3D Printing

BHAVYA THARAKAN
REVATHY NAIR
KHANDWALA KAVYA DHARIT
PARMAR PRAKASH CHANDUBHAI
DURVA PATEL
 Table of contents
0 0 0
1 2
Component 3
Introduction s Working

0 0 0 0
4 5 6 7
Types Applicatio Pros & Future
ns Cons Scope
 Introduction
3D printing, also known as additive manufacturing, is a
technology that creates physical objects from digital designs
by building them layer by layer.
It enables customized production, allowing the creation of
complex geometries that traditional manufacturing cannot
achieve.

Invented in the 1980s, with Stereolithography (SLA) being the

first commercial 3D printing technology.
Evolved over decades, now used in various industries like
healthcare, aerospace, automotive, and consumer goods.

3D printing enables you to produce complex shapes using less

material than traditional manufacturing methods.
Components of 3D Printer
● Hotend - this is the nozzle that melts the
plastic filament
● Extruder - electric motor and gear assembly
used to push filament through the hot end
● Print Bed - the surface where the 3D
printed part is built on
● XYZ Stepper Motors - In order to print a
desired shape, the hot end must move while
extruding plastic. Most machines come with
3 or 4 stepper motors to handle the motion
● Controller Board - a small computer that
reads the print file (G-Code) and controls the
machine's components to print the desired
object
● Controller Display - small LCD display used
to show information from the Controller
board
● Power Supply - this system is responsible
for taking your household power, converting
it, and making it suitable for the various
 Working of 3D Printers
1. Design
The process begins with a 3D digital model created using CAD software or a
3D scanner.
The model is saved in formats like STL or OBJ for compatibility with 3D
printers.

2. Slicing
Slicing software divides the 3D model into thin horizontal layers.
It generates G-code, which contains precise instructions for the printer,
including:
Layer thickness.
Print speed and temperature.
Path for material deposition.

3. Printing Process
The printer uses the G-code to create the object layer by layer:
FDM Printers: Melt and extrude filament (e.g., PLA, ABS) onto a build plate.
SLA Printers: Use UV light to cure liquid resin into solid layers.
SLS Printers: Fuse powdered material with a laser.
4. Layer Cooling and Solidification
Each layer is deposited and solidifies before the next is added.
Resin-based printers may need additional curing using UV light.

5. Post-Processing
Once printing is complete, additional steps might be needed:
Support removal: For overhangs or intricate designs.
Sanding: To smooth surfaces.
Curing: For resin-based parts to strengthen them.
Finishing: Painting or coating for aesthetics or durability.

Advantages of Layer-by-Layer Construction

Enables creation of highly intricate geometries.
Reduces material waste, making it cost-effective and sustainable.
 Types of 3D Printers
3D
PRINTERS

Fusion
Stereo Laser
Deposition Stereolithography Sintering
Modelling (SLA) (SLS)
(FDM)
 Fused deposition modeling
(FDM)
What is FDM ?
Fused Deposition Modelling (FDM), also known as Fused Filament Fabrication (FFF), is the most
widely used 3D printing technology at the consumer level.
Uses thermoplastic filaments (e.g., ABS and PLA) extruded through a heated nozzle, melting the
material and depositing it layer by layer on a build platform.

Advantages and Limitations

Advantages:
Affordable and accessible for consumers.
Ideal for basic prototypes and general applications.

Limitations:
Lower resolution and accuracy than SLA or SLS.
Not suitable for complex designs or intricate features.
Key Mechanical Elements of FDM
Core Components

1. Extruder:
The main component that melts the filament and pushes it through a nozzle
to deposit molten plastic onto the build plate.

2. Stepper Motors:
Enable precise movement of the print head along the X, Y, and Z axes,
ensuring accurate layer placement.

3. Print Bed:
A heated platform critical for proper adhesion of the first layer of the print.

4. Filament Feed System:

Pulls the filament from the spool and ensures consistent delivery to the
extruder.

5. Nozzle:
The small opening through which melted plastic is dispensed to create
layers.

Build Volume
Defines the maximum printable area constrained by the printer's physical
 Stereo Laser Sintering (SLS)
What is SLS?
Selective Laser Sintering (SLS) is a 3D printing technology that uses a high-power laser to sinter
small particles of polymer powder into a solid structure.
SLS parts have mechanical strength comparable to injection-molded parts, making them
suitable for functional applications.

Key Features
Excellent layer adhesion, contributing to high tensile strength and modulus.
Mechanical properties depend on:
Powder material used.
Fabrication parameters: laser power, scan speed, hatch spacing.
Part orientation during printing.
SLS Mechanical Properties
1. Strength and Stiffness:
High tensile strength and modulus, comparable to the bulk
material of the powder.
Ideal for load-bearing applications.

2. Porosity and Brittleness:

Parts may have internal porosity, leading to lower elongation at
break and increased brittleness compared to solid materials.

3. Material Dependence:
The powder material chosen has a significant impact on final part
performance.

4. Fabrication Parameter Influence:

Parameters like laser power, scan speed, and hatch spacing
determine the degree of sintering and layer fusion.

5. Part Orientation:
Orientation in the build chamber affects strength.
Parts aligned parallel to the build plate generally have better
mechanical properties.
 Stereolithography (SLA)
What is SLA?

Stereolithography (SLA) is the first 3D printing technology, invented in the 1980s,

and remains highly popular among professionals.
Utilizes thermoset polymers (resins) that are solidified using light to create
detailed and accurate 3D objects.

Key Features

Produces parts with a smooth surface finish and high resolution.

Suitable for prototypes and end-use parts requiring high accuracy.
Capable of producing watertight parts for specific applications.
SLA Mechanical Properties
1. Materials:
SLA uses thermoset resins, made up of monomers,
oligomers, and photoinitiators, to form parts through
light-based polymerization.

2. Tensile Strength:
SLA parts have good surface finish but relatively lower
tensile strength compared to other technologies.

3. Accuracy:
Known for exceptional precision, capable of creating
features as small as 0.002 inches.

4. Watertight Capability:
SLA can produce watertight prototypes and functional
parts for applications like fluid flow analysis.
 Applications
1. Prototyping and Product Design

Rapid Prototyping: Allows designers to create quick prototypes to test the form, fit, and function
of products before manufacturing.
Concept Development: Helps in visualizing and refining product concepts without needing
traditional molds or tooling.

2. Manufacturing and Production

Custom Parts: 3D printing enables the production of customized parts, such as for machinery,
tools, or consumer goods, without the need for large-scale production runs.
Low-Volume Manufacturing: Ideal for producing small batches of parts with high complexity that
would be expensive or impossible to manufacture using traditional methods.

3. Consumer Products
Customized Accessories: Creation of custom jewelry, footwear, and eyewear that is designed
specifically to an individual’s preferences and measurements.
Home Decor Items: Production of personalized or unique home decor products, like furniture,
vases, and lighting fixtures.
3. Medical Applications

Prosthetics: Custom-made prosthetics that are tailored to an individual’s specific anatomy,

improving comfort and fit.
Surgical Planning and Models: Doctors use 3D-printed models of organs or bones for pre-surgical
planning, improving accuracy and outcomes.
Bioprinting: Printing tissues and organs for research, drug testing, and potentially for future
transplant options.

4. Aerospace and Automotive Industries

Lightweight Parts: Creation of lightweight but durable components for aircraft and automobiles,
leading to enhanced fuel efficiency and performance.
Spare Parts Production: Printing spare parts on-demand to avoid delays in repairs and maintenance,
reducing inventory costs.

5. Architecture and Construction

Building Models: 3D printing is used for creating detailed, accurate architectural models for
presentations and planning.
Building Components: Large-scale 3D printers can be used to print entire buildings or components,
reducing material waste and labor costs.
1.
 Pros & Cons
Pros Cons
1. Flexible Design: Enables the creation of intricate 1. Limited Material Choices: The selection of
and complex designs that are otherwise difficult to materials, especially metals and plastics, is still not
achieve with traditional methods. exhaustive.

2. Rapid Prototyping: Allows parts or prototypes to 2. Restricted Build Size: Print chambers are small,
be manufactured within hours, speeding up the requiring larger parts to be printed in sections and
design process. joined later.

3. Print on Demand: Reduces the need for large 3. Post-Processing Requirements: Many 3D-printed
stock inventories, saving storage space and costs, parts require additional cleaning and finishing
thus minimise waste processes.

4. Strong and Lightweight Parts: Essential for 4. High Cost for Large Volumes: The cost per unit
industries such as automotive and aerospace, where remains high when scaled for mass production,
these properties are critical. limiting economic feasibility.

5. Fast Design and Production: Accelerates the 5. Layered Part Structure: The layer-by-layer
manufacturing process, especially for complex manufacturing process can cause delamination
objects. under stress.
 Future Trends in 3D Printing
Multi-Material Bioprinting for Sustainability
Printing Healthcare Focus
Advancements in 3D printing 3D bioprinting of tissues and Innovations in large-scale 3D
technology will allow for the organs is expected to printers will expand
simultaneous use of different revolutionize healthcare, with applications in industries like
materials, including metals, potential applications in construction, where entire
polymers, and ceramics, enabling the personalized medicine, buildings and infrastructure
creation of complex and functional prosthetics, and regenerative can be 3D-printed.
products. treatments
Large-Scale Mass Integration with
Printing Customization AI and IoT
Innovations in large-scale 3D 3D printing will enable the AI-driven designs and IoT-
printers will expand production of customized enabled monitoring will
applications in industries like products on a large scale, enhance 3D printing
construction, where entire particularly in fashion, efficiency, quality control, and
buildings and infrastructure consumer electronics, and predictive maintenance.
can be 3D-printed. automotive industries.
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