Department of Mechanical Engineering

ME-303L Manufacturing Processes Lab

Experiment No. 03
Experiment Name: Part Manufacturing using 3D Printing

Name of Student: Muhammad Hanzallah

Signature of Student:
Registration No: BS-21-KB-105392
Date of Experiment: 24 April’2024
Group: G-3

Report Marks: _____ out of 10

Date of Report Submission: 1stMay’2024
Signature of Lab Engineer: __________________
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Table Of Content
1 Abstract .............................................................................................................................. 1
2 Introduction (Background & Theory) ................................................................................ 1
2.1 Historical Background................................................................................................. 1
2.2 Theory (Types of 3D printing) .................................................................................... 1
2.2.1 Stereolithography ................................................................................................. 2
2.2.2 Digital Light Processing (DLP) Technology ....................................................... 2
2.2.3 Fused Deposition Modeling (FDM) Technology ................................................ 3
2.2.4 Selective Laser Sintering (SLS) Technology ....................................................... 3
3 Procedure ........................................................................................................................... 4
3.1 Printer Setup and 3D Printing Process Overview ....................................................... 4
Setting up the printer........................................................................................................... 4
Creating a model .................................................................................................................. 4
Slicing .................................................................................................................................... 4
3.2 Some Basic Setting of Software: ................................................................................. 4
3.3 Foundation ................................................................................................................... 5
4 Analysis and Discussion .................................................................................................... 5
5 Conclusion ......................................................................................................................... 6
6 Sustainability...................................................................................................................... 6
7 References .......................................................................................................................... 8
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List of Figures
Figure 1 : 3D Printer .................................................................................................................. 1
Figure 2 : Stereolithography [2] ................................................................................................. 2
Figure 3 : Fused Deposition Modeling (FDM) Technology [2] ................................................ 3
Figure 4 : Selective Laser Sintering (SLS) Technology [2] ...................................................... 4
Figure 5 : Generated Part using 3D Printer ................................................................................ 6
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1 Abstract
The goal of this experiment was to get an overview of a 3D printer, its parts, working, operation
and typical applications. This branch of additive manufacturing is of extreme importance in the
industries where complicated parts are to be made. The near net shape and the cost effectiveness
of the products make them very attractive for multiple industries. This lab focused on making
a rectangular shape having 2 holes some distance apart, which helped to cover key areas and
operations in 3D printing. A slicing software named Craft Bot was used and then 3D printed.
The part produced didn’t have the perfect shape and have minor several distortions.

2 Introduction (Background & Theory)

3D printing or additive manufacturing (AM) is any of various processes for making a three-
dimensional object of almost any shape from a 3D model or other electronic data source
primarily through additive processes in which successive layers of material are laid down under
computer control. 3D Printers are machines that produce physical 3D models from digital data
by printing layer by layer. It can make physical models of objects either designed with a CAD
program or scanned with a 3D Scanner. It is used in a variety of industries including jewelry,
footwear, industrial design, architecture, engineering and construction, automotive, aerospace,
dental and medical industries, education and consumer products.

Figure 1 : 3D Printer

2.1 Historical Background

The technology for printing physical 3D objects from digital data was first developed by
Charles Hull in 1984. He named the technique as Stereo lithography and obtained a patent for
the technique in 1986. While Stereo lithography systems had become popular by the end of
1980s, other similar technologies such as Fused Deposition Modeling (FDM) and Selective
Laser Sintering (SLS) were introduced.
Another breakthrough in 3D Printing occurred in 2006 with the initiation of an open-source
project, named Reprap, which was aimed at developing a self-replicating 3D printer.
2.2 Theory (Types of 3D printing)
The theory section contains the important types of 3D Printer.
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2.2.1 Stereolithography
SLA is a fast-prototyping process. Those who use this technology are serious about accuracy
and precision. It can produce objects from 3D CAD data (computer-generated) files in just a
few hours. This is a 3D printing process that’s popular for its fine details and exactness.
Machines that use this technology produce unique models, patterns, prototypes, and various
production parts. They do this by converting liquid photopolymers (a special type of plastic)
into solid 3D objects, one layer at a time. The plastic is first heated to turn it into a semi-liquid
form, and then it hardens on contact. The printer constructs each of these layers using an
ultraviolet laser, directed by X and Y scanning mirrors. Just before each print cycle, a recoated
blade moves across the surface to ensure each thin layer of resin spreads evenly across the
object. The print cycle continues in this way, building 3D objects from the bottom up.
Once completed, someone takes the 3D object from the printer and detaches it carefully from
the platform. The 3D part will usually have a chemical bath to remove any excess resin. It’s
also common practice to post-cure the object in an ultra violet oven. What this does is render
the finished item stronger and more stable. Depending on the part, it may then go through a
hand sanding process and have some professional painting done. SLA printing has become a
favored economical choice for a wide variety of industries. Some of these include automotive,
medical, aerospace, entertainment, and also to create various consumer products. [1]

Figure 2 : Stereolithography [2]

2.2.2 Digital Light Processing (DLP) Technology

DLP is the oldest of the 3D printing technologies, created by a man called Larry Hornbeck back
in 1987. It’s similar to SLA (see above), given that it also works with photopolymers. The
liquid plastic resin used by the printer goes into a translucent resin container. There is, however,
one major difference between the two, which is the source of light. While SLA uses ultra violet
light, DLP uses a more traditional light source, usually arc lamps. This process results in pretty
impressive printing speeds. When there’s plenty of light, the resin is quick to harden (we’re
talking seconds). Compared to SLA 3D printing, DLP achieves quicker print times for most
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parts. The reason it’s faster is because it exposes entire layers at once. With SLA printing, a
laser has to draw out each of these layers, and this takes time. [3]

2.2.3 Fused Deposition Modeling (FDM) Technology

In FDM is a 3D printing process developed by Scot, and then implemented by Stratasys Ltd.,
in the 1980s. It uses production grade thermal plastic materials to print its 3D objects. It’s
popular for producing functional prototypes, concept models, and manufacturing aids. It’s a
technology that can create accurate details and boasts an exceptional strength to weight ratio.
Before the FDM printing process begins, the user has to slice the 3D CAD data (the 3D model)
into multiple layers using special software. The sliced CAD data goes to the printer which then
builds the object layer at a time on the build platform. It does this simply by heating and then
extruding the thermoplastic filament through the nozzle and onto the base. The printer can also
extrude various support materials as well as the thermoplastic. For example, as a way to support
upper layers, the printer can add special support material underneath, which then dissolves after
the printing process. As with all 3D printers, the time it takes to print all depends on the objects
size and its complexity. [1]

Figure 3 : Fused Deposition Modeling (FDM) Technology [2]

2.2.4 Selective Laser Sintering (SLS) Technology

An American businessman, inventor, and teacher named Dr. Carl Deckard developed and
patented SLS technology in the mid-1980s. It’s a 3D printing technique that uses high power
CO2 lasers to fuse particles together. The laser sinters powdered metal materials (though it can
utilize other materials too, like white nylon powder, ceramics and even glass). Here’s how it
works:
The build platform, or bed, lowers incrementally with each successive laser scan. It’s a process
that repeats one layer at a time until it reaches the object’s height. There is un-sintered support
from other powders during the build process that surround and protect the model. This means
the 3D objects don’t need other support structures during the build. Someone will remove the
un-sintered powders manually after printing. SLS produces durable, high precision parts, and
it can use a wide range of materials. It’s a perfect technology for fully-functional, end-use parts
and prototypes. SLS is quite similar to SLA technology with regards to speed and quality. The
main difference is with the materials, as SLS uses powdered substances, whereas SLA uses
liquid resins. It’s this wide variety of available materials that makes SLA technology so popular
for printing customized objects. [1]
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Figure 4 : Selective Laser Sintering (SLS) Technology [2]

3 Procedure
Procedure of this experiment is mentioned below:
3.1 Printer Setup and 3D Printing Process Overview
Setting up the printer
o Heat up the printer platform and head to the required temperatures. (Head to the melting
point of ABS, 240 degrees and bed to 110 degrees centigrade)
o Insert the material wire feed into the head and using motor driving levers, lower the wire
into the head
Creating a model
o Create the CAD model of the product that is required to be 3D printed
o Export it as stereolithography file (.stl)
Slicing
o Create a new model in Slicing software Craft Bot
o Import a new part in the environment
o Open settings
o Select the material and the layer height. Rest is to be set automatically.

3.2 Some Basic Setting of Software:

• Resolution: This affects the quality and the look of your objects.
o Extrusion width: Width of a single extruder line.
o Layer height: The smaller the layer height, the better the quality but longer the print
time
• Extruder: The extruder-specific settings.
o Filament diameter: Input the diameter of filament you’ll be using.
• Infill: The infill settings of the model are controlled in this section
o Type: The structure of infill responsible for imparting strength to object.
o Density: The amount of infill you want to extrude material inside the object. A higher
value means improved strength, but also uses more material and takes more time.
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o Width: The extrusion width of a single line of infill. A higher value gives you more
strength
o Angle: The angle of the first layer of infill.
3.3 Foundation
These settings control the initial layers of your model.

o First layer: Denote the first layer settings of the model.

o Height: A higher first layer height, improves bed adhesion.
o Draw speed: Printing speed for the first layer should be slow. This ensures that the
material lays down smoothly and sticks to the bed well.
o Travel speed: The movement of extruder during the first layer. Should be lower than
base setting.
o Temperature: A hotter first layer means a better adhesion to the print surface.
o Skirt: It’s an outline of your printed model for just a single layer. Helps in priming the
nozzle before actual printing begins.
4 Analysis and Discussion
The objective of this experiment was to gain an understanding of 3D printing technology,
including printer setup, software utilization, and the production of a physical model. The
experiment simulated key steps involved in typical 3D printing processes, aiming to replicate
a simple rectangular shape with holes to explore fundamental aspects of additive
manufacturing.
The initial phase involved setting up the 3D printer to specific temperature requirements
suitable for ABS material, which is commonly used in additive manufacturing. Heating the
printer platform and extruder head to precise temperatures (240 degrees Celsius for the extruder
and 110 degrees Celsius for the bed) is crucial to ensure proper material flow and adhesion
during printing. Furthermore, feeding the material wire into the extruder head via motor driving
levers was demonstrated, highlighting the mechanical processes involved in material
deposition.
CAD modeling was employed to design the desired product—a rectangular shape with
strategically placed holes—emphasizing the importance of digital design in additive
manufacturing. The CAD model was then exported as an STL file, a common format
compatible with slicing software used in 3D printing.
The use of slicing software was pivotal in preparing the CAD model for printing. Slicing
involves segmenting the 3D model into layers (or slices) and generating the necessary toolpaths
for the printer. Key settings such as material selection and layer height were specified to
optimize print quality and structural integrity. The slicing process bridges the gap between
virtual design and physical production, demonstrating the critical role of software in additive
manufacturing workflows. Notable considerations include extrusion width, layer height, infill
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type, density, and temperature management, each impacting the physical characteristics of the
printed object.
Generally, the part manufactured was in a roughly precise form. The small uneven surfaces did
occur the printed part. But all in all, there were almost no major errors, cracks and over
extrusions in the part.3D printing technique had great quality and was much cheaper to
manufacture as compared to the traditional techniques of machining. However, during the first
run, the height adjustment of the part was poor, hence the edges of the part being manufactured
were very rough. The part was made better by decreasing the layers height.
The part generated by the 3D printing technique is mentioned below:

Figure 5 : Generated Part using 3D Printer

The part was successfully made using the procedure of 3D printing and almost near net shape
was obtained. There were a few distortions in the final product but all in all, a complicated
shape which would have been very difficult to obtain using subtractive manufacturing.
Precautions
• Keep safe distances from the machine as the temperatures rise to very high degrees
• Prevent burning of skin and other body parts
• Always wear safety goggles and gloves
5 Conclusion
Despite of small deviations from expected results, the experiment was performed successfully,
and the it was learnt how to operate a 3D printer. It was also learnt that additive manufacturing
is the hot topic in the current manufacturing industry as it provides several benefits over
subtractive manufacturing. Apart from that, modal slicing of the model was also learnt. During
the slicing, expert settings of the printers were set which gave a first-hand knowledge of how
to fine tune the final product to one’s liking. It was also learnt how to reduce and overcome
manufacturing defects in common 3D printing methods.
6 Sustainability
3D printers can be considered relatively sustainable compared to traditional manufacturing
methods due to several factors. First, they often result in reduced material waste since they
typically add material layer by layer, creating objects with precise geometries, which can
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minimize the need for excess material and reduce scrap. Additionally, 3D printing allows for
on-demand manufacturing, enabling localized production and potentially reducing
transportation emissions associated with shipping finished products. Furthermore, certain 3D
printing technologies, such as those that use biodegradable or recyclable materials, contribute
to sustainability by offering eco-friendly material options. Overall, while 3D printing has the
potential to be more sustainable.
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7 References

[1] "3D Prinitng- an overview | ScienceDirect Topics," 06 June 2021. [Online]. Available:
https://www.sciencedirect.com/topics/materials-science/3D-Printing. [Accessed 17
March 2024].

[2] "Research Gate," 23 May 2019. [Online]. Available:

https://www.researchgate.net/figure/Simple 3D-Printing-machine_fig1_236836771.
[Accessed 17 March 2024].

[3] "sybridge," 14 October 2023. [Online]. Available: https://sybridge.com/3D-Printers-

errors/. [Accessed 17 March 2024].
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Department of Mechanical Engineering

Pakistan Institute of Engineering and

Applied Sciences (PIEAS)
Experiment Risk and Safety Proforma
Lab: Date:
Equipment code: Equipment Name:

1. Was the experiment safe to perform? ☐Yes☐No

2. Were the working conditions appropriate for the experiment? ☐Yes☐No
Comment (No):

3. Please mention the risks and their severity associated with the experiment performed:
a. Fire/Burn Hazard:☐Applicable☐Not Applicable
• Severity: ☐Low☐Moderate☐High
• Likelihood:☐Low☐Moderate☐High
b. Electrical Hazard: ☐Applicable☐Not Applicable
• Severity: ☐Low☐Moderate☐High
• Likelihood:☐Low☐Moderate☐High
c. Sharp edges / falling items hazard: ☐Applicable☐Not Applicable
• Severity: ☐Low☐Moderate☐High
• Likelihood:☐Low☐Moderate☐High
d. Slippage hazard: ☐Applicable☐Not Applicable
• Severity: ☐Low☐Moderate☐High
• Likelihood:☐Low☐Moderate☐High
e. Any other risk:
• Severity: ☐Low☐Moderate☐High
• Likelihood:☐Low☐Moderate☐High

Student Name and Signature:

Instruction
1. Please report any incident to the concerned lab personnel or lab coordinator
2. This proforma will be a part of the lab report and must be submitted to lab Engineer.