3-D printing (Additive manufacturing)

서지우 , Jiwoo Seo

Ateam Ventures

St. George’s School

General idea CAD (computer aid design),(can be achieved by 3D scanning/ download)

Readable file format (STL, OBJ, 3Ds, 3MF)

Files’ errors fixed (netfabb, Meshmixer, Cura, Slic3r)

G-code file (layer by layer) (Skeinforge, Slic3r, and Cura)

3d printing

Finishing touch. (Sanding, removing extra material, painting colors)

7 Standard Terminology for Additive Manufacturing Technologies

1. Material Extrusion

2. Vat Photopolymerisation

3. Material Jetting

4. Binder Jetting

5. Powder Bed Fusion

6. Sheet Lamination

7. Directed Energy Deposition

Chosen by ASTM (American Society for Testing and Materials )

1. Material Extrusion Most common method: Fused Filament Fabrication

(FDM) (FFF) plastic filament/ metal wire unwound from a coil, supply

nozzle. Can turn the flow on/off Nozzle is heated to melt the material and controlled by a

CAM (computer-aided manufacturing) software package Material immediately hardens after extrusion from

nozzle.

1. Material Extrusion Material extrusion is the most common method of 3D printing Most common materials:

ABS (Acrylonitrile Butadiene Styrene)

PLA (Polylactic acid) It is the method used by the 3D printer Creatable D2 Often, the products’ layers can be seen, and material extrusion

produce rougher surfaces compared to other methods.

FFF problems

FFF can’t print “overhangs” and “bridges” Overhangs are parts that extrude out in a way that there is nothing

underneath it to print on, and therefore the printer has problems printing. Makers follow the “45° rule”, which says overhangs with overhang angles

under 45 degrees will be successfully printed without any support. Each printer has different maximum overhang angles it can print. One

way to find your printer’s overhang angle is to print the “Overhang Test Model”

45°

Overhang angle

Overhangs solutions

Change orientation Attach a fan by the nozzle to harden material faster, making it easier to

print overhangs Add support material and remove them after printing. (more time and

work needed. Can leave marks/ otherwise damage the product)

Removing the support material caused marks

PVA, HIPS – support material PVA (polyvinyl alcohol) - water-soluble thermoplastic

PVA has a special characteristic of dissolving in water, so it is becoming popular as a support material. Using PVA gets rid of the long, hard process of removing support material, and instead lets people just drop it in water for the post-printing process.

HIPS (High Impact Polystyrene) – similar material that dissolves in Limonene instead of water.

Hygroscopic PVA attracts lots of water from the air, so it must be stored in an air-tight container with a dehumidifier. Compared to the difficult storage of PVA, HIPS is easier to store.

http://3dprintingforbeginners.com/3d-printing-technology/

A product of PLA with PVA as support. It is dissolved in water and the post-printing work is done.

2. Vat photopolymerisation Most common method: Stereolithography (SLA)

The printing bed is inside a pool of resin, just under the surface.

An UV laser moves and shoots down in the desired shape on a layer of resin.

Layer of resin solidifies into a desired shape on to the bed Platform moves down The UV laser solidifies the next layer Repeat

Video of SLA printing: https://youtu.be/yYGycgnYlBM

2. Vat photopolymerisation New, innovative method: CLIP (Continuous Liquid Interface Production)

O2 permeable window; oxygen inhibits the solidification process. The window can control the amount of oxygen entering, making a “dead zone”: a thin layer (30microns) of liquid.

The platform starts from the bottom of the resin pool, and moves up, lifting the product up from the liquid.

Instead printing in layers, UV light is shone continuously in different shapes like a movie, printing extremely fast.

An interesting TED talk of CLIPhttp://www.ted.com/talks/joe_desimone_what_if_3d_printing_was_25x_faster?language=en#t-2881https://youtu.be/8uD0d1IPsF4

CLIP Introduced by Carbon 3D in March, and had quietly

raised $41 million of funding from Sequoia Capital and Silver Lake.

Claims that CLIP prints 25~100 times faster than average 3D printing

Very Smooth surfaces, no visible layers. “It was immediately clear to us that 3D printing

would never be the same.” - Jim Goetz Variety of materials, elastic, flexible, rigid.

Joseph DeSimone

2. Vat photopolymerisation

Accurate, detailed shape. CLIP- very fast! With one of the biggest problem

of 3D printing being its slow printing speed, CLIP will have significant impact in the 3D printing field.

SLA – very slow. Need lots of post-print work to clean/make

stronger. Expensive, limited material. (resin)

3. Material Jetting

Like a 2D ink-jet printer Material laid down, hardened and cured

by UV light. Platform moves down, repeat

3. Material Jetting Pros: Very accurate, good surface finishes Can print multiple materials colors

Cons: Only polymers and wax materials can be used for

jetting. Parts are rather fragile Building process is slow. Support material needed.

Material: Polypropylene, HDPE, PS, PMMA, PC, ABS, HIPS, EDP

4. Binder Jetting Layer of powder is set on a platform Liquid adhesive (binder) is applied in desired shape

with a nozzle Next layer of powder is laid down

Metals: Stainless steel

Polymers: ABS, PA, PC

Ceramics: Glass

4. Binder Jetting Pros: Wide range of materials: metal, polymers and ceramics Parts can be printed with range of different colors. Generally faster. No need for support structure.

Cons: Weak because of the use of binder. Not for structural

purposes. Lots of post-print process needed to remove the un-binded

material.

5. Powder Bed Fusion  Most common method: Selective laser sintering (SLS)

powder of material is laid down on a layer

Laser heats powder, fuses them together. Unheated powder remains there as the support material.

Another layer of powder is laid down, and repeats.

The chamber is heated to few degrees below the material melting point, to make the powder easier to fuse.

EBM (electron beam melting) has the same concept, but uses an electron beam instead of a laser.

SHS: Nylon DMLS, SLS, SLM: Stainless Steel, Titainium, Aluminium, Cobalt Chrome, Steel EBM: titanum, Cobalt Chrome, ss, al and copper

5. Powder Bed Fusion Pros: Doesn’t require support material. (Unheated powder

acts as support) So faster than most other methods. Variety of materials like: glass, ceramics, and even

metal. Useful in aerospace engineering

Cons: High power usage Lots of post-printing work Size limitation

http://www.livescience.com/38862-selective-laser-sintering.html

6. Sheet Lamination Most common methods: UAM (ultrasonic additive manufacturing),

LOM (laminated object manufacturing)

A sheet of material is placed on cutting bed. The sheet is cut in a desired shape The sheets are attached by adhesive for paper and ultrasonic-

welding for metal Next layer is added, and the process is repeated.

http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing

6. Sheet Lamination Sheet lamination is generally used to make visual models

and not for structural use Materials: Paper, plastic, sheet metals. A4 paper is the most common material because it’s cheap

and easy to get.

Pros: Cheap and fast printing Cons: Requires lots of material and produces lots of waste Printed products have bad strength/integrity Detailed colors can be added to create incredible effects and

achieve artistic visuals (like a human head).

7. Directed Energy Deposition

Material(powder, wire) is deposited from a nozzle onto an object.

Material is melted by laser/electron beam/plasma EMB (Electron beam melting) – uses metals

Metals: Cobalt Chrome, Titanium SLM (Selective laser melting)

Material: 3 major plastic filaments

ABS (Acrylonitrile Butadiene Styrene)

PLA (polyactic acid)

PVA (polyvinyl alcohol)

From 3D Hubs database

Materials: 3 plastic filaments ABS (FFF) (Acrylonitrile Butadiene Styrene) filament

Durable, strong, slightly flexible. Resistant to heat. Variety of applications, including: pipes, automobile parts, protective

headgear, kitchen appliances, toys. (also the material of LEGOs). Nozzle must be heated to (210~250)°C. Print bed should be heated to

prevent cracks/ warping. Cheapest of the plastic filaments. Can be easily sanded, painted Can be glued by “ABS glue” Recyclable but is non-biodegradable because it’s petroleum- based Many colors, including transparent. Attracts water from air when not in use for a long time. Creates fumes, which might irritate sensitive people.

http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/materials/

PLA (FFF) – (polyactic acid) filament

PLA: bio-degradable thermoplastic (resin-SLA) (filament-FFF) Most environmentally friendly material in 3D printing because it’s bio-degradable. Degrades into inoffensive lactic acid in the body. Used in medical suturing as well as

surgical implants. Surgically implanted screws, pins, rods or mesh simply break down in the body within 6 months to 2 years.

Extruded at 160°C-220 °C. Unlike ABS, it doesn’t create fumes, but lets off a slight odor that apparently smells like pancakes and corn. It’s slow to cool, so a fan is recommended.

After printing, it can be sanded and painted with acrylic paint, but it unlike ABS, it can’t be not easily glued

PLA is increasing for its low toxicity and environmental friendliness. It has a low resistance to heat and becomes soft at 50 °C. This could be a flaw but also a benefit, letting the user easily correct and bend the product.

Many say that PLA will soon beat ABS to become the most popular material Easy to work with, many colors including transparent and “glow in the dark”. More water-absorbing than ABS. Water saturated PLA is very hard to print.

PVA (FFF) – (polyvinyl alcohol) filament Water-soluble plastic.

White, odorless Most commonly used as support structure to help with overhang

issues. It’s a very convenient support structure because all the user has to do is drop the product into water, instead of the long, hard process of removing the support structure.

Has an extremely strong water attraction, so hard to store. Extruded at 190°C. If it absorbed water, the printing quality goes very

bad, so it is sometimes dried before printing. High price, difficult sourcing.

Material: other plastics Nylon 12 (powder, filament)

Popular in traditional manufacturing for its superb price-performance.

High fatigue-resistance, chemical resistance. Highest impact-resistance of any FFF thermoplastic. You can create advanced prototypes and custom tooling for

applications that demand high fatigue resistance Naturally white, but can be colored pre/post-painting When combined with aluminum powder, it can create Alumide,

another common material in 3D printing

Laywood (FFF) - filament

Laywood- specially for FFF. Filament form. Wood/polymer composite The prints actually look and smell like wood and post-processing

presents various options, as the prints can be sanded, grinded and painted like standard wooden products.

It’s very popular to those who are interested in art and design and who are bored of printing just plastic.

Manufacturer recommends to print at 175°C and 250°C. Interestingly, different printing temperatures cause different texture and color, so interesting and artistic textures that change by layers

The filament is fragile so it must be carefully handled. If the user wants, laywood can be printed in smooth surfaces with layers unnoticeable.

Materials Ceramics: Silica/Glass Porcelain Silicon-Carbide Strong, but after printing, need to go under firing, glazing.

Paper: Easily obtainable, cost effective Safe, Environmentally friendly, recyclable Requires no post-processing

Materials

Metals: Aluminum, cobalt Stainless Steel-most common.

powder (sintering, melting, EBM) Gold, silver-powder. Very strong Titanium-powder (sintering, melting,

EBM) the strongest metal.

Materials Bio Materials: Being researched. Living tissues, can make human body parts

Food: Chocolate, Pasta and meat. Pizza!

Physical computing How humans interact/

communicate through computers.

Interactive physical systems by the use of software and hardware that can sense and respond to the analog world.

https://en.wikipedia.org/wiki/Physical_computing

Digital Fabrication Process that joins design

with construction/production

3D printing is a major part of digital fabrication

Community sharing

Shape Engine: A 3D printing sharing platform that connects 3D printer owners and 3D printer users without a printer.

Makerspace: Areas people gather to create, share skills, supplies, ideas, work on project.

Fablab: originated at MIT’s Center for Bits and Atoms (CBA) by Professor Neil Gershenfeld

Fab Labs provide access to digital fabrication. “Give ordinary people the right tools, and they will

design and build the most extraordinary things.” Thingiverse: Webite sharing of user-created digital

design files. Providing primarily open source hardware designs

Shape Engine

3D printing sharing platform where 3D printer owners can take advantage of the printer’s idle time by sharing the printers to customers and making profit.

People who want to 3D print but don’t own a 3D printer can use Shape Engine to connect to a local 3D printer owner and become a customer by ordering the owner to print a product, then picking it up with a payment.

Shape Engine also provides help with 3D modeling to anyone who needs help so people who aren’t skilled with 3D modeling can use Shape Engine to receive help and successfully print their desired products.

Makerbot Thingiverse

Biggest website for sharing 3D files. People share open source hardware designs licensed under the GNU

General Public License or Creative Commons licenses. (The license allows anyone to share, change, and save the files, as long as it is in the boundary set by the owner

Numerous projects and maker communities

use Thingiverse, with a big one being the

RepRap project.

Number of items on Thingiverse:

3D Hubs

Uses the same concept as Shape Engine. People can upload 3D designs, choose a printer location, and

print their desired products

Largest network for 3D printers. 100 new printers per week. 15,000 locations in 140 countries, providing over 1 billion people

access to a 3D printer within 10 miles of their home

3d printed guns

Defense Distributed – open-source organization that designs weapons that can be downloaded and 3D printed.

Liberator – first fully 3d printable gun, available for download on the internet. May 6, 2013

It was downloaded 100,000 times in just 2 days after its upload. US Department of State demanded it the Liberator to be taken

down from the internet 3 days later in May 9, 2013. However, it was too late: there were already 100,000 downloads that people downloaded world wide.

It was a big issue in the sensitive field of Unite States’

gun control, and attracted lots of attention to

3D printing.

3d printed food

Mechanical engineer Anjan Contractor won a $125,000 grant last year to build a prototype 3D printer designed to print food for astronauts on long missions.

He printed a pizza with his open-source RepRap Mendel 3D printer

Anti-gravity 3d printing Made in Space has made the “Zero-G Printer”   Launched into orbit on September 21, 2014.

Mataerial makes 3d printers that print without gravity, and freely prints without the need for a flat printing surface.

Plastic extruded from the printer solidifies instantly, allowing to draw freeform shapes in the air from any surface, (a wall or a ceiling)

Zero-G Printer

3D printing in the medical field

South Korean doctors of Yonsei University Severance hospital successfully implanted 3D printed pelvis in teenage patient, March 2015. Customized implant significantly shortened the surgery time and allowed patient to heal faster.

Kyoto University successfully transplanted 3D-printed spines (with titanium powder) in 4 patients.

RepRap project

Invented by 아드리언 Adrian Bowyer, RepRap (Replicating Rapid-prototype) is a (as in “free” software)free desktop 3d printer that is capable of printing many of its own parts.

The goal of RepRap is to create an affordable, self-replicating machine that will spread around the world to let people create not only various goods, but also the machines themselves so that they could “give one to a friend”. But the current reality is far from the goal, the machines being extremely expensive and only able to print about half of its parts. The RepRap team is working to make the machines accessible to communities in the developing world and individuals in the developed world.

RepRap was the first of the low-cost 3D printers, and the RepRap Project started the open-source 3D printer revolution. It has become the most widely-used 3D printer among the global members of the Maker Community.

Source: Moilanen, J. & Vadén, T.: Manufacturing in motion: first survey on the 3D printing community, Statistical Studies of Peer Production.

The impact of 3D printing. 3Dprinting revolutionized the prototype manufacturing industry.

3d printing shortened the time of prototype production by 1/7 and the cost by 1/8. Through 3D printing, we are able to manufacture faster and cheaper than ever. With the recent uses of 3D printing, its demand is increasing in the manufacturing field, where 3D printing has various applications, like producing tools needed in medical apparatus manufacturing such as jig and fixture.

Source:MEDICAL DEVICE & DIAGNOSTIC INDUSTRY, January 2009

Cost of 3D printing. According to a survey, one of the biggest obstacle in using 3D printers

was the high price of the printers. (31.5% of the response)

Also, producing goods like prototypes and models takes at least 200$, making it is hard for ordinary people to use.

Domestic mockup/prototype manufacturing prices

NC manufacturing (design mockup)

At least 200$

CNC manufacturing(working mockup)

At least 500$

3D planning/ business planning

At least 1000$

Product Development At least 3000$

Growing market of 3d printing

Allied Market Research (AMR) projects that the 3D printing market will grow from $2.3B in 2013 to $8.6B in 2020

3D printing will impact all major industries.

Siemens prediction of future 3D printing:

Market by industries

Market growth

3D printing in manufacturers 67% of manufacturers surveyed are currently implementing 3D printing

either in full production or pilot and 25% intend to adopt 3D printing in the future.

92% of manufacturers using/ going to use 3D printers

Distribution Hardware/software:

Ateam Ventures

Stratasys

Makerbot

Autodesk

3Ds Systems

WYNIT

Retailer:

Lulzbot

Amazon, ebay

Internet/software:

HP, microsoft

Google, intel

http://www.forbes.com/sites/louiscolumbus/2015/08/11/mobile-driving-more-dollars-in-tech-84-of-execs-say-they-will-meet-or-beat-revenue-targets/