prepara on of this handbook would not have been possible without the instrumenta on and
automa on industry’s support. Industry feedback has been extremely beneficial since incep on to
conclusion, and it is with their guidance that we have tried to bridge the exis ng skill gaps in the industry.
This par cipant handbook is dedicated to the aspiring youth, who desire to achieve special skills that will
be a long-term asset for their future pursuits.
v
Par cipant Handbook
About this Book

The Industrial Automa on Technician is responsible for installing control panels, integra ng it with a
customer’s system, and assis ng the engineer in commissioning and powering up at the customer’s site.
The individual on the job should be well organised, display logical thinking, have an eye for detail, and
should be able to work for long hours at the customer’s site in a team environment and under ght
deadlines. Among others, the individual must have decent communica on skills and be able to priori se
tasks. The trainee will enhance his/her knowledge under the trainer’s guidance in the following skills:
Ÿ Knowledge and understanding: Adequate opera onal knowledge and understanding to perform
the required task
Ÿ Performance criteria: Achieve the required skills via hands-on training and perform the required
opera ons within the specified standards
Ÿ Professional skills: Ability to make opera onal decisions related to the area of work
The handbook incorporates well-defined responsibili es of an Industrial Automa on Technician.
Symbols Used
Key Learning Unit

Tips Notes Ac vity
Outcomes Objec ves
Summary
vi
Table of Contents
1. Introduc on to Role of an Addi ve Manufacturing 3D Prin ng (Bridge Module) 1
Unit 1.1 - About Addi ve Manufacturing in Industry 3
Unit 1.2 - Role of an Addi ve Manufacturing (3D Printer) 7
2. Install a 3D Printer (IAS/N5606) 9
Unit 2.1 - About 3D Prin ng Technology 11
Unit 2.2 - 3D Prin ng Applica on 25
Unit2.3 - So ware & 3D Printer Installa on 29
3. Maintain and Provide Technical Support for 3D Printer (IAS/N5607) 34
Unit 3.1 - Get Started with 3D Printer 36
Unit 3.2 - Use of 3D Printer So ware 38
Unit 3.3 - Maintenance of 3D Printer 44
4. Operate and Op mise 3D Prin ng for Addi ve Manufacturing (IAS/N5608) 48
Unit 4.1 - Prototype Development 50
Unit 4.2 -3D Printer Opera on 55
5. Work Effec vely with Teams (IAS/N9001) 60
Unit 5.1 - Work and Communicate effec vely at workplace 62
Unit 5.2 - Work in a disciplined and ethical manner 65
Unit 5.3 - Uphold social diversity at the workplace 67
6. Health and Safety in Workplace (IAS/N9002) 70
Unit 6.1 - Dealing with Workplace Hazards & Risks 72
Unit 6.2 - Fire Safety Prac ces 76
Unit 6.3 - Emergency, Rescue and First-aid Prac ces 78
Unit 6.4 - Effec ve Waste Management Prac ces 81
ii
Par cipant Handbook
Table of Contents
7. Employability Skills - 90 Hours 85
The book on New Employability Skills is available at the following loca on:
h ps://eskillindia.org/NewEmployability
8. Annexure 87
Annexure- QR Code 88
iii
x
Par cipant Handbook
1. Introduc on to Role
of an Addi ve
Manufacturing (3D
Prin ng)
Unit 1.1 - About Addi ve Manufacturing in Industry
Unit 1.2 - Role of an Addi ve Manufacturing (3D
Printer)
Bridge Module
1
Key Learning Outcomes

At the end of this module, Par cipant will be able to:
1. Describe Addi ve Manufacturing Industry
2. Describe benefits of Addi ve manufacturing
3. List role and responsibili es of an Addi ve Manufacturing (3D Prin ng) Operator
2
Par cipant Handbook
UNIT 1.1: About Addi ve Manufacturing in Industry
Unit Objec ves

At the end of this unit, Par cipant will be able to:
1. Addi ve Manufacturing Industry
2. Describe benefits of Addi ve Manufacturing
1.1.1 Overview
Addi ve Manufacturing (AM)
The basic principle of this technology is that a model, ini ally generated using a three-dimensional
Computer Aided Design (3D CAD) system, can be fabricated directly without the need for process
planning. Although this is not in reality as simple as it first sounds, AM technology certainly significantly
simplifies the process of producing complex 3D objects directly from CAD data. Other manufacturing
processes require a careful and detailed analysis of the part geometry to determine things like the order
in which different features can be fabricated, what tools and processes must be used, and what
addi onal fixtures may be required to complete the part. In contrast, AM needs only some basic
dimensional details and a small amount of understanding of how the AM machine works and the
materials used.
The key to how AM works is that parts are made by
adding material in layers; each layer is a thin cross-
sec on of the part derived from the original CAD data.
Obviously, in the physical world, each layer must have a
finite thickness to it and so the resul ng part will be an
approxima on of the original data, as illustrated in Fig.
below. The thinner each layer is, the closer the final
part will be to the original. All commercialized AM
machines to date use a layer-based approach; the
major ways they differ are in the materials that can be
used, how the layers are created, and how they are
bonded to each other. Such differences will determine
factors like the accuracy of the final part plus its
material proper es and mechanical proper es. They
will also determine factors like how quickly the part can
be made, how much post-processing is required, the
size of the AM machine used, and the overall cost of the Fig 1.1.1: Product Modelling
machine and process.
AM was used specifically to create visualiza on models for products as they were being developed. It is
widely known that models can be much more helpful than drawings or renderings in fully understanding
the intent of the designer when presen ng the conceptual design. While drawings are quicker and easier
to create, models are nearly always required in the end to fully validate the design.
3
Following this ini al purpose of simple model making, AM technology developed as materials, accuracy,
and the overall quality of the output improved. Models were quickly employed to supply informa on
about what is known as the “3 Fs” of Form, Fit, and Func on. The ini al models were used to help fully
appreciate the shape and general purpose of a design (Form). Improved accuracy in the process meant
that components were capable of being built to the tolerances required for assembly purposes (Fit).
Improved material proper es meant that parts could be properly handled so that they could be assessed
according to how they would eventually work (Func on)
To say that AM technology is only useful for making models, though, would be inaccurate and
undervaluing the technology. AM, when used in conjunc on with other technologies to form process
chains, can be used to significantly shorten product development mes and costs. More recently, some
of these technologies have been developed to the extent that the output is suitable for end use.
By now, you should realize that the technology we are referring to is primarily the use of addi ve
processes, combining materials layer-by-layer. The term Addi ve Manufacturing, or AM, seems to
describe this quite well, but there are many other terms that are in use. This sec on discusses other
terms that have been used to describe this technology as a way of explaining the overall purpose and
benefits of the technology for product development.
1.1.2 Automated Fabrica on (Autofab)

This term was popularized by Marshall Burns in his book of the same name, which was one of the first
texts to cover this technology in the early 1990s. The emphasis here is on the use of automa on to
manufacturing products, thus implying the simplifica on or removal of manual tasks from the process.
Computers and microcontrollers are used to control the actuators and monitor the system variables. This
term can also be used to describe other forms of Computer Numerical Controlled (CNC) machining
centers since there is no direct reference as to how parts are built or the number of stages it would take to
build them, although Burns does primarily focus on the technologies.
1.1.3 Freeform Fabrica on or Solid Freeform Fabrica on

The emphasis here is in the capability of the processes to fabricate complex geometric shapes.
Some mes the advantage of these technologies is described in terms of providing “complexity for free,”
implying that it doesn’t par cularly ma er what the shape of the input object actually is. A simple cube
or cylinder would take almost as much me and effort to fabricate within the machine as a complex
anatomical structure with the same enclosing volume. The reference to “Freeform” relates to the
independence of form from the manufacturing process. This is very different from most conven onal
manufacturing processes that become much more involved as the geometric complexity increases.
4
Par cipant Handbook
1.1.4 Addi ve Manufacturing or Layer-based Manufacturing

These descrip ons relate to the way the processes fabricate parts by adding material in layers. This is in
contrast to machining technology that removes, or subtracts material from a block of raw material. It
should be noted that some of the processes are not purely addi ve, in that they may add material at one
point but also use subtrac ve processes at some stage as well. Currently, every commercial process
works in a layer-wise fashion. However, there is nothing to suggest that this is an essen al approach to
use and that future systems may add material in other ways and yet s ll come under a broad
classifica on that is appropriate to this text. A slight varia on on this, Addi ve Fabrica on, is a term that
was popularized by Terry Wohlers, a well-known industry consultant in this field and who compiles a
widely regarded annual industry report on the state of this industry . However, many professionals prefer
the term “manufacturing” to “fabrica on” since “fabrica on” has some nega ve connota ons that
infer the part may s ll be a “prototype” rather than a finished ar cle. Addi onally, in some regions of the
world the term fabrica on is associated with sheet metal bending and related processes, and thus
professionals from these regions o en object to the use of the word fabrica on for this industry. Addi ve
Manufacturing is, therefore, star ng to become widely used, and has also been adopted by Wohlers in
his most recent publica ons and presenta on.
1.1.5 Stereolithographic or 3D Prin ng

These two terms were ini ally used to describe specific machines. Stereolithography (SL) was termed by
the US company 3D Systems and 3D Prin ng (3DP) was widely used by researchers at MIT who invented
an ink-jet prin ng-based technology. Both terms allude to the use of 2D processes (lithography and
prin ng) and extending them into the third dimension. Since most people are very familiar with prin ng
technology, the idea of prin ng a physical three-dimensional object should make sense. Many consider
that eventually the term 3D Prin ng will become the most commonly used wording to describe AM
technologies.
1.1.6 Benefits of AM
Many people have described this technology as revolu onizing product development and
manufacturing. Some have even gone on to say that manufacturing, as we know it today, may not exist if
we follow AM to its ul mate conclusion. We might, therefore, like to ask “why is this the case?” What is it
about AM that enthuses and inspires some to make these kinds of statements?
First, let’s consider the “rapid” character of this technology. The speed advantage is not just in terms of
the me it takes to build parts. The speeding up of the whole product development process relies much
on the fact that we are using computers throughout. Since 3D CAD is being used as the star ng point and
the transfer to AM is rela vely seamless, there is much less concern over data conversion or
interpreta on of the design intent. Just as 3D CAD is becoming What You See Is What You Get
(WYSIWYG), so it is the same with AM and we might just as easily say that What you See Is What You Build
(WYSIWYB).
5
The seamlessness can also be seen in terms of the reduc on in process steps. Regardless of the
complexity of parts to be built, building within an AM machine is generally performed in a single step.
Most other manufacturing processes would require mul ple and itera ve stages to be carried out. As
you include more features in a design, the number of these stages may increase drama cally. Even a
rela vely simple change in the design may result in a significant increase in the me required to build
using conven onal methods. AM can, therefore, be seen as a way to more effec vely predict the amount
of me to fabricate models, regardless of what changes may be implemented during this forma ve stage
of the product development.
Similarly, the number of processes and resources required can be significantly reduced when using AM.
If a skilled cra sman was requested to build a prototype according to a set of CAD drawings, he may find
that he must manufacture the part in a number of stages. This may be because he must employ a variety
of construc on methods, ranging from hand carving, through molding and forming techniques, to CNC
machining. Hand carving and similar opera ons are tedious, difficult, and prone to error. Molding
technology can be messy and obviously requires the building of one or more molds. CNC machining
requires careful planning and a sequen al approach that may also require construc on of fixtures
before the part itself can be made. All this presupposes that these technologies are within the repertoire
of the cra sman and readily available.
AM can be used to remove or at least simplify many of these mul -stage processes. With the addi on of
some suppor ng technologies like silicon-rubber molding, drills, polishers, grinders, etc. it can be
possible to manufacture a vast range of different parts with different characteris cs. Workshops which
adopt AM technology can be much cleaner, more streamlined and more versa le than before.
Notes
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
6
Par cipant Handbook
UNIT 1.2: Role of Addi ve Manufacturing (3D Prin ng)
Unit Objec ves

1. List role and responsibili es of an Installer Addi ve Manufacturing (3D Prin ng)
1.2.1 Role of an Addi ve Manufacturing (3D Prin ng)

Ÿ An Addi ve Manufacturing (3D Prin ng) is responsible for Installing, opera ng and maintaining 3D
prin ng machine for manufacturing of parts.
Ÿ Iden fy the work to be done and work requirements by interpre ng instruc ons received from the
supervisor
Ÿ Check material and machine for any issues and required quality standards before use
Ÿ Determine the part orienta on and support structure requirement from Computer Aided Design
(CAD) data
Ÿ Set the 3D prin ng machine and its parameters such as room temperature range, air cleanliness as
per SOP/WI
Ÿ Clean the 3D prin ng machine by following organiza onal recommended process before star ng the
opera on
Ÿ Select the standard tessella on language (.stl) code file needed for machine opera on
Ÿ Connect the data storage devices with the machine
Ÿ Pre-heat the bed of the machine to adequate temperature as per process specifica ons
Ÿ Set the laser or nozzles temperature to defined values as per process specifica on
Ÿ Start and operate the machine and perform 3D prin ng opera ons as per SOP/WI
Ÿ Inspect the part as per the drawing/process using for required quality and if non-conforming, take
ac on as per organiza onal guidelines
Ÿ Store & preserve the automo ve parts manufactured as per organiza onal guidelines and
procedure.
Ÿ Carry out minor repairs, adjustments and alignment of loose bolts, belts, drive slacks, guards and
covers
Ÿ Carry out troubleshoo ng of machine for issues and defects iden fica on
Ÿ Perform lubrica on of machine by using appropriate lubricant
Ÿ Maintain records of maintenance ac vi es done on machine as per organiza onal procedures
7
1.2.2 Personal A ributes Required

Personal a ributes required for this job are:
Ÿ Read equipment manuals and process documents
Ÿ A en vely listen and comprehend the informa on given by the process managers
Ÿ Communicate effec vely at the workplace
Ÿ Write observa ons and any work related informa on in English/regional language
Ÿ Recognize a workplace problem and take suitable ac on
Ÿ Analyze and apply the informa on gathered from observa on, experience, reasoning or
communica on to act efficiently
Ÿ Complete assigned tasks in a mely and efficient manner
Notes
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
QR Codes
Scan the QR Code to watch the related video
What is addi ve manufacturing? 3D printer - Unbox & Setup

Youtube.com/watch?v=EHvO-MlzAIM Youtube.com/watch?v=ibsOYzXduYc
8
Par cipant Handbook
2. Install a 3D Printer
Unit 2.1 - About 3D Prin ng Technology
Unit 2.2 - 3D Prin ng Applica on
Unit 2.3 - So ware & 3D Printer Installa on
IAS/N5606
9

1. What is 3D Prin ng
2. History of 3D Prin ng
3. 3D Prin ng technology
4. 3D Prin ng Process
5. 3D prin ng Material
6. 3D Prin ng Applica on
7. 3D Printer So ware & Printer Installa on
10
Par cipant Handbook
UNIT 2.1: About 3D Prin ng Technology
Unit Objec ves

1. History of Addi ve Manufacturing
2. Different Technology used in 3D Prin ng
Overview of 3D Prin ng
In the 20th century, no inven on has impacted humanity more than technology. With the advent of
computers in the 1950s and the internet in his 1990s, the fundamental way of working has changed a lot.
Ÿ These technologies have improved our lives, opened up new paths and opportuni es, and gave us
hope for the future. But generally speaking, it takes decades to build an ecosystem across a given
technology, bring it to the masses, and reach the truly disrup ve nature of that technology.
Ÿ 3D prin ng or addi ve manufacturing (AM) is widely believed to have great poten al to become one
of these technologies. There is a lot of coverage about 3D prin ng on many TV channels, newspapers
and online resources.
Ÿ The most fundamental differen a ng principle behind 3D prin ng technology is that it is an addi ve
manufacturing process. 3D prin ng is a fundamentally different manufacturing method, as it is
based on advanced technology and incrementally builds parts in sub-mm scale layers.
Ÿ Tradi onal manufacturing processes have evolved significantly over me, from manual
manufacturing to automated processes such as machining, cas ng, molding, and molding.
Ÿ In many applica ons, tradi onal design and manufacturing processes impose unacceptable
limita ons, such as the need to assemble expensive tools, fixtures, and complex parts.
Ÿ In contrast, the 3D prin ng process can create objects directly by adding materials layer by layer in
different ways, depending on the technology used.
Ÿ To simplify the ideology behind 3D prin ng, for those trying to understand the concept, it can be
compared to the process of automa cally building something out of LEGO bricks.
Ÿ 3D prin ng is a fundamental technology that accelerates and drives innova on with unprecedented
design freedom, while being a tool-less process that reduces prohibi ve costs and lead mes.
Ÿ Components can be specifically designed to avoid assembly requirements with complex geometries
and complex features created at no addi onal cost.
11
Ÿ 3D prin ng is also emerging as an energy-efficient technology that can save the environment both in
the manufacturing process itself, which uses up to 90% of standard materials, and throughout the
product's life me with its lightweight, strong design.
Ÿ In recent years, 3D prin ng has evolved beyond industrial prototyping and manufacturing processes
as the technology has become more accessible to small businesses and individuals.
Only big companies owned 3D printers. Because the scale and economics of owning a 3D printer make it
prohibi vely expensive for a small business to own his 3D printer. But as the cost of printers plummeted,
the technology became more affordable.
History of 3D Prin ng
Early 3D prin ng technology first emerged in the late 1980s when it was called Rapid Prototyping (RP)
technology. This is because the process was originally conceived as a quick and cost-effec ve way to
create prototypes for product development in industry.
• As an interes ng side note, the first patent applica on for RP technology was filed in May 1980 by Dr.
Kodama in Japan. However, the patent applica on was invalidated because a complete patent
specifica on was not filed within one year a er filing.
• The first patent in 3D prin ng technology was granted to Charles Hull in 1986 for his
Stereolithography Apparatus (SLA). He invented the machine in 1983 and later co-founded 3D
Systems Corpora on. This makes him one of the largest and most prolific organiza ons involved in
3D prin ng today. 3D Systems' first commercial RP system, his SLA-1, was introduced in 1987.
12
Par cipant Handbook
• As with any new technology, in the 1980s many researchers were working on different ways to make
addi ve manufacturing a reality. In 1987, while working at the University of Texas, Carl Deckard
applied for a US patent for the Selec ve Laser Sintering (SLS) RP process.
• This patent was granted to him in 1989 and SLS was later licensed by him to DTM Inc and later
acquired by 3D Systems. In 1989, a Sco Crump also applied for a patent on Fused Deposi on
Modeling (FDM). He co-founded his Stratasys Inc., another major his 3D prin ng company.
• As of 2015, FDM is the most popular 3D prin ng technology for entry-level devices. This technology
is based on his RepRap model which is open source.
• The FDM patent was granted to Stratasys in 1992 by him. In Europe, EOS GmbH, founded by Hans
Langer, was also founded in Germany in 1989. A er dealing with the SL process, EOS' R&D focus
turned to the increasingly popular laser sintering (LS) process.
• Today, EOS systems are recognized worldwide for their high-quality output for industrial prototyping
and produc on 3D prin ng applica ons. EOS sold his first "Stereos" system in 1990.
• The company's Direct Metal Laser Sintering (DMLS) process grew out of his first project with a
division of Electrolux Finland, which was later acquired by his EOS.
• Other 3D prin ng technologies and processes have also emerged during these years.
13
• Throughout the 1990`s and early 2000`s a bunch of recent technology endured to be added,
nonetheless centered totally on commercial programs and at the same me as they had been
nonetheless in large part approaches for prototyping programs, R&D turned into addi onally being
performed through the greater superior era companies for par cular tooling, cas ng and direct
produc on programs.
• This no ced the emergence of recent terminology, par cularly Rapid Tooling (RT), Rapid Cas ng and
Rapid Manufacturing (RM) respec vely. In phrases of industrial opera ons, Sanders Prototype (later
Solidscape) and ZCorpora on had been installa on in 1996, Arcam turned into mounted in 1997,
Objet Geometries released in 1998, MCP Technologies (a long me vacuum cas ng OEM) added the
SLM era in 2000, EnvisionTec turned into based in 2002, ExOne turned into mounted in 2005 as a
deriva ve from the Extrude Hone Corpora on and Sciaky Inc turned into pioneering its very own
addi ve method primarily based totally on its proprietary electron beam welding era.
• These businesses all served to swell the ranks of Western businesses working throughout an
interna onal marketplace. The terminology had addi onally developed with a prolifera on of
producing programs and the standard umbrella me period for all the approaches turned into
Addi ve Manufacturing (AM).
• During the mid-nine es, the world began out to reveal symptoms and symptoms of wonderful
diversifica on with par cular regions of emphasis which can be a good deal greater certainly
described today. First, there has been the excessive stop of three-D prin ng, nonetheless very high
priced systems, which had been geared toward component manufacturing for excessive value,
no ceably engineered, complicated parts.
• At the opposite stop of the spectrum, a number of the three-D prin ng gadget producers had been
growing and advancing three-D printers that stored the point of interest on enhancing idea
improvement and prac cal prototyping. These had been constructed to be cost-powerful systems.
• These machines were the predecessors of today's desktop machines. This was partly due to the
system itself, but also due to other market influences. This was seen by many industry insiders, users
and commentators as the key to opening up 3D prin ng technology to a wider audience.
14
Par cipant Handbook
• All eyes have been on the highly an cipated arrival of Desktop Factory for most of this year. It failed
when the organiza on got bogged down in the run-up to produc on. Desktop Factory and its
director Cathy Lewis were acquired by 3D Systems along with her IP in 2008 and all but disappeared.
• But 2007 was actually a turning point for accessible 3D prin ng technology. Dr. Bowyer came up with
the concept of RepRap. RepRap's concept is to build an open-source, self-replica ng 3D printer.
• The idea was born in 2004, and spent several years seeding it, and his team in Bath, in par cular Vik
Oliver and Rhys Jones, developed the concept and created a working prototype 3D printer using the
deposi on process. was built.
• 2007 was the year Chutes began to emerge, and this early open source 3D prin ng movement began
to gain trac on. However, it wasn't un l January 2009 that the first commercially available 3D printer
based on his RepRap concept was launched in kit form. That was the BfB RapMan 3D printer.
Makerbot Industries followed closely in April of the same year, whose founder was instrumental in
developing his RepRap, but abandoned its open source philosophy a er a major investment. Since
2009, there have been many similar deposi on printers with limited unique selling proposi ons
(USPs), and so on.
15
An interes ng dichotomy here is that the RepRap phenomenon has spawned a whole new field of entry-
level commercial 3D printers, while the spirit of the RepRap community is all about open source 3D
prin ng development and commercializa on. 2012 was the year that an alterna ve 3D prin ng process
was introduced at the entry level of the market. First came the B9Creator (with DLP technology) in June,
followed by the Form 1 (with Stereolithographic) in December. Both launched through the Kickstarter
funding site and both have been hugely successful. 2012 was also the year many different mainstream
media channels adopted this technology due to market differences, significant advancements in
features and applica ons at the industrial level, and a drama c increase in awareness and acceptance
from the growing maker movement. was. 2013 was a year of significant growth and consolida on. One
of the most notable moves is the acquisi on of Makerbot by Stratasys. Known as the 2nd, 3rd, and
some mes 4th Industrial Revolu on, there is no denying the impact 3D prin ng will have on the
industrial sector and the enormous poten al it holds for the future of consumers. What form this
possibility takes is s ll in front of us.
3D Prin ng Technology
The whole 3D prin ng technology can be divided into three steps:
a. 3D design
b. Slicing
c. 3D prin ng
• A 3D digital model is the star ng point for any 3D prin ng process. This digital model can be
created in various 3D design so ware or 3D scans.
• Once the 3D model is created, it is sliced into layers and the design is converted to a file that can
be read by a 3D printer.
• The 3D printer then prints this file layer by layer, using the materials specified as input to the 3D
printer.
• As men oned earlier, there are many different types of 3D prin ng techniques that process
different materials in different ways to create the final object.
3D design using 3D Slicer u lity

Extract.STL file 3D food prin ng 3D printed object
so ware (G-code generator)
Func onal plas cs, metals, ceramics, and sand are rou nely used for industrial prototyping and
produc on applica ons. Research is also being done on his 3D prin ng of biomaterials and different
types of food. However, entry-level materials on the market are generally much more limited. Plas c is
currently the only material in widespread use, usually ABS or PLA.
• Spraying microscopic droplets is another 3D prin ng process reminiscent of 2D inkjet prin ng, but
with good materials for the ink and a binder to hold the layers together.
16
Par cipant Handbook
Perhaps the most common and recognizable process is deposi on, which is the process used by most
entry-level 3D printers. In this process, a plas c (usually PLA or ABS) is extruded through a heated
extruder in the form of filaments that are layered to create a desired shape.
Parts can be printed directly to create highly detailed and complex objects, o en with built-in features
that do not require assembly. Another important point to highlight, however, is that none of the 3D
prin ng processes are currently available as a plug-and-play op on. There are many steps before you hit
print, and many more a er prin ng is complete.
• Aside from the challenging reality of 3D prin ng designs, file prepara on and conversion can be me
consuming and complex, especially for parts that require complex supports during the build process.
However, the so ware for these features is undergoing regular updates and upgrades to improve the
situa on. In addi on, the object s ll needs finishing work a er 3D prin ng.
• Support removal is obvious in processes that require supports, but other processes include sanding,
varnishing, varnishing, or other types of conven onal finishing opera ons. All of this usually has to
be done by hand and requires skill, me, and pa ence.
17
3D Prin ng Processes
SLA
Stereolithography (SL) is widely recognized as the first 3D prin ng process. Of course, this is the first me
it has been commercialized. SL is a laser-based process that uses a photopolymer resin that reacts with a
laser and cures into a solid in a very precise manner. This is a complex process, but in a nutshell,
photopolymer resin is held in a vat with a movable pla orm. A laser beam is directed across the surface
of the resin in the X-Y axis according to 3D data (.stl files) supplied to the machine, curing the resin exactly
where the laser hits the surface. Once a layer is completed, the pla orm in the vat is lowered slightly
(along the Z axis) and the subsequent layers are traced by the laser.
This con nues un l the en re object is complete and the pla orm can be li ed to retrieve it from the vat.
Due to the nature of the SL process, some parts require supports, especially those with overhangs or
undercuts. These structures must be removed manually. As for other post-processing steps, many
objects 3D printed in SL need to be cleaned and cured. Curing involves exposing the part to intense light
in a machine, such as an oven, to fully cure the resin. Stereolithography is widely recognized as one of the
most accurate 3D prin ng processes with excellent surface finish. However, the limi ng factors are the
required post-processing steps and the stability of the material over me, which can make it more bri le.
DLP
18
Par cipant Handbook
DLP (Digital Light Processing) is similar to stereolithography in that it is a 3D prin ng process that uses
photopolymers. The main difference is the light source. DLP uses conven onal light sources such as: B.
An arc lamp in which the liquid crystal display panel is applied over the en re surface of a vat of
photopolymer resin in one pass and is generally faster than SL.
Like SL, DLP produces high-precision parts with excellent resolu on, but the similari es also include the
same support structure and post-hardening requirements. However, the advantage of DLP over SL is that
only shallow tanks of resin are required to facilitate the process, generally resul ng in less waste and
lower running costs.
Laser Sintering / Laser Mel ng
Laser sintering and laser mel ng are interchangeable terms that refer to laser-based 3D prin ng
processes that work with powder materials. According to the 3D data fed into the machine, the laser
moves along her X-Y axis over a powder bed of ghtly compacted powder material. When the laser
interacts with the surface of the powder material, the par cles are sintered or fused to form a solid. As
each layer is completed, the powder bed gradually falls off, and before the next laser pass is made, the
roller smoothes the powder over the surface of the bed so that the next layer can form and fuse with the
previous layer. Increase.
The build chamber is completely sealed because the exact temperature specific to the mel ng point of
the selected powder material must be maintained throughout the process. Once complete, the en re
powder bed is removed from the machine and excess powder can be removed to leave a "printed" part.
One of the main advantages of this process is that the powder bed acts as an in-process support structure
for overhangs and undercuts, enabling complex geometries that could not otherwise be produced with
this process. On the other hand, laser sintering requires high temperatures, which can result in
significantly longer cooling mes.
Addi onally, porosity has been a historical concern in this process, and although significant
improvements have been made towards fully dense parts, in some applica ons separate of material
must be impregnated. Laser sintering can process plas c and metal materials, but sintering metals
requires much more powerful lasers and higher process temperatures. Parts made with this process are
much stronger than SL and DLP, but the surface finish and accuracy are generally not as good.
19
Extrusion / FDM / FFF

3D prin ng using extrusion of thermoplas c materials is the most popular and well-known 3DP process.
The most famous name for this process is Fused Deposi on Modeling (FDM). However, it is a trade name
registered by the company that originally developed it, Stratasys. Stratasys FDM technology has been
around since his early 1990s and is now his industrial grade 3D prin ng process.
However, the prolifera on of entry-level 3D printers that have emerged since 2009 have largely used a
similar process, commonly referred to as free-form fabrica on (FFF), due to patents s ll held by
Stratasys. , which has a simpler form. His early RepRap machines and all subsequent developments use
the extrusion method. However, following his Stratasys patent infringement lawsuit against Afinia, it is
ques onable what will happen to the entry-level segment of the market now that every machine could
be subject to his Stratasys patent infringement. The process works by mel ng plas c filaments that are
deposited layer by layer onto a build pla orm via a heated extruder according to 3D data fed into the
printer. Each layer cures as it is applied and bonds to the previous layer. Stratasys has developed a
number of proprietary industrial grade materials for the FDM process suitable for some produc on
applica ons. At the entry end of the market, materials are more limited, but the range is expanding.
The most common materials for entry-level FFF 3D printers are ABS and PLA. FDM/FFF processes require
support structures for all applica ons with prominent geometries. For FDM, this means a second water-
soluble material that allows the support structure to be washed away rela vely easily a er prin ng.
Alterna vely, fragile supports are possible and can be manually snapped off the part. Support structures,
or lack thereof, have generally been a limita on of entry-level FFF 3D printers. However, as the system
has evolved and improved to incorporate dual extrusion heads, this is no longer an issue. For generated
models, Stratasys' FDM process is an accurate and reliable process, rela vely suitable for offices and
studios, but may require extensive post-processing. At the entry level, the FFF process produces
predictably less accurate models, but things are improving all the me. Depending on the shape of the
part, the process can be slow, adhesion between layers can be a problem, and the part can lose its
waterproofness. Again, post-treatment with acetone can solve these problems.
20
Par cipant Handbook
Inkjet: Binder Je ng
There are two 3D prin ng process that u lize a je ng technique.
Binder Je ng: Where the sprayed material is a binder and is selec vely sprayed onto a powder bed of
part material to fuse layer by layer to create/print the desired part. As with other powder bed systems,
as a layer is completed, the powder bed gradually falls off and a roller or blade smoothes the powder
over the surface of the bed before the next pass of the binder-carrying jet head. to A layer is formed and
merged with the previous layer. Benefits of this process include the fact that, like SLS, the powder bed
itself provides this func on, thus elimina ng the need for support. In addi on, various materials can be
used, such as ceramics and food. Another important advantage of this process is the ability to easily add
different colors to the binder. However, the parts obtained directly from the machine are not as strong as
the sintering process and require post-treatment to ensure durability.
21
Material Je ng: A 3D prin ng process in which the actual build material (liquid or molten) is selec vely
je ed from mul ple nozzle heads (other nozzle heads simultaneously je ng support material).
However, the material is typically a liquid photopolymer that is UV cured as each layer is applied. Due to
the nature of this product, co-evapora on of various materials is possible. This means that a single part
can be made from mul ple materials with different proper es and characteris cs. Material je ng is a
highly precise 3D prin ng process that produces precision parts with extremely smooth surfaces.
Selec ve Deposi on Lamina on (SDL)
SDL is a proprietary 3D prin ng process developed and manufactured by Mcor Technologies. It is

temp ng to compare this process to the addi ve manufacturing (LOM) process he developed with
Helisys in the 1990s. This is due to the similarity of paper lamina on and molding to form the final part.
However, the similari es end there. In SDL 3D prin ng, parts are built layer by layer using standard copy
paper. Each new layer is a ached to the previous one with glue applied selec vely according to his 3D
data supplied to the machine. This means that the area that will become the part will have a much
higher density of adhesive, and the surrounding area that will act as the backing will have a much lower
density of adhesive. Backing is guaranteed. A new sheet of paper is fed into the 3D printer from the paper
feed mechanism and placed on top of the selec vely applied adhesive of the previous layer, then the
build plate is moved to the heated platen and pressure is applied.
This pressure ensures a secure connec on between the two sheets of paper. The build plate then returns
to build height and an adjustable tungsten carbide blade allows him to cut one sheet of paper at a me,
tracing the contours of the object to create the edges of the part. Once this cu ng sequence is complete,
the 3D printer applies the next layer of adhesive and so on un l the part is complete. SDL is one of the few
3D prin ng processes that can produce full-color 3D printed parts using the CYMK color pale e.
Moreover, since the parts are made of plain paper, there is no need to post them.
22
Par cipant Handbook
EBM
Electron beam mel ng 3D prin ng technology is a proprietary process developed by the Swedish
company Arcam. This metal prin ng process is very similar to direct metal laser sintering (DMLS) in that it
forms parts from metal powders. The main difference is the heat source. As the name suggests, it is an
electron beam rather than a laser and the process must be performed under vacuum condi ons. EBM is
capable of producing fully high density parts in a variety of metal alloys. As a result, this technology has
been par cularly successful in many manufacturing applica ons in the medical industry, especially
implants. But other high-tech sectors, such as aerospace and automo ve, are also looking to his EBM
technology for manufacturing fulfillment.
3D Prin ng Materials
Materials available for 3D prin ng have come a long way since the dawn of technology. There are
currently many different types of materials in different states (powder, filament, pellet, granule, resin,
etc.). Certain materials are now commonly developed for specific pla orms running dedicated
applica ons (the dental sector is an example). It has material proper es be er suited to the applica on.
There are too many unique materials like this from many different 3D printer vendors. In this ar cle, we'll
look at the most common types of common materials available.
23
Plas cs
Nylon or polyamide are typically used in powder form in the sintering process and in filament form in the
FDM process. It's a strong, flexible, and durable plas c material with proven reliability for 3D prin ng. It is
naturally white, but can be colored before or a er prin ng. This material can also be combined (in
powder form) with aluminum powder to create another popular 3D prin ng material for sintering,
Alumide. ABS is another popular plas c used for 3D prin ng and is commonly used in his filament format
entry level FDM 3D printers. This is a par cularly strong plas c and is available in a wide range of colors.
ABS can be purchased in filament form from many non-proprietary sources. This made filament very
popular in the market. PLA is a biodegradable plas c material and is gaining popularity in 3D prin ng for
exactly this reason. Available in resin format for DLP/SL processes and in filament form for FDM
processes. Available in a variety of colors, including transparent, it has proven to be a useful op on for
some 3D prin ng applica ons. However, it is not as durable or flexible as ABS. LayWood is a 3D prin ng
material specifically for entry-level extrusion 3D printers. It is in the form of filaments and is a
wood/polymer composite.
Metals
An increasing number of metals and metal composites are being used for industrial 3D prin ng. The two
most common are aluminum and cobalt deriva ves. One of the strongest and therefore most commonly
used metals in 3D prin ng is powdered stainless steel for sintering/mel ng/EBM processes. Originally
silver, it can be plated with other materials to create a gold or bronze effect. Gold and silver have recently
added to the list of metallic materials that can be directly 3D printed, with obvious applica ons across
the jewelery sector. Both of these are very strong materials and are processed in powder form. Titanium
is one of the strongest metallic materials and has been used for industrial 3D prin ng applica ons for
some me.
Other 3D Prin ng Materials
a. Ceramics
Ceramics are a rela vely new group of materials that can be used for 3D prin ng with varying degrees of
success. What is special about these materials is that a er prin ng the ceramic parts must go through
the same process as ceramic parts made by tradi onal manufacturing methods: firing and glazing.
b. Paper
Standard A4 copy paper is the 3D prin ng material used in Mcor Technologies' proprietary SDL process.
The investment cost for the machine is moderate, but the emphasis is on supplying easily available and
cheap materials that can be purchased locally. 3D printed paper models are safe, environmentally
friendly, easily recyclable and require no post-processing.
c. Bio Materials
Much research has been done on the poten al of 3D printed biomaterials for various medical
applica ons. Living ssue is being studied at many major ins tu ons for the development of applica ons
including the prin ng of external ssue to replace human organs and body parts for transplanta on.
Other research in this area has focused on food development - meat being a prime example.
24
Par cipant Handbook
UNIT 2.2: 3D Prin ng Applica ons
Unit Objec ves

1. Interpret the applica ons of 3D Prin ng in Different Field
3D prin ng's origins in "rapid prototyping" are based on the principles of industrial prototyping as a
means of accelera ng the early stages of product development. This saves me and money at the start of
the en re product development process and creates trust before the produc on tools. Prototyping is
s ll probably the biggest applica on of 3D prin ng today. Since the advent of 3D prin ng for prototyping,
the development and improvement of processes and materials have led to their adop on for
applica ons further down the product development process chain.
Tooling and foundry applica ons are developed using a variety of processes.
The technology combines off-the-shelf items such as hip and knee implants with pa ent-specific
bespoke products such as hearing aids, orthopedic shoe inserts, personalized prostheses, and single
implants for pa ents with osteoarthri s. used to directly manufacture both osteoporosis and cancer. 3D
printed surgical guides for specific surgeries are also emerging applica ons, helping surgeons in their
work and pa ents recovering.
25
The aerospace industry was an early adopter of 3D prin ng technology in its earliest form for product
development and prototyping.
Many car companies, especially those at the forefront of motorsport and his F1, have followed a similar
path as the aerospace companies. Ini ally using techniques for prototyping applica ons, we have
evolved and adapted our manufacturing processes to incorporate the benefits of improved materials
and end results for automo ve components.
26
Par cipant Handbook
Tradi onally, the jewelry design and manufacturing process involved a high degree of exper se
encompassing specific disciplines such as manufacturing, mold making, cas ng, electropla ng,
blacksmithing, silver/goldsmithing, stone cu ng, engraving, and polishing. and knowledge were always
needed.
Many ar sts have made a name for themselves by specializing in 3D modeling, 3D scanning and 3D
prin ng techniques. Architectural models have long used 3D prin ng technology primarily to create
accurate demonstra on models of an architect's vision.
3D printed accessories such as shoes, hats, caps and bags have hit the global catwalks. Some even more
visionary fashion designers have demonstrated the poten al of haute couture technology. Dresses,
capes, long her gowns and even underwear have been presented at various fashion venues around the
world.
27
3D prin ng is a latecomer, but food is a new applica on that people are very excited about and has the
poten al to really make the technology mainstream. 3D prin ng is emerging as a new way to prepare
and serve food. His first foray into 3D prin ng of 28 foodstuffs was chocolate and sugar, but development
of these has rapidly followed with the launch of his dedicated 3D printer. Other early experiments with
food include 3D prin ng "meat" at the cellular protein level.
Recently, pasta is another food group being explored for food 3D prin ng. Looking to the future, 3D
prin ng is seen as both a complete food prepara on method and a way to balance nutrients in a holis c
and healthy way. The holy grail for 3D print providers is consumer 3D prin ng. Whether this is feasible in
the future is widely debated. Consumer acceptance is low due to accessibility and usage issues that
currently exist in entry-level machines. Leading 3D prin ng companies such as Stratasys subsidiaries 3D
Systems and Makerbot are moving in this direc on, aiming to make the 3D prin ng process and ancillary
components (so ware, digital content, etc.) more accessible and user-friendly.
28
Par cipant Handbook
UNIT 2.3: So ware & 3D Printer Installa on
Unit Objec ves

1. Install the 3D Printer & So ware as per Manual
Printer Selec on:

First, what type of 3D prin ng kit do you have? Most kits come in one of three styles — pre-assembled,
par ally assembled or DIY. The type of prin ng kit you have will determine how much work it will take
to set it up. Pre-assembled kits are ready to use right out of the box. While they might need a li le bit
of setup before you can start prin ng — which we’ll talk about more in a minute — they’re generally
plug-and-play ready.
Par ally assembled kits are usually split right down the middle and packaged to save space. You’ll
typically need to bolt them together and make a few electrical connec ons before your new printer is
ready to use. DIY kits take quite a bit more assembly and will likely take you longer. Once you know what
type of kit you have, move on to the next step of how to set up a 3D printer.
29
Follow the Instruc ons

This step might seem like common sense, but it bears repea ng: Make sure you read the assembly and
setup instruc ons. Take the me to read through them thoroughly before you start making connec ons
or pu ng things together. Don’t try to set up anything or start playing with the printer un l you have all
the informa on possible. Right out of the box, it’s essen al to read the instruc ons. Once you have
everything assembled and calibrated, you won’t have to do a lot of tweaking.
This advice is especially crucial if you’ve got a par ally assembled or DIY kit. Part of knowing how to set up
a 3D printer is making sure to connect all your wires, balance the device and secure it before you try to
print anything.
Don’t Assume It’s Already Calibrated
If you have a fully or par ally assembled 3D printer, you might feel tempted to start prin ng as soon as
you hook it up to your computer. However, you might end up was ng a lot of filament by assuming your
printer is already fully calibrated. Even if it’s supposed to come calibrated and ready to use, things can get
knocked out of alignment during shipping. If you’re too rough with it when you take it out of the box
things can also get misaligned.
Luckily, calibra on instruc ons should be a sec on in your instruc on manual. Go over them and make
sure to properly calibrate everything before you click that print bu on. Mild calibra on errors might not
cause problems, but significant errors could damage your equipment. Don’t print with De-calibrated
machine.
Make Sure Everything Is Square and Level
For this step, you’ll want to break out a level and T-square or other similar tools. If the frame isn’t square
and the prin ng bed isn’t level, everything will end up crooked and lopsided. Unlevel machines could
also lead to the hot print head, the thing that melts the plas c filament, mel ng into the print bed. Any
way you look at it, prin ng without a square and level printer will be a giant mess.
You don’t need a lot of extra tools to ensure everything is squared away, but if the print bed isn’t level,
there aren’t a lot of ways to fix it, short of ordering a new prin ng bed and star ng from scratch. Some
printers will come with an op on to adjust the level of the print bed, so again — check your instruc ons.
If the printer does not have an auto-leveling feature, you’ll need to adjust the screws found at each
corner of the print area. The goal is to make the surface and print area a uniform distance from the
extruder. Your prin ng manual should have more specifics about the op mal measurement between the
prin ng surface and extruder.
It may also include ps on how to get the right distance. One possibility suggested by at least one printer
manufacturer is slipping a piece of paper between the prin ng surface and extruder. Encountering slight
resistance when sliding it is a good sign. However, since printer models vary, always priori ze what the
printer’s manufacturer suggests over more generalized guidance.
Lubricate Everything Sufficiently
3D printers have so many moving parts that adequate lubrica on is essen al for regular opera on.
A good rule of thumb is that a component needs lubrica on if it moves against another surface. However,
the part receiving lubrica on determines the best product to use on it.
30
Par cipant Handbook
One of the parts requiring lubrica on is the threaded rod and nut along the Z-axis that change the printer
nozzle’s height. The X and Y-axis guiderails along the print head and print bed also need lubrica on.
Besides promo ng a hassle-free prin ng process, proper lubrica on helps prevent the premature
breakdown of parts.
A lubricant’s suitability for a 3D printer depends on how well it protects against the adverse effects of
materials rubbing together and whether it helps the printer components move smoothly during
opera on. Because it’s so popular and widely available, some people wonder if they can use WD-40 as a
lubricant. However, it’s not a suitable op on, regardless of the brand of printer you have. Ongoing and
excessive use of the product could even damage the printer.
Check your owner’s manual or setup instruc ons to find out what kind of lubricant you should be using,
as well as your maintenance schedule. It’s one of those ques ons that if you ask 10 different people,
you’ll get 10 different answers. Therefore, it’s always best to refer to your owner’s manual.
Before you start prin ng, slide the print head along the axles and manipulate the other moving parts to
ensure that everything moves smoothly. There shouldn’t be any grinding. You’ll no ce if there’s a
problem, and it’s always be er to find out before you’ve started prin ng.
Set the Desired Print Speed
One of the main advantages of 3D prin ng is that it is much faster than many other produc on methods.
So, many people understandably wonder how the print speed affects the print quality. Generally, slower
print speeds result in be er-quality results. However, the specifics vary depending on the types of
materials used and what the prin ng project involves.
As the extruder moves progressively faster, it vibrates more. That effect causes a reduc on in the overall
print quality. Many people find it par cularly no ceable on consumer-grade printers. Manufacturers
typically don’t make those with the expecta on that people will be trying to print at very high speeds.
Whether a printer can handle a certain speed is not the only considera on. Limita ons also exist
regarding how fast the prin ng filament melts, impac ng the maximum extruder flow speed. Different
filaments have various physical and chemical proper es. So, just se ng the same print speed with two
types of filament is not necessarily enough to get a similar outcome with each a empt.
Feed Filament Into the Extruder
The filament has a significant impact on the prin ng process. Check the instruc ons associated with the
printer and filament before proceeding. Some people recommend making a sharp, angled cut at the end
you feed into the printer so it’s easier to load. Some printer models come with a cu ng tool. Filaments
may also have circular ends, and people some mes find them harder to load. Bending and twis ng the
end before feeding it through can help.
Push the filament through the extruder’s entrance and keep going un l you feel a bit of resistance. Then,
the filament has likely reached the nozzle.
Choose a Design
Setup is complete and you have everything ready to print. The next thing you need to do is choose and
create a design. You can make nearly anything with a 3D printer — from a tripod for your phone to a bag
hook so you can carry in all your groceries in one trip. There are plenty of op ons available for free online
for you to choose from, or you can create designs in a CAD program.
31
It might be easier to ask what you can’t make with a 3D printer than to list what you can create with these
devices. You can make everything from guitars and camera lenses to 3D printed models of anything you
can scan. This could even include a working gun if you’ve got the right supplies. Even NASA uses 3D
printers to send pa erns for specialized tools to astronauts on the Interna onal Space Sta on.
Tips for Crea ng Great 3D Prin ng Projects
Learning how to set up a 3D printer is just the beginning of this awesome hobby. The more models you
create and print, the more you’ll learn about the process, materials, printers and even CAD. There are a
few ps that can come in handy early on.
Choosing Your Print Material
There are thousands of op ons for 3D printer materials today. Every 3D printer is limited to certain types
of material. For example, a filament 3D printer cannot print with the fluid resin used for SLA 3D printers.
Most consumer 3D printers today use FDM technology, or Fused Deposi on Modeling.
FDM printers use spools of prin ng filament, most o en various polymer plas cs. Due to the high
popularity of FDM 3D prin ng, there are a vast range of filament op ons on the market today.
Choosing the right one can be confusing at first. There are plenty of expensive niche filaments out there,
but beginners should s ck with something simple and affordable.
PLA filaments are usually the best fit for a good value filament op on. PLA is one of the most common 3D
prin ng materials, so it’s easy to find at a low price. It s ll delivers excellent print quality, though, making
it an excellent choice for beginners. Plus, you’ll have plenty of colors to choose from.
How to Find Easy Beginner 3D Prin ng Designs
One of the biggest stumbling blocks beginners can run into in 3D prin ng is finding a first model to print.
Some may think they need to learn to create their own CAD designs first, but this isn’t true. Many 3D
prin ng enthusiasts do learn how to use CAD so ware. However, it’s not a necessity to learn how to set
up a 3D printer or have a good me using one.
There are plenty of websites out there today where you can find thousands of free-to-use 3D printer
models. Other hobbyists create these models and post them online for others to print for fun. Model
databases can also be a great place to learn more about 3D prin ng and connect with other hobbyists.
For example, 3D prin ng community Printable has a database of thousands of free models you can
browse through. They also run design contests and have free educa onal resources that can be helpful
for beginners.
What to Do With Your 3D Prin ng Models
There are all kinds of things you can do with your 3D printed models a er they’re finished prin ng. Even
if you printed a simple ac on figure to display on your desk, there are s ll many further customiza on
op ons.
This stage of the 3D prin ng process is known as post-processing. It involves a variety of extra processes
that can spruce up the look of your finished model. Examples include sanding, gluing, priming, pain ng
and adding various coa ngs. Some of these processes are more difficult than others.
A few easy post-processing op ons are ideal for beginners. Start by removing any supports on your
model. Supports are thin s cks of printer material that are included in designs to ensure the model prints
correctly. You can also go over the model and pick off excess bits and strings of filament.
32
Par cipant Handbook
A er removing the supports, sanding is another easy post-processing step you can try. It may be a good
idea to do this outside or in a well-ven lated area to keep indoor air clear of debris. Sanding is a great step
to take before pain ng or polishing your model. It will help remove the jagged edges printers can leave
behind.
A er sanding, beginners can try pain ng or coa ng their models. Coa ngs like epoxy can give your
model a clear shine. With some sanding and coa ng, it may even be hard to tell that the model is 3D
printed! If you do want to paint your model, though, make sure to do so before applying a final glossy or
ma e coa ng.
Notes
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
QR Codes
Types of 3D Prin ng Technology Introduc on to 3D Prin ng

Youtube.com/watch?v=0FrcgPd-7G8 Youtube.com/watch?v=DMWzMpjSJLM
The Ul mate Beginner's Guide to 3D Prin ng

Youtube.com/watch?v=3LBTkLsjHGQ
33
3. Maintain and
Provide Technical
Support for 3D
Printer
Unit 3.1 - Get Started with 3D Printer
Unit 3.2 - Use of 3D Printer So ware
Unit 3.3 - Maintenance of 3D Printer
IAS/N5607
34
Par cipant Handbook

1. Ge ng Started with 3D Printer
2. Use of 3D Prin ng So ware
3. Maintenance of 3D Printer
35
UNIT 3.1: Ge ng Started with 3D Printer
Unit Objec ves

1. Prepare the 3D Printer for the Prin ng Process as per Manual
Working of 3DPrinter
Printhead
Extrude
Cold end
Hot end
Build pla orm
Control interface
The easiest way to understand how FDM works is to first learn the parts of an FDM 3D printer. Before we
talk about specific parts, though, it’s worth men oning that most 3D printers use three axes: X, Y, and Z.
The X- and Y-axes are responsible for le , right, forward, and backward movements, while the Z-axis
handles ver cal movement.
Now, let’s look at the main components of a 3D printer:
• Build pla orm: The build pla orm (also called a print bed) is essen ally the surface on which the
parts are made. Build pla orms usually include heated beds to make it easier for parts to s ck to
them, but more on that later.
• Extruder: The extruder is the component responsible for pulling and pushing the filament through
the print head. Depending on the extruder setup (direct or Bowden), the extruder and the print head
are some mes considered to be the same thing (i.e. the block that moves along the gantry or
gantries). This is o en the case when considering or discussing en re extruder and hot end
assemblies. From this perspec ve, the extruder consists of two sub-components:
◦ The cold end is the mechanical por on that consists of a motor, drive gears, and other small
components that push and pull the filament. Regardless of naming conven ons, the extruder
always consists of at least the cold end.
◦ The hot end contains a heater and a nozzle, where the former heats up the filament so that it can
be extruded out of the la er. In the case of a Bowden setup, the hot end is never considered to
be part of the extruder.
36
Par cipant Handbook
• Print head(s): There can be one or more print heads on a printer, though most printers only have
one.
◦ On the print head, between the hot end and the cold end, is a heat sink and fan, which are
impera ve for keeping the cold end cool to prevent jamming.
◦ In addi on to the heat sink fan, there’s usually at least one other fan for cooling the molten
filament a er it exits the hot end. This is usually called the part cooling fan.
• Control interface: Some modern 3D printers have a touchscreen that’s used for controlling the 3D
printer. On older printers, a simple LCD display with a physical scroll and click wheel may be present
instead of a touch interface. Depending on the model, an SD card slot and a USB port might also be
present.
Preparing the Printer:
A er slicing a model, a couple of steps need to be taken before a 3D printer is ready to print:
1. Loading filament: The extruder needs to be ready to extrude filament before prin ng begins. The
loading process begins by hea ng the hot end to the filament’s molten temperature (usually above
175 °C, depending on the filament) and then loading the filament into the heated extruder. O en,
the printer will have pre-configured opera ons that will aid you through the process.
2. Bed levelling: In order for the printer to accurately deposit filament and build the object, the build
pla orm must be level. Depending on the machine, levelling can be either manual or automa c. Bed
levelling is very important because, if the print bed is too far away from the nozzle, the first and the
most important layer won’t s ck to the bed, causing the print to automa cally fail.
Notes
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
37
UNIT 3.2: Use of 3D Printer So ware
Unit Objec ves

1. Install the 3D Printer so ware for the 3D Printer Machine Parameters & Design
GrabCAD PRINT SOFTWARE

The printer builds parts by processing an original CAD or STL file into a Stratasys CMB file which is then
downloaded to the printer. GrabCAD Print is the so ware used to process files and then transfer them to
the printer to be built. As part of the ini al installa on and setup process, you must download and install
GrabCAD Print so ware.
Jobs are sent to the printer in CMB format and placed into the Job Queue. The header of the CMB file
contains the processed job’s basic informa on.
INSIGHT SOFTWARE
Insight is a so ware applica on used for processing STL files. Insight provides the user with the ability to
u lize advanced features and manipulate numerous parameters within the file. For most applica ons,
GrabCAD Print so ware will provide sufficient capabili es. However, in some cases, the advanced
capabili es of Insight may be required. When using Insight with the F123 Series, use the following
process:
1. Open and process the STL file.
2. When completed, save the CMB file to a known loca on.
3. In GrabCAD Print, navigate to File > Import File and select the CMB file you wish to import.
4. Con nue with normal work flow using GrabCAD Print.
DISPLAY AREA
The Display Area contains the body por on of each page of the User Interface; this is where you can
select from available func ons and view current status. A er selec ng a bu on from the Naviga on
Menu, the Display Area will refresh and the main page corresponding to the selected bu on will be
displayed. The informa on and bu ons/icons shown within the Display Area will vary depending on
which main page of the UI was selected.
WORKING WITH THE BUILD PAGE
The Build page is composed of the three main areas of func onality that are necessary for building parts
on the printer; these items are highlighted in Figure Build page. Within the Build page you can start,
pause, and abort a job, view a build me es mate for the selected job, see status and es mated ac on
points for a job in progress, and view a visual representa on of the completed part. Please note that you
must load a job file to the printer and select the file to be built before the job’s details will be displayed
within the Build page.
38
Par cipant Handbook
The Build page also contains the No fica ons Display. Depending on the state of the printer a variety of
no fica ons/warnings will be displayed within this area of the page. Touching the text on the screen will
open a dialog indica ng the reason(s) for the no fica on, and in some cases, steps to correct the
no fica on (see Figure No fica on details). Once all no fica ons have been corrected, press the Close
bu on within the dialog to exit the dialog. To access the Build page, press the Build bu on within the
Naviga on Menu; a screen similar to the one in Figure build page, will be displayed.
Build Page
No fica on
Display
Print Job
Build Informa on
Status Panel
Display
Print
Job
Controls
No fica on Details
2 no fica ons
- Close the door

- Remove the part
LOADING A FILE
The Print Job Informa on Panel is empty upon ini al startup and the Build Status Display reflects its idle
state. When there are no job files are available within the Job Queue, the Load File bu on will be
displayed within the Build page. Visibility of this bu on is dependent upon the method used to load job
files to the printer. A job must be selected for building before the job’s details will be displayed within the
Build page. In order to build a job, you must first load the job’s corresponding job file to the printer. Job
files can be loaded via network transfer (Ethernet or Wi-Fi) using the GrabCAD Print applica on on your
worksta on PC or by plugging a USB flash drive into one of the printer’s USB ports and naviga ng to the
job file via the Queue page. The job file you wish to build must be the first item listed in the Job Queue.
Job files can be sorted as needed within the Queue page allowing you to select the job you’d like to build.
39
• If you send a single job file to the printer via network transfer using GrabCAD Print, the job’s details
will automa cally be displayed within the Build Status Display once the job file is received by the
printer, as this job will be the only item in the Job Queue. The Load File bu on will be hidden from
view once the job file is received by the printer via network transfer.
Note: A job file must be loaded onto the printer and selected for building before the job’s details
will be displayed within the Build
• If you send two or more job files to the printer via network transfer using GrabCAD Print, the job
details of the first file sent will automa cally be displayed within the Build Status Display once the job
file is received by the printer, as jobs are built in the order they’re sent to the printer. The Load File
bu on will be hidden from view once the first job file is received by the printer via network transfer.
• If you do not send files to the printer using GrabCAD Print and instead plug a USB flash drive into one
of the printer’s USB ports, the Load File bu on will be visible within the Build page. You can use this
bu on to select a single job file you’d like to build directly from the flash drive.
To load a file:
1. Plug a USB flash drive into one of the available USB ports on the front of the printer.
2. Press the Load File bu on within the Build page. Figure: Load File Bu on
3. The Load File page will be displayed; press the USB bu on within this page.
40
Par cipant Handbook
4. The Load File page will display the contents of the USB flash drive. Locate the desired job and select it
by touching its row on the screen; doing so will open its Job Details page.
5. Within the Job Details page press the Add to Queue bu on; this will load the job into the Job Queue.
6. A er pressing the Add to Queue bu on you will be returned to the Build page. The Load File bu on will
no longer be visible. Instead, the details of the selected job file will be displayed within the Print Job
Informa on Panel.
7. Pressing the Print bu on within the Build page will ini ate the build. Build progress will be displayed
within the Build Status Display, see “Build Status Display” for details.
41
VIEWING PRINT JOB INFORMATION

Informa on pertaining to a selected job is displayed within the right half of the Build page, within the
Print Job Informa on Panel. This informa on is sta c and represents the details of the job file.
Informa on displayed within this panel is divided into the two sec ons: The top-most sec on displays a
visual representa on of what the selected job will look like a er it is successfully built. The bo om-most
sec on displays a variety of informa on pertaining to the selected job, including:
• Name of the job.
• Es mated build me for the job.
• Name of the user that submi ed the job.
• Model and support materials associated with the job.
Touching anywhere within this por on of the screen will open a page displaying addi onal details
pertaining to the selected job.
BUILD STATUS DISPLAY
The Build Status Display sec on of the Build page is composed of a two-part graphic. The center por on
provides informa on on a selected and/or building job while the outer progress ring corresponds with
the build informa on displayed; the informa on displayed will vary depending on the state of the
printer.
Build
Progress
Ring
Build Status
Informa on
42
Par cipant Handbook
IDLE
When the printer is idle, "IDLE" will be displayed within the center of the Build Status Display. This
indicates that the printer is in a state where it is ready to start a build. No progress is indicated within the
outer build progress ring and the me remaining is displayed as zero.
A er pressing the Print bu on to start a build, "PREPARING" is briefly displayed within the Build Status
Display, and the outer progress ring will fill, in gray, in a clockwise direc on. This indicates the amount of
me the printer requires to prepare for the start of the build, including the amount of me required for a
Z Zero Calibra on to occur.
Once build prepara on is complete, "BUILDING" will be displayed within the center of the Build Status
Display along with the amount of me remaining un l the build is complete. As build progress is made,
the amount of me remaining will get smaller un l zero is reached, indica ng that the build is complete.
The build's percentage of comple on is also displayed by radially filling in the outer progress ring, in blue,
in a clockwise direc on.
Touching the screen within the center of the Build Status Display while a part is being built will toggle the
informa on displayed. A er touching the screen, the me es ma on informa on will be hidden from
view and instead the Build Status Display will show the number of completed layers as compared to the
total number of layers in the build. Touching the screen again, will toggle back to the me es ma on
informa on displayed ini ally.
43
UNIT 3.3: 3D Printer Maintenance
Unit Objec ves

1. Perform the 3D Printer maintenance as per Maker Specifica on
Maintenance tasks must be performed on a regular basis in order to maintain op mal system opera on.
Table Maintenance Schedule outlines the general maintenance schedule for the F123 Series. Detailed
instruc ons for each task make up the rest of this chapter.
Table Replacement Consumable lists part numbers for various replacement consumable items. Use the
part numbers listed in this table when ordering replacement parts from Stratasys or your regional
Stratasys office.
44
Par cipant Handbook
WEEKLY MAINTENANCE
a) CLEANING THE OVEN CHAMBER
The purge chute is designed to guide purged material debris from the p wipe assemblies to the
bo om of the oven chamber for disposal. Purged material debris then collects within the bo om of
the oven chamber, beneath the platen. Do not allow excess material debris to accumulate in the oven
chamber as this could cause damage to the printer. Clean the oven chamber on a weekly basis to
remove build material debris and dust. A standard vacuum can be used to clean this area if needed. If
excessive accumula on occurs vacuum the oven chamber as needed.
b) CLEANING THE PLATEN
The steel platen provides the level surface on which parts are built. A substrate is securely affixed to
the platen by the substrate ejec on handle. If debris collects on the platen, it can adversely affect
substrate adhesion.
1. Remove the substrate from the platen.
• Push down on the substrate ejec on handle to release it from the platen.
• Slide the substrate from the platen.
2. Carefully remove purged material debris that have fallen into the openings of the platen.
• A standard vacuum can be used to clean the platen.
MONTHLY MAINTENANCE
a. CLEAN/INSPECT TIP WIPE ASSEMBLIES
The p wipe assemblies should be cleaned once a month. While cleaning the assemblies, inspect the
flicker/ brush assemblies for wear and replace as necessary when wear is detected. Once material is
purged from a p, the flicker por on of the p wipe assembly passes across the p’s opening, cu ng
purged material off in small segments. The brush por on of the p wipe assembly then passes across the
p’s opening cleaning the p and its p shield. As a result, the flicker will wear at the loca on where the
p contacts its surface and eventually develop a notch large enough for the p to completely pass
through the flicker; a notched flicker cannot properly cut purging material. Similarly, material can
become embedded within the bristles of the brush resul ng in clumping; clumped bristles cannot
properly clean a p or its p shield.
The p wipe assembly should be replaced once a significant notch develops within the flicker por on of
the assembly or whenever bristle clumping (which cannot be removed with a brush) is apparent within
the brush por on of the assembly. The p wipe assembly is replaced as a single unit.
To clean the p wipe assembly and inspect its components:
1. Ensure that the printer is stopped (idle) and is not building.
2. Open the oven door.
3. Remove the model side p wipe assembly by li ing it upward un l it clears its loca ng pins. Tip Wipe
Assembly Removal
45
4. Repeat step 3 to remove the support side p wipe assembly.

5. Clean and inspect the surface around the loca ng pins. Make sure that the p wipe assemblies can
sit flush on the surface.
6. Inspect the flicker por on of the p wipe assemblies. The top edge of the flicker should be straight
and must not contain excessive notching/wear.
7. Inspect the brush por on of the p wipe assemblies. Brush bristles must not show evidence of wear
(i.e. no notches in bristle pa ern) and should not contain significant bristle clumping. Frayed bristles
are acceptable as long as the top edge is even across all of the bristles.
8. Replace one or both of the p wipe assemblies if excessive wear is present. See Table Replacement
Consumable for informa on on ordering replacement assemblies.
• The components of the assembly cannot be replaced individually. The en re p wipe assembly
must be replaced if excessive wear is present on the flicker or the brush.
9. Reinstall the support side p wipe assembly by placing the assembly onto its loca ng pins and sliding
the assembly downward.
10. Repeat step 9 to reinstall the model side p wipe assembly.
46
Par cipant Handbook
AS NEEDED MAINTENANCE
a. CLEANING THE EXTERIOR SURFACE OF THE PRINTER
The printer’s exterior surfaces (doors and panels) may accumulate dust and periodically require
cleaning. Exterior doors and panels, with the excep on of the touchscreen display, can be cleaned using
a slightly damp microfiber cloth (supplied in the Welcome Kit). The cloth should be only slightly damp to
ensure that water does not enter the printer. Excess water can cause damage to interior components.
b. CLEANING THE TOUCHSCREEN DISPLAY
As needed, to remove smudge marks and buildup, clean the touchscreen display using the LCD cleaner
and microfiber cloth provided in the Welcome Kit. Apply an adequate amount of LCD cleaning solu on to
the provided microfiber cloth and then gently wipe the exterior surface of the touchscreen display to
clean its surface. It is recommended that you apply LCD cleaner to the microfiber cloth rather than
applying cleaner directly to the touchscreen display, as excess moisture may damage the display.
c. INSPECTING AND CLEANING THE TIP SHIELDS
The p shields may accumulate purged material or debris. As required, this material can be removed by
manually wiping the p shields with a clean cloth.
QR Codes
BEST 3D Prin ng Design So ware Tips for 3D Printer Maintenance

Youtube.com/watch?v=vhjYeMymjt4 Youtube.com/watch?v=4kJThmWDcCo
3D printer essen al maintenance

Youtube.com/watch?v=kAafiApJs9A
47
4. Operate and
Op mise 3D
Prin ng for Addi ve
Manufacturing
Unit 4.1 - Prototype Development
Unit 4.2 - 3D Printer Opera on
IAS/N5608
48
Par cipant Handbook

1. Op mize the opera ons of 3D printer
49
UNIT 4.1: Prototype Development
Unit Objec ves

1. Different Prototype & Its Developing Techniques
2. Describe the Opera on of 3D Printer
4.1.1 Prototype Development Overview

• WHAT IS PROTOTYPE DEVELOPMENT?
Simply put, prototyping is developing a working copy of a product. A company that wants to gain a
posi on in the market must have products that meet the standards of the market and are ready to
meet the needs of its users.In order to survive in the market, the company must func on efficiently
and use resources You need a machine that produces in a way that saves Prototyping is the defini on
of a product type and determining various a ributes such as customer requirements, problem
defini on, and conceptual design of the product. Before proceeding to prototyping, you should
know that prototyping is expensive and me consuming.
• PROTOTYPE DEVELOPMENT TECHNIQUES
There are various prototyping techniques and methods that you can use to create the products you
want to market. When working on a prototype development model, you will come across many
common terms such as people, things, places, and interac ons. When working on a prototype
development model, make sure the product you are developing is suitable for different
environments rather than just condi ons. Below are some prototyping techniques and methods you
should know before proceeding to prototyping.
r Sketch - Start by crea ng a sketch or diagram of your product. This method or technique requires
li le effort and is inexpensive. Using this method, you can easily describe your ideas based on
sketches and transfer them to the real world. This is useful if you don’t want to spend too much
me developing a prototype.
r Paper Interfaces - Paper interfaces are similar to sketching, but this technique also focuses on
different parts of the product, such as B. Create drop-down menus or text boxes on your paper.
Storyboards – Another preferred method for developing prototypes is the storyboard method.
This includes telling the user his experience with the product from start to finish. This approach
requirescompanies tofocus on theircustomer’s solu ons and fully describe them.
r Roleplay - This can be a unique experience for both your team and your client. This includes real
human emo ons when using the product. This helps us get a be er idea of how users react to
the product when they use it for the first me. And how do they feel when they use the product?
r Physical Model - A real model is not ready un l you test it or plan it properly, but developing a
physical prototype cheaply works well. This works to give the physical model a 3D shape. Help
your team test the model. Wizard Of Oz Prototypes - These are prototypes with fake features of
human origin. The prototype mimics the func ons and interac ons of humans rather than
machine algorithms and so ware.
50
Par cipant Handbook
r User-Driver Prototypes - This type of prototyping method is very famous because it is this one
user who is proposed to develop a product prototype. Instead of building prototypes and tes ng
them with users, users build their own prototypes. This helps us get to know our customers
be er.
• DECIDING WHICH PROTOTYPE TECHNIQUE TO USE?
From the above, you will know which technique to use. Well, it depends on your business and what it
is. Know what your product is. Write down all the major components of the product and any ideas
related to the product. Next, determine the product’s usability, usage, prac cal poten al, and target
audience. Think and choose which prototype fits your product. Once done, you can con nue the
process.
• WHAT ARE THE STAGES OF PROTOTYPE DEVELOPMENT
There are three prototype development stages-
r Alpha - This phase is the ini al phase of prototype development. At this stage, the product
design must meet the required specifica ons of the product. At this stage, the team acts as if the
product is the final product, adding similar products to help develop a highly efficient product
without many shortcomings.
r Beta - Next comes the beta phase, which includes design refinements established in alpha
development. These design improvements are implemented in PCBs, cases, GUIs, PCBs,
produc on tools, etc. This phase eliminates errors that existed during the alpha phase of
product prototype development.
r Pilot Produc on - This is the stage where the design is transferred to produc on. The product
design is then created and put on the market. The developed product is suitable for the first
launch, and the design and produc on process are stable.
IMPORTANCE OF PROTOTYPE DEVELOPMENT
r Prototype development can be beneficial in many ways, such as.
r This allows customers to see the product in the early stages of its launch. Also, at the ini al stage,
there is ample assurance that the customer’s product is sa sfactory and meets their
requirements.
r This method allows you to easily incorporate changes to your design. Product prototyping
services make making changes a lot easier.
r This helps companies spot errors in product adver sing. This allows the company to catch errors
and bugs early, before the product hits the market.
r The design also offers flexibility.
r Designs can also be reused by developers who can help with similar projects in the future.
r Func onal valida on is easy, and missing func onality can be easily iden fied and fixed in a
product before it hits the market.
51
4.1.2 Types of Prototyping

Here are some of the most common ways that prototypes are created for both digital and physical
products -
1. Sketches and diagrams
Whether you’re sketching out your first ideas on a napkin on your lunch break or crea ng a more
formal image with a ruler and ink, paper prototypes can help kick-start the process of
conceptualizing and designing new products. Although perhaps the most basic form of prototyping,
using paper drawings is s ll a widely used method for sharing concepts.
2. 3D prin ng or rapid model
3D prin ng allows engineers to use computers and prin ng presses to quickly create realis c
mockups of designs. With this prototype, the company can use his 3D model to iden fy errors and
areas that need adjustment, thus shortening the me from design to produc on. Once the design is
complete, it can be easily modified based on observa on and tes ng. Prototype files only need to be
digitally reprogrammed. 3D prototypes are used to simplify large-scale designs such as engines and
aircra parts.
3. Physical model
Prototype models can be created using anything from building blocks to construc on paper. You
don’t have to have working parts - it just gives you a rough idea of the design. Physical model
prototypes are also useful for small handcra ed objects and architectural designs.
4. Wireframe
Wireframes act as digital diagrams or layouts for your product. This is a common prototype used for
websites, so ware, or other digital tools. It can be used by everyone involved in a project, from
copywriters to developers, to navigate the structure and placement of different content.
5. Role-play through virtual or augmented reality
Certain designs can benefit from visualiza on tools such as virtual and augmented reality. Imagine
you are presen ng the first dra of a new amusement park. By “walking” in the park with VR goggles
and smartphones, you can test the development as if the construc on was completed.
6. Feasibility
Proof-of-concept prototypes are used to test specific features added later in the design process.
Used for both digital and physical models, designers can extend designs a er the ini al prototype. If
the designer suddenly realizes that a key part of the product is missing, it creates a feasibility model
that can be adjusted as new ideas arise.
7. Working model
Working Prototypes allow you to test your product ideas to see if they actually work as intended. This
is useful for mechanized inven ons and other designs with features that need to be moved or
adjusted in a certain way. The idea is to follow the ini al plan and see if the design actually works.
8. Video prototype
Video prototypes are o en used to present products in the form of animated videos or simula ons
that illustrate and graphically represent the project. They o en show movies of other prototypes to
help other designers, managers, and even others, such as consumers, visualize the product.
52
Par cipant Handbook
9. Horizontal
A horizontal prototype shows the design from the user’s perspec ve. Used primarily in so ware
design, it helps engineers understand the human interface of their projects. Horizontal prototypes
display menus, windows, and screens on a computer to test how users interact with your product.
10. Ver cal
These prototypes are digitally created to enhance the database design. These are considered “back-
end” models and are used to test the main func onality of the so ware before proceeding to
another design phase.
4.1.3 Selec on of a Prototype

Before building a prototype, the designer or engineer should consider what results they want to test. If
you’re just trying to create a simple mockup that makes your design stand out from the paper, you don’t
need to pay too much a en on to details. Tes ng whether a product works on a working model requires
greater accuracy.
Designers also need to consider who will see the prototype. If your prototype is intended for a sales
presenta on or mee ng with management, it should work with a clean, straigh orward design. For
example, a so ware engineer works with a team in wireframes, but may create user interface
anima ons for presenta ons to company execu ves.
Notes
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
53
Exercise
Answer the following ques ons
1. What is Prototype?
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
2. How many types of Prototype are there name them?
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
3. Explain the stages of Prototyping.
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
4. What is the difference between actual product and a prototype?
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
5. What is the use of 3D printer in prototyping?
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
6. Is metal prototyping being possible?
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
7. Explain the importance of Prototyping.
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
54
Par cipant Handbook
UNIT 4.2: 3D Printer Opera on
Unit Objec ves

1. Perform the Opera on of 3D Printer which includes Pre & Post Processing of Prin ng
4.2.1 Prototype Development Overview

How 3D Printer Prints?
The process starts when you send a 3D model file to the printer. The file contains a set of instruc ons for
everything, including what temperatures to keep the nozzle and build pla orm at as well as how to move
the nozzle and how much filament to extrude.
When the print job starts, the nozzle heats up. When the nozzle reaches the required temperature to
melt the filament, the extruder pushes the filament into the hot end. At this point, the printer is ready to
start 3D prin ng the part. The print head lowers and starts deposi ng molten filament, squeezing out the
first layer between the nozzle and the build surface. The material cools and begins to harden shortly a er
exi ng the nozzle, thanks to the part cooling fan (or fans). A er the layer is complete, the print head
moves up along the Z-axis by a ny amount, and the process repeats un l the part is complete.
Acquiring & Designing 3D Models
55
Naturally, if you want to 3D print a part, you have to have a 3D model of that part. 3D models are created
using 3D modelling so ware, such as CAD (computer-aided design) so ware. Here are some examples of
popular 3D modelling programs:
• Fusion 360 (free for non-commercial use CAD)
• Solid Works (paid CAD)
• Blender (free surface and organic modeler)
However, most 3D prin ng beginners don’t have the skills required to use such so ware. If that’s the
case, don’t worry, because there are other solu ons.
For starters, there are simpler CAD so ware op ons, such as Tinker cad, a program that almost anyone
can use without any prior experience. It’s an online app designed by Autodesk, one of the industry’s
leading CAD so ware creators.
Downloading Files
With so many people gaining access to 3D printers in recent years, numerous sites have emerged as
repositories for 3D models. Here are some of the most popular ones:
• Thing verse (all free)
• MyMiniFactory (many free and some paid)
• Cults3D (free and paid)
• CGTrader (few free and most paid)
• Printables (all free)
Preparing Models
Cura is one of the most popular slicer op ons

Once a model is finished in 3D design so ware, it s ll needs to be prepared using a special kind of
so ware that translates the model into the script of machine instruc ons we men oned earlier. This is
done using slicing so ware, also referred to as a slicer. A er impor ng your 3D model to the slicer, you
can adjust the se ngs to meet your requirements. You can use the slicer to set many important
parameters, such as prin ng speed and temperature, wall thickness, infill percentage, layer height, and
many others.
The resul ng file consists of G-code, the “language” of 3D printers and CNC machines. G-code is
essen ally a long list of instruc ons that the 3D printer will follow to build your model. In other words, 3D
prin ng is impossible without G-code files!
56
Par cipant Handbook
Supports
One of the main func ons of a slicer is to analyse your model and determine whether or not to generate
support material. Specifically, supports are needed for parts with severe overhangs. The slicer lets you
choose where to put supports and how dense you want them to be. Some slicers even offer users the
ability to choose different types of support structures, which might be easier to remove or more stable.
Materials
ABS being 3D printed

As we’ve already men oned, FDM 3D printers use spools of filament as the material for crea ng parts.
These filaments are basically specially-engineered thermoplas cs that are capable of being melted and
cooled and s ll maintain their structural integrity.
Filaments for 3D prin ng usually come in two different diameters: 1.75 mm and 3 mm (or 2.85 mm).
Apart from the diameter, filaments also come in different spool sizes. A quick glance at the market
reveals that the most common sizes are 500 g, 750 g, 1 kg, 2 kg, and 3 kg.
One of the best features of FDM 3D printers is that they can work with a variety of filament types. Here
are just some of the different types of filament that are used in FDM 3D prin ng:
• Most commonly, you will find PLA, ABS, and PETG. These tend to be cheaper and rela vely easy to
work with.
• Some special kinds of filament would be flexible (TPU, TPE), nylon, filled (with wood, metal, etc.),
and polycarbonate (PC).
• If your printer is capable of extruding mul ple materials, you can use PVA or HIPS to provide soluble
supports.
57
Post-Processing
Sanding a 3D printed part

Post-processing is the final step of the 3D prin ng process (though, we advocate recycling). Depending
on your requirements, you may need to perform some of the following common post-processing steps
for an FDM 3D printed part:
• Removing supports: A er prin ng, you will most likely want to remove any extraneous support
material. It’s not uncommon to see some marks le behind on the part’s surface.
• Sanding: Removing blemishes, such as those le over from removing support material, is where
sanding comes in. Lightly sanding 3D printed parts can make the surface smoother.
• Pain ng: O en, you’ll be prin ng in a single color. To add any desired colors, details, or protec on,
you can paint your model!
• Polishing or smoothing: Epoxy coa ng is also one way to smooth the surface of a printed part.
Certain filaments, such as ABS, work par cularly well with specific processes, such as vapor
smoothing, for achieving a smooth, glossy finish.
• Welding or gluing: When you want to print a large 3D model that doesn’t fit in your printer’s build
volume, you can print the part in two (or more) pieces and glue them together later.
Notes
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
58
Par cipant Handbook
Notes
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
QR Codes
What is Rapid Prototyping? What is 3D Prin ng and how does it work?

Youtube.com/watch?v=-TDn25K-Jh4 Youtube.com/watch?v=Llgko_GpXbI
How Do 3D Printers Work?

Youtube.com/watch?v=qoBU0r7pT84
59
Par cipant Handbook Addi ve Manufacturing (3D Prin ng)
5. Work Effec vely

with Team
Unit 5.1 - Coordinate Effec vely with Team Members

Unit 5.2 - Effec ve Communica on
Unit 5.3 - Ac ve Listening Skills
IAS/N9001
60
Par cipant Handbook

At the end of this module, the trainee will be able to:
1. Prac se effec ve coordina on with team members
2. Communicate effec vely with the team
3. Prac se ac ve listening skills while communica ng
61
Unit 5.1 Coordinate Effec vely with Team Members
Unit Objec ves

At the end of this unit, the trainee will be able to:
1. Prac se effec ve team coordina on
2. Provide equal opportuni es for all genders
3. Review the importance of PwD (persons with disability) sensi za on
5.1.1 Coordina ng Effec vely with Team Members

The different ways to respond to inappropriate behaviour towards oneself and the others in a
professional manner are as follows:
Recognising unethical conduct
Provide support Do not engage in nega vity
Use apprecia ve inquiry Steer the conversa on
Help the person understand how they can take

A empt to disrupt nega ve rumina ons control of the situa on
62
Par cipant Handbook
5.1.2 Gender Sensi vity

Gender sensi vity refers to making the concerns of both men and women an integral part of all policies
and programs in an organiza on so that both the men and women benefit equally. Gender sensi za on
is the prac ce undertaken by an organiza on to check its gender discriminatory ac vi es and create a
balanced environment where the interests of both men and women are given equal importance. Some
of the effec ve ways by which gender equality can be promoted at the workplace are as follows:
• Equal number of male and female technicians should be hired
• Leadership roles should be considered for members of all genders
• Members of all gender staff should be offered equal pay
• Stricter implementa on of an -harassment policies to prevent exploita on of human resources
• Crea ng an open-minded atmosphere where all employees can put forward their points without
any fear or hesita on
Gender Spectrum
The gender spectrum states that gender is not binary (male/female) but a spectrum of biological,
mental, and emo onal traits that exist along a con nuum. There are clusters of characteris cs that are
expressed more in an individual compared to the other irrespec ve of their gender. For instance, the
average height of a man is more compared to the average height of a woman. However, some women
have been found to be taller than some men.
The physiological and sociological condi oning for men and women is different. Men are expected to be
pshyiologically stronger than women, which o en makes them feel they are superior to women. This
mentality also affects their mindset and behaviour within the workplace, where women are o en kept
out of important decision making. Hence, equal opportuni es should be created for both men and
women in the workplace.
• Some of the na onal and interna onal frameworks for gender equality have been discussed below:
• Prohibi on of gender-based violence and harassment
• Prohibi on of discrimina on on grounds of marital status or family responsibili es
• Women should get 12 consecu ve week’s maternity leave; six weeks of which are paid and six weeks
paid at 20 percent of full pay
• Pregnant or breas eeding mothers should not be allowed to do ac vi es that may be harmful to
their lives or that of their baby
• A woman cannot be sacked from her job because she is pregnant
63
5.1.3 PwD Sensi vity

Persons with Disability (PwD) are o en secluded from mainstaream ac vi es. They are debarred from
equal employment opportuni es. PwD refers to any person with long term physical, mental, intellectual,
or sensory impairment, which in interac on with barriers hinders their full and effec ve par cipa on in
society equally with others. The popula on of PwD is 2.21% of the total popula on of India. As per the
World Bank, excluding PwD from the economy affects GDP of 5% to 7%. As per sta s cs, 50% of the PwDs
are in employable age. Out of the male disabled persons, only 47% are working, whereas for females
only 23% is working.
There has been a gradual evolu on in the concept of disability. Some of these have bee discussed over
here, such as the Charity model. It states that the PwD needs to be looked a er and protected as they
make their own decisions. The medical model states that disability of any form may hamper an
individual’s quality of life. However, this form of disability can be diminished or corrected with medical
interven on. The empowerment model states that the problem does not lie with an individual.
However, it is the environment that enables or disables a person.
Some of the Na onal Disability Acts have been discussed below:
• Right of Persons with Diability Act (2016) provides 5% reserva on in all schemes for key disability
categories and 4% reserva on in jobs with poor outcomes. This law protects disabled persons in
Indian from various forms of discrimina on and ensures their access to equal employment
opportuni es.
• SANKALP program aims to increase % of women, SC, ST, and PwDs in all skilling programs under
inclusion and diversity
Exercise
A. Answer the following ques ons by choosing the correct op on:
1. Which of the following ways help one in bonding well with team members?
a. Support them in mes of need b. Appreciate them
c. Avoid nega ve conversa ons d. All of these
2. An organisa on hiring more male candidates and paying them more than female employees
Needs___________ .
a. HR compliance b. PwD sensi vity
c. Gender sensi vity d. None of these
3. Right of Persons with Disability Act (2016) provides % reserva on in all schemes for key disability
categories and % reserva on in jobs with poor outcomes.
a. 5, 4 b. 4, 5 c. 1, 3 d. 6, 8
64
Par cipant Handbook
Unit 5.2 Effec ve Communica on
Unit Objec ves

1. Prac se the basics of communica on
2. Communicate effec vely with colleagues
5.2.1 Communica on Basics

There are a number of communica on basics that should be followed within the workplace. Some of
these have been discussed below as:
• Address people by their names, as people feel important once their name is brought into the
conversa on
• Try and maintain an open conversa on channel with each and every employee that you work with
• Analyse the rela onship dynamics that you are maintaining with your colleagues. In case there exists
any dispute, try sor ng them out in me
• Ensure that you maintain a file line and don’t open up too much in front of your colleagues
• Avoid sharing personal life details in the workplace, as it may have a nega ve impact
• Try and respect other people’s personal space
5.2.2 Effec ve Communica on with Colleagues

Some of the ways to communicate effec vely with colleagues at the workplace are as follows:
Ac ve listening: Ac ve Listening is an important part of non-verbal communica on. It helps in building
trust between the two people in a conversa on. It makes the other person feel important and accepted
within their workplace. Addi onally, ac ve listening is a good way to analyse the other person in the
conversa on.
Speak with clarity: While making important conversa ons, an individual should speak with clarity, as it
reduces the chances of any form of misunderstanding. The openness in the conversa on helps address
the important points.
Prac se construc ve cri cism: Construc ve Feedback reinforces posi ve work culture as well as helps
improve the efficiency of the employees. If a fellow colleague has done great work, they should be
encouraged by offering praise. Similarly, if anyone has done badly, they should be offered construc ve
feedback, leaving aside personal rivalries. One should ensure not to become mean or bossy while
poin ng out mistakes.
Trust and respect each other: You should trust and respect everyone within your workplace. Clear and
concise communica on helps in building understanding and trust between two people.
65
Maintain space while making personal conversa ons: While making personal conversa ons, ensure
that you maintain a boundary, as crossing the line can make the other person uncomfortable within a
conversa on.
Make relevant conversa ons: The communica on made should address the requirements/concern of
the other person. Don’t engage in long, worthless conversa ons, as it kills the produc ve me of the
organisa on and gives a nega ve impression of the speaker.
Keep spoken and wri en communica ons short: Avoid giving complicated and incomprehensible
informa on. Keep the conversa ons short and direct as it facilitates be er understanding.
Exercise
1. ___________ listening involves listening carefully and speaking only when needed.
a. Ac ve b. Proac ve
c. Fast d. Passive
2. _____________ feedback reinforces posi ve work culture as well as helps improve the efficiency
of the employees.
a. Ac ve b. Passive
c. Posi ve d. Nega ve
3. ____________ the personal space may make a person feel uncomfortable in a conversa on.
a. Invading b. Breaching
c. Crea ng d. Elimina ng
66
Par cipant Handbook
Unit 5.3 Ac ve Listening Skills
Unit Objec ves

1. Iden fy various ac ve listening techniques
2. Prac se various ways of ac ve listening
5.3.1 Techniques of Ac ve Listening

Ac ve listening is the process by which an individual secures informa on from another individual or
group. The ac ve element involves taking measures to draw out details that might otherwise not be
shared. Ac ve listening helps an individual comprehend what others are saying or intend to say.
A few of the techniques of ac ve listening have been men oned below:
• Paraphrasing to show understanding
• Using non-verbal cues such as nodding, eye contact and leaning forward
• Using brief verbal affirma ons like, “ I see,” “I know,” “Thank you” or “ I understand”
• Asking open-ended ques ons
• Asking specific ques ons to seek clarifica on
• Being pa ent while someone is comple ng their talking
5.3.2 Ways to Prac ce Effec ve Listening

Some of the ways to prac ce ac ve listening have been discussed below:
Different ways to prac se ac ve listening
Show the other person that you are ready to

Focus your a en on en rely on the speaker listen
Make eye contact with the speaker Use your voice to convey a en veness
67
Exercise
1. One must to prove one’s understanding of a conversa on.
a. Paraphrase b. Cross-ques on
c. Take notes d. Reply
2. One must ask ques ons to seek clarifica ons.
a. Special b. Specific
c. General d. Generic
3. One must make with the speaker during a conversa on.
a. Handshake b. Eye contact
c. Arguments d. Fist pumps
Summary
• Effec ve team working
• Communica on basics
• Effec ve communica on with colleagues
• Different techniques of ac ve listening
• Ways to prac se ac ve listening
Ac vity
• Imagine a situa on where one of your colleagues have been facing workplace harassment in terms
of misbehaviour and unequal pay
• He/ She has reported the ma er to you
• Discuss the set of ac ons that will be undertaken by you, and why?
68
Par cipant Handbook
Exercise
1. Which one is NOT an effec ve way of communica on with colleagues?
a) Ac ve listening b) Speak with a nega ve a tude
c) Prac se construc ve cri cism d) Respect each other
2. Which one of the following is NOT an effec ve technique of Ac ve Listening?
a)Use of body language b) Ask open-ended ques ons
c) Paraphrasing statements d) None of the above
3. Which of the following is NOT an effec ve ac ve listening skill?
a)Focus en rely on the speaker b) Maintain eye contact with the speaker
c) Pretend not to listen d) Use your voice to convey a en veness
4. Which one of the following communica on basics should NOT be prac sed by people in their
workplace?
a)Address people by their names b) Maintain an open conversa on channel
c) Share personal details d) Respect each other's personal space
5. Which of the following can be prac sed for improving organisa onal culture?
a)Ac ve listening b) Give construc ve feedback
c) Implement communica on basics d) All of the above
69
Par cipant Handbook Addi ve Manufacturing (3D Prin ng)
6. Health and Safety

in Workplace
Unit 6.1 - Safety and First-Aid

Unit 6.2 - Components of a Basic First-Aid Kit
Unit 6.3 - Correct Use of Fire Ex nguishers
Unit 6.4 - Electrical Safety Measures while Opera ng
Electrical Tools
IAS/N9002
70
Par cipant Handbook

At the end of this module, the trainee will be able to:
1. Summarise the importance of safety and first-aid at the workplace
2. Prac se safety and first-aid appropriate to the workplace
3. Iden fy the components of a basic first-aid kit
4. Implement basic first aid techniques at the me of emergency
5. Prac se the correct use of fire ex nguishers
6. Comply with the general safety procedures as defined by the organisa on
7. Implement safety measures while opera ng electrical tools
8. Par cipate in safety drills at the workplace
71
Unit 6.1 Safety and First-Aid
Unit Objec ves

1. Implement general safety procedures as defined by the organisa on
2. Develop awareness on the need of greening
6.1.1 General Safety Procedures in the Organisa on

Some of the general safety procedures as followed within an organisa on have been discussed below:
• One must cri cally and ra onally evaluate the severity of the emergency and determine, what
requires to be done on an immediate basis
• One must look for addi onal help by calling up the emergency toll-free number, which would help
the caller reach an official or “dispatcher”
• It is recommended that one should call from a GPS (global posi oning system) equipped phone so
that the emergency dispatcher is able to track the loca on, even if the caller is unable to speak
• One must assess the immediate threats, for example, in case a person is severely injured from a
running machine, the machine must be turned off immediately to prevent others from ge ng hurt
as well
• Extremely high casual es must be reported to the occupa onal health and safety commi ee (OHSC)
• One must move farther from the emergency spot and help others do the same
• Evacua on plans must be adopted, and escape routes must be taken
• Secondary hazards must be eliminated or mi gated, at least. For example, a car accident involves
the risk of a violent explosion and fire outbreak resul ng from spilled fuel
• One must help the other vic ms and take appropriate measures to help the specially-abled ones
• A first-aid kit must be used, wherever applicable
• One must try reviving a seemingly unconscious vic m by rubbing the chest, pinching the earlobes,
providing cardiopulmonary resuscita on (a combina on of chest compression and ar ficial
respira on)
• One must avoid moving a severely injured vic m and provide only the basic first aids
72
Par cipant Handbook
6.1.2 Awareness on the need for Greening

The reduc on in the amount of greenhouse gases is a step forward towards genera ng a greerner
environment. A decrease in the emission of greenhouse gases can reduce the rate of global warming.
Some of the steps which should be undertaken to reduce Co2 emissions in the industry processes as
follows:
• Measuring carbon footprint
The carbon footprint can be measured by undertaking an assessment of greenhouse gases. The size of
the carbon footprint can be reduced through technological developments, be er process management,
carbon capture, be er consump on strategies and others.
• Reducing energy use
The energy consump on can be reduced by implemen ng the following methods:
◦ By conduc ng an energy audit that will help quan fy how much energy each department is
consuming
◦ Schedule opera on of machinery outside of peak hours as peak hours cons tute up to 30
percent of a manufacturing facili es’ bill
◦ Schedule produc on floor shut downs where all types of machinery are shut down for a length
of me, as it can substan ally reduce energy consump on
◦ Regular maintenance of air compressors can prevent energy wastage due to leakage
• Reducing fossil fuel dependence
The burning of fossil fuel results in the emission of carbon dioxide leading to irreversible climate change.
Therefore, switching to sustainable energy sources such as wind or solar power can help reduce the
dependency on non-renewable energy resources.
Source of pollu on in factories, industries and plants
The common forms of industrial pollu on from heavy industries or large scale manufacturing plants
include heavy metals such as lead, mercury, cadmium, etc. Factory emissions contribute to the release of
carbon dioxide, carbon monoxide and others suphur gases into the atmosphere. The suphur gases on
combining with the moisture (water vapour) present in the atmosphere result in the forma on of acid
rain. Air pollu on from factories and vehicles results in the forma on of smog, which has deleterious
health effects. A large amount of chlorofluorocarbons released as an industrial by-product can result in
ozone deple on.
Waste Segrega on and Sor ng
Waste Sor ng is the process through which waste is separated into different elements. The Waste
sor ng can be done either manually at the household or collected through proper collec on schemes at
industries or plants. Waste segrega on means dividing the waste into dry and wet. The dry waste
includes wood and related products such as metal and glass. Wet waste typically refers to organic waste
generated mostly by households, farms, ea ng establishments, etc.
73
The waste sor ng can be done by maintaining different color codes as described below:
Colour Coding Type of Container Waste Categories

Yellow Plas c bags, Puncture proof Human anatomical waste, animal
containers, etc. waste, microbiological waste, solid
waste
Red Disinfected containers, plas c Microbiological, soiled, solid waste
bags, puncture-proof containers, such as tubes, catheters, etc.
etc.
Blue/white Plas c bags, puncture-proof Discarded medicines, incinera on
containers, etc. ash, chemical waste
Black Plas c bags, puncture-proof Discarded medicines, incinera on
containers ash, chemical waste
Exercise
1. Which of the following is/are NOT general safety procedure(s) in an organisa on?
a. One must assess the immediate threats, for example, in case a person is severely injured from a
running machine, the machine must be turned off immediately to prevent others from ge ng
hurt as well
b. Extremely high casual es must be reported to the occupa onal health and safety commi ee
(OHSC)
c. There’s no need of maintaining a medical centre in a plant; it is sufficient if there is a hospital
nearby
d. In case of emergency, one must try incorpora ng first-aid only if he/she knows it
2. Which of the following is/are methods help in energy conserva on?
a. Conduc ng an energy audit that will help quan fy how much energy each department is
consuming
b. Scheduling opera on of machinery outside of peak hours as peak hours cons tute up to 30% of a
manufacturing facili es’ bill
c. Scheduling produc on floor shut-downs where all types of machinery are shut down for a
certain dura on of me, as it can substan ally reduce energy consump on
d. All of these
3. Yellow is to human anatomical waste while red is to waste.
a. Chemical b. Soiled
c. Combus ble d. Nuclear
74
Par cipant Handbook
4. Wood, metal, and glass are categorised as:

a. Wet waste b. Dry waste
c. Combus ble waste d. Sharps
5. Which of the following toxins was behind the Vizag gas leakage accident dated 7th May 2020?
a. Methyl carbide b. Acetylene
c. Styrene d. Potassium cyanide
75
Unit 6.2 Components of a Basic First-Aid Kit
Unit Objec ves

1. Perform first-aid techniques at the me of emergency
6.2.1 Administer First Aid at the Time of Emergency

Some of the basic components of a first-aid kit are as follows:
• Plasters of different shape and sizes
• Small, medium and large sterile gauze dressings
• Sterile eye dressings (at least 2)
• Triangular bandages
Fig. 6.2.1: Sterile Gauze
• Crepe rolled bandages
• Safety pins
• Alcohol-free cleansing wipes
• S cky tape
• Thermometer
• Skin rash creams such as hydrocor sone or calendula
• Cream or spray to relieve insect bites and s ngs
• An sep c cream
• Painkillers such as paracetamol, aspirin or ibuprofen
• An histamine cream or tablets Fig. 6.2.2: Sterile Eye Dressing
• Dis lled water for cleaning wounds
• Eye drops
Fig. 6.2.3: Creme Rolled bandages Fig. 6.2.4: An sep c cream Fig. 6.2.5: An histamine cream
76
Par cipant Handbook
Exercise
Answer the following ques ons by choosing the correct op on:
1. Which of the following is/are not a component/components of a common first-aid kit?
a. Crepe bandages b. Nail polish remover
c. Co on d. An sep c solu on/cream
2. Paracetamol, aspirin or ibuprofen are:
a. Painkillers b. An sep c solu ons
c. Antacids d. Sterilisers
3. Hydrocor sone is a/an:
a. Painkillers b. An sep c solu ons
c. Antacids d. Skin rash cream
4. “Sterile” means:
a. Germ-free b. Clean
c. Boiled d. None of these
77
Unit 6.3 Correct Use of Fire Ex nguishers
Unit Objec ves

1. Categorise fire ex nguishers
2. Compare various fire ex nguishers
3. Select an appropriate fire ex nguisher as per the class of fire
4. Use a fire ex nguisher correctly and safely
6.3.1 Types of Fire Ex nguishers

The various classes of fire are as follows:
Class of Fire Source

A Fire from combus ble objects like wood, paper, plas c, cloth, charcoal, etc.
B Fire from flammable liquids like gasoline, petrol, diesel, grease, other greasy liquids,
etc.
Fire from flammable gases like Propane, Butane, Methane, etc.
C Fire from electrical equipment
D Fire from combus ble metals like sodium, magnesium, potassium, lithium, tanium,
aluminium, etc.
E A fire caused by electrical equipment
F A fire caused by cooking oils
Fire ex nguishers vary according to the ex nguishing material and the class of fire, as given below:
Equipment Descrip on Image

Water fire ex nguishers Suitable for use on wood,
paper, fabrics, and coal
Foam fire ex nguishers Suitable for class A and class B

fires
78
Par cipant Handbook
Equipment Descrip on Image

Powder fire ex nguishers Ideal for usage on class A, B,
and C fires. It is also safe on
electrical equipment.
CO2 fire ex nguishers Suitable for class B fire. Also

recommended for use on
electrical equipment.
6.3.2 Correct Use of a Fire Ex nguisher

The PASS technique of using fire ex nguishers involves the following steps:
• Pull (P)
• Aim (A)
• Squeeze (S)
• Sweep (S)
Pull Aim
Squeeze Sweep
Fig. 6.3.1: Electric Sparks
79
Exercise
A. Match the columns by choosing the right answer.
Class of Fire Func ons
Ex nguisher
1. A i. Fire from flammable gases like Propane, Butane, Methane, etc.
2. B ii. Fire caused by electrical equip
3. C iii. Fire from combus ble objects like wood, paper, plas c, cloth,
charcoal, etc.
4. D iv. Fire from combus ble metals like sodium, magnesium, potassium,
lithium, tanium, aluminium, etc.
5. E v. Fire from flammable liquids like gasoline, petrol, diesel, grease,
other greasy liquids, etc.
6. F vi. Fire from electrical equipment
a. 1-iii, 2-v, 3-i, 4-iv, 5-ii, 6-vi

b. 1-i, 2-ii, 3-iii, 4-iv, 5-v, 6-vi
c. 1 – vi, 2 – v, 3 – iv, 4 – iii, 5 – ii 6 – i
d. 1 – ii, 2 – iv, 3 – vi, 4 – v 5 – i, 6 –iii
B. Answer the following ques ons by choosing the correct op on:
1. Which of the following is the correct expansion of P.A.S.S?
A.Pull, Aim, Squeeze, and Swish b. Pull, Angle, Shunt, and Sweep
c. Pull, Access, Shunt, and Sweep d. Pull, Aim, Squeeze, and Sweep
2. Which of the following fire ex nguishers are suitable for electrical fire?
a.Water-based
b.Powder
c. CO2-based
d. Both b and c
3. Which of the following fire ex nguishers can be used on fire from wood, paper, fabrics, and coal?
a. Foam-based b. CO2 based
c. Water-based d. Powder-based
80
Par cipant Handbook
Unit 6.4 Electrical Safety Measures
Unit Objec ves

1. Par cipate in safety drills at the workplace
2. Implement electrical safety measures at the workplace
3. Demonstrate the steps of trea ng an electrocuted vic m
6.4.1 Safety Drills at the Workplace

Electrical Safety measures
Some of the safety measures which can be undertaken while opera ng electrical tools are as follows:
• Avoid wearing loose clothes that can get caught in a tool’s moving part
• Never carry a power tool by its cord
• Wear wooden boots to prevent injuries from sudden electrical shock
• Regularly inspect the control panels for any kinds of short circuit or fault
• Use tools that are double insulated and are plugged into a ground receptacle
• Do not use electrical tools in wet condi ons
• Use a ground fault circuit interpreter
First-aid treatment for Electrocu on
The steps which should be undertaken to free a person from electrocu on are as follows:
Steps to first-aid treatment for electrocu on
Shut off the current Separate the vic m from the source
Place the vic m in the recovery posi on Cover the vic m in a blanket
81
Steps to first-aid treatment for electrocu on
Talk to the vic m and try reviving them to

consciousness Control any bleeding
Check the vic m's airways, breathing, and circulatory system before beginning any sort of
compressions
Exercise
Answer the following ques ons by choosing the correct op on:
1. Which of the following is not a safe prac ce?
a. Wear loose clothes
b. Wear wooden boots to prevent injuries from sudden electrical shock
c. Always use electrical tools in wet condi ons
d. Both a and c
2. Not wearing insula ng PPE while working on electrical equipment run the risk of:
a. Electrocu on b. Short circuit
c. Electrical fire d. All of these
82
Par cipant Handbook
3. The 1st step of rescuing an electrocuted vic m is to:

a. Talking to the vic m and trying reviving them to consciousness
b. Covering the vic m in a blanket
c. Shu ng off the current
d. Placing the vic m in the recovery posi on
Summary
• General safety procedures as defined by the organisa on
• First-aid at the me of emergency
• Different types of fire ex nguishers
• Correct use of a fire ex nguisher
• Safety drills at workplace
Ac vity
You have been given a number of emergency situa ons:
1. One of your colleagues falls unconscious due to electrocu on
2. There is a fire in the building
3. You find one your colleagues choking
What mi ga on efforts will be undertaken by you in each case, and why?
83
Exercise
A. Choose the correct alterna ve:
1. Which of the following is NOT a source of class A fire?
a) Wood b) Paper
c) Combus ble metals like Sodium d) Charcoal
2. Which of the following fire ex nguisher is suitable for dousing Class A and Class B fire?
a) Powder fire ex nguishers b) Water fire ex nguishers
c) CO2 fire ex nguishers d) Foam fire ex nguishers
3. What is the correct sequence of dousing a fire?
a) Pull-Aim-Squeeze-Sweep b) Pull-Aim-Sweep-Squeeze
c) Pull-Aim-Squint-Sweep d) Pull-Aim-Sweep-Squint
4. Which one of the fire ex nguisher/s can be used for dousing class B type fire?
a) Powder fire ex nguisher b) Foam fire ex nguisher
c) CO2 fire ex nguisher d) Water fire ex nguisher
5. Which of the following could result in a Class B type of fire?
a) Propane b) Wood
C) Paper d) A fire caused by electrical equipment
84
Par cipant Handbook
7. Employability Skills
DGT/VSQ/N0102
85
Scan the QR code for Employability Skills
h ps://eskillindia.org/NewEmployability
Employability and Entrepreneurship Skills
86
Par cipant Handbook
8. Annexure
Annexure - QR Codes
87
Annexure of QR Codes for Addi ve

Manufacturing (3D Prin ng)
Chapter No. Unit No. Topic Name Page URL Link QR Code
No.
Unit 1.1 - About What is addi ve
Addi ve manufacturing? Youtube.com/
Manufacturing watch?v=EHv
in Industry O-MlzAIM
Chapter 1 :
Introduc on
to Role of an What is addi ve
Addi ve manufacturing?
8
Manufacturin Unit 1.2 - Role of 3D printer - Unbox
g (3D Prin ng) an Addi ve & Setup Youtube.com/
Manufacturing
(3D Printer) watch?v=ibs
OYzXduYc
3D printer - Unbox & Setup

Types of 3D Prin ng
Technology
Youtube.com/
watch?v=0Frc
gPd-7G8
Unit 2.1 - About Types of 3D Prin ng

3D Prin ng Technology
Technology Introduc on to 3D
Chapter 2 : Prin ng Youtube.com/
Install a 3D watch?v=DM
33
Printer WzMpjSJLM
Introduc on to 3D Prin ng
Unit 2.2 - 3D The Ul mate
Prin ng Beginner's Guide to
Youtube.com/
Applica ons 3D Prin ng watch?v=3LBT
kLsjHGQ
The Ul mate Beginner's
Guide to 3D Prin ng
Chapter 3: Unit 3.2 - Use of BEST 3D Prin ng
Maintain 3D Printer Design So ware
and provide So ware
Youtube.com/
technical 47 watch?v=vh
support for jYeMymjt4
3D printer BEST 3D Prin ng Design
So ware
88
Par cipant Handbook
Chapter No. Unit No. Topic Name Page URL Link QR Code
No.
Unit 3.3 - Tips for 3D Printer
Maintenance Maintenance
of 3D Printer Youtube.com/
watch?v=4kJT
hmWDcCo
Tips for 3D Printer
Maintenance
Unit 3.3 - 3D printer essen al 47
Maintenance maintenance
of 3D Printer Youtube.com/
watch?v=kA
afiApJs9A
3D printer essen al
maintenance
Chapter 4 : Unit 4.1 - What is Rapid
Operate and Prototype Prototyping?
op mise 3D Development Youtube.com/
prin ng for watch?v=-T
addi ve Dn25K-Jh4
manufacturing What is Rapid Prototyping?
Unit 4.2 - 3D What is 3D Prin ng
Printer and how does it
Opera on Youtube.com/
work? watch?v=Llg
59 ko_GpXbI
What is 3D Prin ng and

how does it work?
How Do 3D Printers
Work?
Youtube.com/
watch?v=qoB
U0r7pT84
How Do 3D Printers Work?
Chapter 7: Employability Skills
Employability H ps://eskill
Skills - 90 Hours india.org/Ne
86
wEmployabil
ity
Employability Skills
89
Scan this QR Code to access eBook
Address: B-12, Udhyog Marg, Block B, Sector 1, Noida, Uttar

Pradesh 201301
Web: info@iascsectorskillcouncil.in
Phone: 0120-2424331 , 0120-2424332
90

Additive-Manufacturing-(3D-Printing)

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Additive-Manufacturing-(3D-Printing)

Uploaded by

Copyright:

Available Formats

Addi ve Manufacturing (3D Prin ng)

SI.No Modules and Units Page No

Par cipant Handbook

This book is sponsored by Instrumenta on, Instrumenta on, Automa on,

Under Crea ve Commons License: CC-BY-SA

Skilling is building a be er India.

Shri Narendra Modi

is hereby issued by the

Complying to National Occupational Standards of

About this Book

Key Learning Unit

1. Introduc on to Role of an Addi ve Manufacturing 3D Prin ng (Bridge Module) 1

Unit 1.1 - About Addi ve Manufacturing in Industry 3

Unit 1.2 - Role of an Addi ve Manufacturing (3D Printer) 7

2. Install a 3D Printer (IAS/N5606) 9

Unit 2.1 - About 3D Prin ng Technology 11

Unit 2.2 - 3D Prin ng Applica on 25

Unit2.3 - So ware & 3D Printer Installa on 29

3. Maintain and Provide Technical Support for 3D Printer (IAS/N5607) 34

Unit 3.1 - Get Started with 3D Printer 36

Unit 3.2 - Use of 3D Printer So ware 38

Unit 3.3 - Maintenance of 3D Printer 44

4. Operate and Op mise 3D Prin ng for Addi ve Manufacturing (IAS/N5608) 48

Unit 4.1 - Prototype Development 50

Unit 4.2 -3D Printer Opera on 55

5. Work Eﬀec vely with Teams (IAS/N9001) 60

Unit 5.1 - Work and Communicate eﬀec vely at workplace 62

Unit 5.2 - Work in a disciplined and ethical manner 65

Unit 5.3 - Uphold social diversity at the workplace 67

6. Health and Safety in Workplace (IAS/N9002) 70

Unit 6.1 - Dealing with Workplace Hazards & Risks 72

Unit 6.2 - Fire Safety Prac ces 76

Unit 6.3 - Emergency, Rescue and First-aid Prac ces 78

Unit 6.4 - Eﬀec ve Waste Management Prac ces 81

7. Employability Skills - 90 Hours 85

Key Learning Outcomes

UNIT 1.1: About Addi ve Manufacturing in Industry

Unit Objec ves

1.1.2 Automated Fabrica on (Autofab)

1.1.3 Freeform Fabrica on or Solid Freeform Fabrica on

1.1.4 Addi ve Manufacturing or Layer-based Manufacturing

1.1.5 Stereolithographic or 3D Prin ng

UNIT 1.2: Role of Addi ve Manufacturing (3D Prin ng)

Unit Objec ves

1.2.1 Role of an Addi ve Manufacturing (3D Prin ng)

1.2.2 Personal A ributes Required

What is addi ve manufacturing? 3D printer - Unbox & Setup

Key Learning Outcomes

UNIT 2.1: About 3D Prin ng Technology

Unit Objec ves

3D design using 3D Slicer u lity

Extrusion / FDM / FFF

SDL is a proprietary 3D prin ng process developed and manufactured by Mcor Technologies. It is

UNIT 2.2: 3D Prin ng Applica ons

Unit Objec ves

UNIT 2.3: So ware & 3D Printer Installa on

Unit Objec ves

Printer Selec on:

Follow the Instruc ons

Types of 3D Prin ng Technology Introduc on to 3D Prin ng

The Ul mate Beginner's Guide to 3D Prin ng

Key Learning Outcomes

UNIT 3.1: Ge ng Started with 3D Printer

Unit Objec ves