UNIT 1

 Digital modeling and fabrication is a design and

production process that combines 3D modeling or
computing-aided design with additive and subtractive
manufacturing
  Definition –
 Additive manufacturing is the official industry standard term (ASTM
F2792) for all applications of the technology. It is defined as the
process of joining materials to make objects from 3D model data,
usually layer upon layer, as opposed to subtractive manufacturing
methodologies.

 3D printing machines to date use a layer-based approach; and the

major ways that they differ are in the materials that can be used, how
the layers are created, and how the layers are bonded to each other.

 Such differences will determine factors like the accuracy of the final
part plus its material properties and mechanical properties.
 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 machine and process.

 Models were quickly employed to supply information about what is known as

the “3 Fs” of Form, Fit, and Function.

 The initial 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). Engineering
tolerance is the permissible variation in measurements deriving from the base measurement.

 Improved material properties meant that parts could be properly handled so

that they could be assessed according to how they would eventually work
(Function).
 LIQUID POLYMER SYSTEMS
 The first commercial system was the 3D Systems Stereolithography
process based on liquid photopolymers. A large portion of systems
in use today are, in fact, not just liquid polymer systems but more
specifically liquid photopolymer systems. However, this
classification should not be restricted to just photopolymers, since
a number of experimental systems are using hydrogels that would
also fit into this category.
 Droplet deposition of polymers using an array of 1D channels can
simplify the curing process to a floodlight (for photopolymers) or
similar method. Controlling the area to be exposed using digital
micro-mirror devices (DMD) or other high-resolution display
technology obviates the need for any scanning at all, thus
increasing throughput and reducing the number of moving parts.
 Classification of 3D Printing
 Discrete Particle Systems
 Discrete particles are normally powders that are generally graded into a
relatively uniform size and shape and narrow distribution. The finer the
particles the better, but there will be problems if the dimensions get too
small in terms of controlling the distribution and dispersion. Again, the
conventional 1D channel approach is to use a laser, this time to produce
thermal energy in a controlled manner and, therefore, raise the
temperature sufficiently to melt the powder.
 Polymer powders must therefore exhibit thermoplastic behavior so that
they can be melted and re-melted to permit bonding of one layer to
another. There are a wide variety of such systems that generally differ in
terms of the material that can be processed.
 The two main polymer-based systems commercially available are the
Selective Laser Sintering (SLS) technology marketed by 3D Systems.
Printing technology is used to print a binder, or glue, onto a powder bed.
The glue sticks the powder particles together to form a 3D structure. This
basic technique has been developed for different applications dependent
on the type of powder and binder combination.
 Classification of 3D Printing

 Molten Material Systems

 Molten material systems are characterized by a pre-heating chamber that
raises the material temperature to melting point so that it can flow
through a delivery system. The most well-known method for doing this is
the Fused Deposition Modeling system. Two extrusion heads are often
used so that support structures can be fabricated from a different material
to facilitate part cleanup and removal.
 Supports are removed by inserting the complete part into a temperature-
controlled bath that melts the support material away, leaving the part
material intact.
 Classification of 3D Printing

 Solid Sheet Systems

 One of the earliest AM technologies was the Laminated Object
Manufacturing (LOM) system. This technology used a laser to cut out
profiles from sheet paper, supplied from a continuous roll, which formed
the layers of the final part. Layers were bonded together using a heat-
activated resin that was coated on one surface of the paper.
 Once all the layers were bonded together the result was very like a
wooden block. A hatch pattern cut into the excess material allowed the
user to separate away waste material and reveal the part.
S.NO 3D PRINTING CNC
3D PRINTING technology was
CNC machining can be used for
originally developed around
soft materials, like medium-
polymeric materials, waxes
density fiberboard (MDF),
1 Material and paper laminates.
machineable foams,
Subsequently, there has been
machineable waxes, and even
introduction of composites,
some polymers
metals, and ceramics.
To make a part in an 3D High speed CNC machining can
PRINTING generally remove material
2 Speed
machine, it may take a few much faster than AM
hours machines
If CNC is being used to create a
part directly in a single piece,
3D PRINTING
3 Complexity then there are some
can build the part all at once.
geometric features that
cannot be fabricated.
S.NO 3D PRINTING CNC

The accuracy of CNC machines

on the other hand is mainly
Accuracy 3D PRINTING
determined by a similar
machines generally operate
4 Accuracy positioning resolution along all
with a resolution of a few tens
three orthogonal axes and by
of microns.
the diameter of the rotary
cutting tools
3D PRINTING
machines essentially break up Perfect geometry can become
a complex, 3D problem into a extremely difficult to produce
5 Geometry
series of simple 2D cross- with CNC, even with 5-axis
sections with a nominal control or greater
thickness
Determining the program
sequence for a CNC machine
3D PRINTING can be very involved, including
6 Programming
don’t require programming tool selection, machine speed
settings, approach position,
and angle, etc
Applications in Aerospace Industry
Engine components of fan jet engine
Prototyping Air Inlet Housing for Gas Turbine Engine
Fabrication of Flight Certified Production Castings

Applications in AutomotiveIndustry
Prototyping complex gear box housing for design verification
Prototyping driving control system
Creating cast metal engine block
Production tooling

Applications in Biomedical Industry

Operation planning for Cancerous Brain Tumor Surgery
Planning reconstructive surgery
Knee Implants
Customized Stents
 Jewellery Applications
Wax patterns used for Invesment casting

 COIN INDUSTRY
Wrapping of the 3D relief onto the coin surface
This is done by wrapping the three-dimensional relief onto the triangular mesh file generated from the coin surfaces.
Pattern of the coin is generated