Seminar Report

On
3D PRINTING
Submitted in partial fulfillment of the requirements for the
award of degree of
BA!"#$R $% T"!N$#$G&
In
Instrumentation and ontrol "ngineering
Guide: Submitted By:-
Mrs. AEKTA SINGH Srian !pad"yay #$%&'$&$($'')



*epartment o+ Instrumentation , -ontro. En/ineerin/
A'IT& S!$$# $% "NGIN""RING ( T"!N$#$G&
GGS Indraprastha )ni*ersit+, New Delhi
-./001./023
1
"RTI%IAT"
T"is is to 0erti+y t"at t"e seminar report entit.ed 43D PRINTING5 submitted
by-
SRI6AN )PAD!&A& /270/7/3/00
"as been a00omp.is"ed under my /uidan0e.
T"is report is submitted +or partia. +u.+i..ment o+ a1ard o+ de/ree o+ Ba0"e.or
o+ Te0"no.o/y in Instrumentation and -ontro. En/ineerin/ at Amity S0"oo. o+
En/ineerin/ and Te0"no.o/y2 a++i.iated to Guru Gobind Sin/" Indraprast"a
!ni3ersity2 Ne1 *e."i.
*ate: 4&2 September2 4$'& Guide:-
'rs8 Ae9ta Singh
I-E *epartment
Amity S0"oo. o+ En/ineerin/ , Te0"no.o/y
Bi1asan2 Ne1 *e."i- 5'

2
A:N$;#"DG"'"NT
I ta6e t"is opportunity to e7press my pro+ound /ratitude and deep re/ards to Dr8 Re9ha
Aggarwal -Dire<tor, Amit+ S<hool of "ngineering and Te<hnolog+, Delhi3 +or "er
en0oura/ement and inspirin/ me to do t"e best o+ my abi.ity.
I 1ou.d a.so .i6e to t"an6 our esteemed 's8 Pin9i Na+a9 and 's8 Bindu "8 -!$D,
Department of Instrumentation and ontrol "ngineering, AS"T, Delhi3, +or t"eir
support and /uidan0e t"ey "ad /i3en me time to time.
I ta6e t"is opportunity to e7press my /ratitude and deep re/ards to my /uide 'rs8 Ae9ta
Singh -Assistant Professor, Department of "le<troni<s and ommuni<ation
"ngineering, AS"T, Delhi3 +or "er e7emp.ary /uidan0e2 monitorin/ and 0onstant
en0oura/ement t"rou/"out t"e 0ourse

SRI6AN )PAD!&A&
-/270/7/3/003
3
ABSTRAT
(* printin/ is a +orm o+ additi3e manu+a0turin/ te0"no.o/y 1"ere a t"ree dimensiona.
obe0t is 0reated by .ayin/ do1n su00essi3e .ayers o+ materia.. It is a.so 6no1n as rapid
prototypin/2 is a me0"ani8ed met"od 1"ereby (* obe0ts are 9ui06.y made on a reasonab.y
si8ed ma0"ine 0onne0ted to a 0omputer 0ontainin/ b.ueprints +or t"e obe0t. T"e (*
printin/ 0on0ept o+ 0ustom manu+a0turin/ is e70itin/ to near.y e3eryone. T"is re3o.utionary
met"od +or 0reatin/ (* mode.s 1it" t"e use o+ in6et te0"no.o/y sa3es time and 0ost by
e.iminatin/ t"e need to desi/n: print and /.ue to/et"er separate mode. parts. No12 you 0an
0reate a 0omp.ete mode. in a sin/.e pro0ess usin/ (* printin/. T"e basi0 prin0ip.es in0.ude
materia.s 0artrid/es2 +.e7ibi.ity o+ output2 and trans.ation o+ 0ode into a 3isib.e pattern. T"e
(* printin/ 0on0ept o+ 0ustom manu+a0turin/ is e70itin/ to near.y e3eryone. T"is
re3o.utionary met"od +or 0reatin/ (* mode.s 1it" t"e use o+ in6et te0"no.o/y sa3es time
and 0ost by e.iminatin/ t"e need to desi/n: print and /.ue to/et"er separate mode. parts.
No12 you 0an 0reate a 0omp.ete mode. in a sin/.e pro0ess usin/ (* printin/. T"e basi0
prin0ip.es in0.ude materia.s 0artrid/es2 +.e7ibi.ity o+ output2 and trans.ation o+ 0ode into a
3isib.e pattern8
(* ;rinters are ma0"ines t"at produ0e p"ysi0a. (* mode.s +rom di/ita. data by printin/
.ayer by .ayer. It 0an ma6e p"ysi0a. mode.s o+ obe0ts eit"er desi/ned 1it" a -A* pro/ram
or s0anned 1it" a (* S0anner. It is used in a 3ariety o+ industries in0.udin/ e1e..ery2
+oot1ear2 industria. desi/n2 ar0"ite0ture2 en/ineerin/ and 0onstru0tion2 automoti3e2
aerospa0e2 denta. and medi0a. industries2 edu0ation and 0onsumer produ0ts.
T+pi<al 3D printer= (* ;rinters are ma0"ines t"at produ0e p"ysi0a. (* mode.s +rom
di/ita. data by printin/ .ayer by .ayer. It 0an ma6e p"ysi0a. mode.s o+ obe0ts eit"er
desi/ned 1it" a -A* pro/ram or s0anned 1it" a (* S0anner. It is used in a 3ariety o+
industries in0.udin/ e1e.ry2 +oot1ear2 industria. desi/n2 ar0"ite0ture2 en/ineerin/ and
0onstru0tion2 automoti3e2 aerospa0e2 denta. and medi0a. industries2 edu0ation and 0onsumer
produ0ts.
4
TAB#" $% $NT"NTS
TIT#" PAG" N$8
-ERTI<I-ATE I
A-KNO=>E*GEMENT II
ABSTRA-T III
>IST O< <IG!RES I?

': Introdu0tion @
'.': Typi0a. (* ;rinter @
4: History o+ (* ;rintin/ A
(: -urrent (* ;rintin/ Te0"no.o/ies '$
(.': Stereo .it"o/rap"y '$
(.4: Se.e0ti3e .aser sinterin/ #S>S) '$
(.(: Mu.ti-et mode.in/ #MBM) '$
(.&: In6et (* printin/ ''
&: Manu+a0turin/ a mode. 1it" t"e (* ;rinter '4
&.': A./orit"m '4
%: =or6+.o1 '(
5: ;ro0ess '&
5.': -A* ;reparation #;re ;ro0ess) '&
5.4: (* ;rintin/ '%
5.(: -.eanin/ (* ;rintouts '5
5.(.': ;o1der Remo3a. 'C
5.(.4: Heatin/ 'C
5
5.(.(: <inis"in/ Tou0" '@
C: Bene+its o+ (* ;rintin/ 'A
@: App.i0ations 4$
@.': *esi/n ;rototypes 4$
@.4: Edu0ation 4'
@.(: Hea.t" 44
A: (* ;rintin/ Su00ess Stories 4(
'$: -on0.usion 4%
''. Re+eren0es 45
#IST $% %IG)R"S
6
<IG!RE &.'.' : A./orit"m '4
<IG!RE %.' : =or6+.o1 '(
<IG!RE 5.'.' : -A* ;reparation #;re ;ro0ess) '&
<IG!RE 5.4.' : (* ;rintin/ '%
<IG!RE 5.(.' : -.eanin/ (* ;rintouts '5
<IG!RE 5.(.'.': ;o1der Remo3a. 'C
<IG!RE 5.(.'.4: Heatin/ '@
<IG!RE 5.(.'.(: <inis"in/ Tou0" 4$
<IG!RE @.'.' : *esi/n ;rototypes 4'
<IG!RE @.4.' : Edu0ation 44
<IG!RE @.(.' : Hea.t"0are 4(
<IG!RE A.'-A.4 : (* ;rintin/ Su00ess Stories 4&
08 INTR$D)TI$N T$ 3D PRINTING
7
(* printin/ is a +orm o+ additi3e manu+a0turin/ te0"no.o/y 1"ere a t"ree dimensiona.
obe0t is 0reated by .ayin/ do1n su00essi3e .ayers o+ materia.. It is a.so 6no1n as rapid
prototypin/2 is a me0"ani8ed met"od 1"ereby (* obe0ts are 9ui06.y made on a reasonab.y
si8ed ma0"ine 0onne0ted to a 0omputer 0ontainin/ b.ueprints +or t"e obe0t. T"e (*
printin/ 0on0ept o+ 0ustom manu+a0turin/ is e70itin/ to near.y e3eryone. T"is re3o.utionary
met"od +or 0reatin/ (* mode.s 1it" t"e use o+ in6et te0"no.o/y sa3es time and 0ost by
e.iminatin/ t"e need to desi/n: print and /.ue to/et"er separate mode. parts. No12 you 0an
0reate a 0omp.ete mode. in a sin/.e pro0ess usin/ (* printin/. T"e basi0 prin0ip.es in0.ude
materia.s 0artrid/es2 +.e7ibi.ity o+ output2 and trans.ation o+ 0ode into a 3isib.e pattern.
080 T+pi<al 3D Printer
(* ;rinters are ma0"ines t"at produ0e p"ysi0a. (* mode.s +rom di/ita. data by printin/
.ayer by .ayer. It 0an ma6e p"ysi0a. mode.s o+ obe0ts eit"er desi/ned 1it" a -A* pro/ram
or s0anned 1it" a (* S0anner. It is used in a 3ariety o+ industries in0.udin/ e1e.ry2
+oot1ear2 industria. desi/n2 ar0"ite0ture2 en/ineerin/ and 0onstru0tion2 automoti3e2
aerospa0e2 denta. and medi0a. industries2 edu0ation and 0onsumer produ0ts.
8
.8 !IST$R& $% 3D PRINTING
T"e te0"no.o/y +or printin/ p"ysi0a. (* obe0ts +rom di/ita. data 1as +irst de3e.oped by
-"ar.es Hu.. in 'A@&. He named t"e te0"ni9ue as Stereo .it"o/rap"y and obtained a patent
+or t"e te0"ni9ue in 'A@5.
="i.e Stereo .it"o/rap"y systems "ad be0ome popu.ar by t"e end o+ 'A@$s2 ot"er simi.ar
te0"no.o/ies su0" as <used *eposition Mode.in/ #<*M) and Se.e0ti3e
>aser Sinterin/ #S>S) 1ere introdu0ed.
In 'AA(2 Massa0"usetts Institute o+ Te0"no.o/y #MIT) patented anot"er te0"no.o/y2 named
D( *imensiona. ;rintin/ te0"ni9uesD2 1"i0" is simi.ar to t"e in6et te0"no.o/y used in 4*
;rinters.
In 'AA52 t"ree maor produ0ts2 DGenisysD +rom Stratasys2 DA0tua 4'$$D +rom (*
Systems and DE&$4D +rom E -orporation 1ere introdu0ed. In 4$$%2 E -orp. .aun0"ed a
brea6t"rou/" produ0t2 named Spe0trum E%'$2 1"i0" 1as t"e +irst "i/" de+inition 0o.or (*
;rinter in t"e mar6et.
Anot"er brea6t"rou/" in (* ;rintin/ o00urred in 4$$5 1it" t"e initiation o+ an open sour0e
proe0t2 named Reprap2 1"i0" 1as aimed at de3e.opin/ a se.+-rep.i0atin/ (* printer.
9
38 )RR"NT 3D PRINTING T"!N$#$GI"S
380 Stereo lithograph+=
Stereo .it"o/rap"i0 (* printers #6no1n as S>As or stereo .it"o/rap"y apparatus) position a
per+orated p.at+orm ust be.o1 t"e sur+a0e o+ a 3at o+ .i9uid p"oto 0urab.e po.ymer. A !?
.aser beam t"en tra0es t"e +irst s.i0e o+ an obe0t on t"e sur+a0e o+ t"is .i9uid2 0ausin/ a 3ery
t"in .ayer o+ p"otopo.ymer to "arden. T"e per+orated p.at+orm is t"en .o1ered 3ery s.i/"t.y
and anot"er s.i0e is tra0ed out and "ardened by t"e .aser. Anot"er s.i0e is t"en 0reated2 and
t"en anot"er2 unti. a 0omp.ete obe0t "as been printed and 0an be remo3ed +rom t"e 3at o+
p"otopo.ymer2 drained o+ e70ess .i9uid2 and 0ured.
<used deposition mode.in/ - Here a "ot t"ermop.asti0 is e7truded +rom a temperature-
0ontro..ed print "ead to produ0e +air.y robust obe0ts to a "i/" de/ree o+ a00ura0y.
38. Sele<ti*e laser sintering -S#S3
T"is bui.ds obe0ts by usin/ a .aser to se.e0ti3e.y +use to/et"er su00essi3e .ayers o+ a
0o06tai. o+ po1dered 1a72 0erami02 meta.2 ny.on or one o+ a ran/e o+ ot"er materia.s.
383 'ulti1>et modeling -'6'3
T"is a/ain bui.ds up obe0ts +rom su00essi3e .ayers o+ po1der2 1it" an in6et-.i6e print
"ead used to spray on a binder so.ution t"at /.ues on.y t"e re9uired /ranu.es to/et"er. T"e
?-<.as" printer2 manu+a0tured by -anon2 is .o1-0ost (* printer. ItFs 6no1n to bui.d .ayers
1it" a .i/"t-0urab.e +i.m. !n.i6e ot"er printers2 t"e ?<.as" bui.ds its parts +rom t"e top
do1n.
*es6top <a0tory is a startup .aun0"ed by t"e Idea .ab in0ubator in ;asadena2
-a.i+ornia.
<abG"ome, an e7perimenta. proe0t based at -orne.. !ni3ersity2 uses a syrin/e to deposit
materia. in a manner simi.ar to <*M. T"e
ine7pensi3e syrin/e ma6es it easy to e7periment 1it" di++erent materia.s +rom /.ues to 0a6e
+rostin/.
10
387 In9>et 3D printing
It 0reates t"e mode. one .ayer at a time by spreadin/ a .ayer o+ po1der #p.aster2 or resins)
and in6et printin/ binder in t"e 0ross-se0tion o+ t"e part. It is t"e most 1ide.y used (-*
;rintin/ te0"no.o/y t"ese days and t"e reasons beyond t"at are stated be.o1.
T"is te0"no.o/y is t"e on.y one

t"at
A..o1s +or t"e printin/ o+ +u.. 0o.or prototypes.
!n.i6e stereo .it"o/rap"y2 in6et (* printin/ is optimi8ed +or speed2 .o1 0ost2 and
ease-o+-use.
No to7i0 0"emi0a.s .i6e t"ose used in stereo .it"o/rap"y are re9uired.
Minima. post printin/ +inis" 1or6 is needed: one needs on.y to use t"e printer itse.+
to b.o1 o++ surroundin/ po1der a+ter t"e printin/ pro0ess.
A..o1s o3er"an/s and e70ess po1der 0an be easi.y remo3ed 1it" an air b.o1er.
11
78 'AN)%AT)RING A '$D"# ;IT! T!" 3D
PRINT"R
T"e mode. to be manu+a0tured is bui.t up a .ayer at a time. A .ayer o+ po1der is
automati0a..y deposited in t"e mode. tray. T"e print "ead t"en app.ies resin in t"e s"ape o+
t"e mode.. T"e .ayer dries so.id a.most immediate.y. T"e mode. tray t"en mo3es do1n t"e
distan0e o+ a .ayer and anot"er .ayer o+ po1er is deposited in position2 in t"e mode. tray.
T"e print "ead a/ain app.ies resin in t"e s"ape o+ t"e mode.2 bindin/ it to t"e +irst .ayer.
T"is se9uen0e o00urs one .ayer at a time unti. t"e mode. is 0omp.ete
780 A#G$RIT!'
T"e a./orit"m used in t"e In6et (-* ;rintin/ is depi0ted in t"e +i/ure mentioned be.o1.
%IG)R" 78080
12
28 ;$R: %#$;
T"e 1or6+.o1 0an be easi.y understood 1it" t"e "e.p o+ t"e +.o10"art /i3en be.o1.
A (-* prototype o+ a desired obe0t is 0reated in t"ree basi0 steps and t"ese steps are:
;re-;ro0ess
(-* ;rintin/
;ost-;ro0ess
%IG)R" 280
13
?8 PR$"SS
?80 AD Preparation -Pre1Pro<ess3
omputer1aided design #AD)2 a.so 6no1n as 0omputer-aided desi/n and dra+tin/
#-A**)2 is used to prepare a (-* or 4-* mode. o+ t"e desired obe0t. Modern -A*
pa06a/es 0an a.so +re9uent.y a..o1 rotations in t"ree dimensions2 a..o1in/ 3ie1in/
o+ a desi/ned obe0t +rom any desired an/.e.
Most (* printers re9uire a spe0ia. +i.e #typi0a..y .st. +ormat) to print. Additiona..y2
1e need to modi+y t"e desi/n to ma6e up +or .imitations o+ t"e printer and bui.d
materia..
<IG!RE 5.'.'
?8. 3D Printing=
T"e (* printer runs automati0a..y2 depositin/ materia.s at .ayers H.$$(I t"i06. T"is
is rou/".y t"e t"i06ness o+ a "uman "air or s"eet o+ paper. T"e time it ta6es to print
a /i3en obe0t depends primari.y on t"e "ei/"t o+ t"e desi/n2 but most desi/ns ta6e a
14
minimum o+ se3era. "ours. T"e a3era/e 0ost +or printin/ a +u.. 0o.or prototype is
some1"ere bet1een %$ - '$$ J.
<IG!RE 5.4.'
?83 leaning 3D Printouts -Post1Pro<ess3=
E3ery (* printer uses some sort o+ materia. to support parts o+ t"e desi/n t"at "a3e
an o3er"an/. Some printers use a .oose po1der 1"i0" 0an be b.o1n o++ and reused
in +uture mode.s.
15
<IG!RE 5.(.'
?8380 Powder Remo*al=
T"is is t"e s0u.pture 1it" most o+ t"e support dust remo3ed and it is t"en dipped in
spe0ia. /.ue t"at ma6es t"em stron/er and more 0o.or+u..
<IG!RE 5.(.'.'
16
?838. !eating
T"e mode.s are "eated to set t"e /.ue. It is +unny to see t"e o3en in t"is pi0ture is a
standard 0onsumer /rade.
%IG)R" ?838.80
?8383 %inishing Tou<hes
T"e output o+ a.. e7istin/ (* printers is rou/". T"e te7tures 3ary +rom pronoun0ed
K1ood /rainL to mere.y KsandyL2 =it" a .itt.e e.bo1 /rease you 0an /et stunnin/
resu.ts.
<IG!RE 5.(.(.'
17
@8 B"N"%ITS $% 3D PRINTING
T"e most su00ess+u. 0ompanies "a3e adopted (* printin/ as a 0riti0a. part o+ t"e iterati3e
desi/n pro0ess to:
In0rease Inno3ation
;rint prototypes in "ours2 obtain +eedba062 re+ine desi/ns and repeat t"e 0y0.e unti.
desi/ns are per+e0t.
Impro3e -ommuni0ation
Ho.d a +u.. 0o.or2 rea.isti0 (* mode. in your "ands to impart in+inite.y more
in+ormation t"an a 0omputer ima/e.
-reate p"ysi0a. (* mode.s 9ui06.y2 easi.y and a++ordab.y +or a 1ide 3ariety o+
app.i0ations.
Speed Time to Mar6et
-ompress desi/n 0y0.es by (* printin/ mu.tip.e prototypes on demand2 ri/"t in
your o++i0e.
Redu0e *e3e.opment -osts
-ut traditiona. prototypin/ and too.in/ 0osts.
Identi+y desi/n errors ear.ier.
18
Redu0e tra3e. to produ0tion +a0i.ities.
=in Business
Brin/ rea.isti0 (* mode.s to prospe0ti3e a00ounts2 sponsors and +o0us /roups
A8 APP#IATI$NS
A80 Design Protot+pes=
(-*imensiona. ;rintin/ 0on0ept mode.2 +un0tiona. prototypes and presentation
mode.s +or e3a.uatin/ and re+inin/ desi/n2 in0.udin/ <inite E.ement Ana.ysis #<EA)
resu.ts and pa06a/in/.
<IG!RE @.'.'
Now, here we ha*e <reated a dumm+ of a No9ia mobile phone for further stud+
and demonstration=
Si8e: (.% 7 4 7 $.C in0"es
#A 7 % 7 4 0m)
19
;rintin/ Time: $.% "ours
A8. "du<ation=
En/a/e students by brin/in/ di/ita. 0on0epts into t"e rea. 1or.d2 turnin/ t"eir ideas
into rea.-.i+e (* 0o.or mode.s t"at t"ey 0an a0tua..y "o.d in t"eir "ands.
!ere an ele<troni< de*i<e <ir<uit has <ome to life with the help of a 31D Printer=
Si8e: @ 7 % 7 4.% in0"es
#4$ 7 '( 7 5 0m)
;rintin/ Time: ( "ours
20
<IG!RE @.4.'
A83 !ealth<are=
Rapid.y produ0e (* mode.s to redu0e operatin/ time2 en"an0e patient and p"ysi0ian
0ommuni0ations2 and impro3e patient out0omes.
A 31D Protot+pe of the horiBontal <rosse<tion of a human s9ull has been
prepared to allow its better stud+=
Si8e: A.@ 7 C.A 7 (.A in0"es
#4% 7 4$ 7 '$ 0m)
;rintin/ Time: %.% "ours
21
<IG!RE @.(.'
C8 3D PRINTING S)"SS ST$R&
-amera mounts +or t"e M' tan6 and Brad.ey +i/"tin/ 3e"i0.e 1ere bui.t and tested
dire0t.y +rom di/ita. +i.es usin/ t"e *imension (* ;rinter.
22
<IG!RE A.'
A (* printer pro3ed to be a 3a.uab.e asset and p.ayed a 6ey ro.e in de3e.opin/ t"e
0on0epts +or t"e AM; Resear0" A..oy <ue. *oor +or Genera. MotorsM Hummer H4
sport uti.ity 3e"i0.e.
23
<IG!RE A.4
0/8 $N#)SI$N
24
Not"in/ 0ommuni0ates ideas +aster t"an a t"ree-dimensiona. part or mode.. =it" a
(* printer you 0an brin/ -A* +i.es and desi/n ideas to .i+e N ri/"t +rom your
des6top. Test +orm2 +it and +un0tion N and as many desi/n 3ariations as you .i6e N
1it" +un0tiona. parts.
In an a/e in 1"i0" t"e ne1s2 boo6s2 musi02 3ideo and e3en our 0ommunities are a..
t"e sube0ts o+ di/ita. demateria.i8ation2 t"e de3e.opment and app.i0ation o+ (*
printin/ reminds us t"at "uman bein/s "a3e bot" a p"ysi0a. and a psy0"o.o/i0a.
need to 6eep at .east one +oot in t"e rea. 1or.d. (* printin/ "as a bri/"t +uture2 not
.east in rapid prototypin/ #1"ere its impa0t is a.ready "i/".y si/ni+i0ant)2 but a.so in
medi0ine t"e arts2 and outer spa0e. *es6top (* printers +or t"e "ome are a.ready a
rea.ity i+ you are prepared to pay +or one andOor bui.d one yourse.+. (* printers
0apab.e o+ outputtin/ in 0o.or and mu.tip.e materia.s a.so e7ist and 1i.. 0ontinue to
impro3e to a point 1"ere +un0tiona. produ0ts 1i.. be ab.e to be output. As de3i0es
t"at 1i.. pro3ide a so.id brid/e bet1een 0yberspa0e and t"e p"ysi0a. 1or.d2 and as
an important mani+estation o+ t"e Se0ond *i/ita. Re3o.ution2 (* printin/ is
t"ere+ore .i6e.y to p.ay some part in a.. o+ our +utures.
008 R"%R"N"S
Arti0.es:
25
The object of 3D printing
P+rom Ad3ertisin/ , Mar6etin/ Re3ie1
Printers produce copies in 3D +rom BB- NE=S
'Gadget printer' promises industrial revolution
N+rom Ne1S0ientist.0om
<rom di++erent 1ebsites in0.udin/ dimensionprintin/.0om2
en.1i6ipedia.or/O1i6iO3DQprinting, et0.
Maor (* printer 0ompanies:
Z Corporation
3D Sstem
!press3D
*imensions ;rintin/
26