A

SEMINAR

ON

“3D Metal Printing ”

by

Mr. Biramane Aditya Dhiraj.

Under the guidance of

Prof.

Department of Mechanical Engineering

D. Y. Patil School of Engg Academy, Ambi

SAVITRIBAI PHULE PUNE UNIVERSITY,PUNE

[2020-2021]
 D. Y. PATIL SCHOOL OF ENGINEERING

ACADEMY, AMBI

2020-21

CERTIFICATE
This is to certify that Mr. Biramane Aditya Dhiraj, has successfully completed the

Seminar- entitled “3D Printing” under my supervision, in the partial fulfilment of Third

Year - Mechanical Engineering of University of Pune.

DATE:

PLACE: Ambi

(Seminar Guide) ( Head of Department)

DYPSOEA, AMBI

(External Examiner)
 ACKNOWLEDGEMENT

Every seminar is a culmination of theoretical ideas transformed into

practical reality. With immense pleasure, sense of gratitude I present
my humble effort in the Seminar titled “3D Metal Printing”. I
dedicate all my seminar work to my esteemed guide whose interest
and guidance helped me to complete the work successfully. This
experience will always steer me to do my work perfectly and
professionally. On this occasion, I also like to thanks HOD. I express
my immense pleasure and thankfulness to all the teachers and staff
of the Department of Mechanical Engineering, for their co-
operation and support.

I also like to thank Hon'. Principal , I also extend my heartfelt thanks

to all the people for their help directly and indirectly to complete our
assignment.

Mr. Biramane Aditya Dhiraj

Exam Seat No: T151070814
Third Year- Mechanical Engg.

I
 TABLE

Sr. No. CONTENT Page Number

1
Title Page 1

2 Certificate 2

3 Acknowledgment 3

4 Content 4

5 Introduction 5

6 General principles 6

6.1 Modelling 6

6.2 Printing 7

7 Working 9

8 Advantages 11

9 Limitations 12

10 Future Scope 13

10 Conclusion 14

11 Reference 15

#
 3D Metal printing

INTRODUCTION

The umbrella term additive manufacturing (AM) gained popularity

in the 2000s, inspired by the theme of material being added together (in any
of various ways). In contrast, the term subtractive manufacturing appeared
as a retronym for the large family of machining processes with
material removal as their common theme. The term 3D printing still referred
only to the polymer technologies in most minds, and the term AM was more
likely to be used in metalworking and end use part production contexts than
among polymer, ink-jet, or stereo lithography enthusiasts.

By early 2010s, the terms 3D printing and additive

manufacturing evolved senses in which they were alternate umbrella terms
for additive technologies, one being used in popular language by consumer-
maker communities and the media, and the other used more formally by
industrial end-use part producers, machine manufacturers, and global
technical standards organizations. Until recently, the term 3D printing has
been associated with machines low in price or in capability. 3D
printing and additive manufacturing reflect that the technologies share the
theme of material addition or joining throughout a 3D work envelope under
automated control. Peter Zelinski, the editor-in-chief of Additive
Manufacturing magazine, pointed out in 2017 that the terms are still
often synonymous in casual usage but some manufacturing industry experts
are trying to make a distinction whereby Additive
Manufacturing comprises 3D printing plus other technologies or other
aspects of a manufacturing process.

DYPSOEA (Mechanical Engineering) Page 5

 3D Metal printing

GENERAL PRINCIPLES

MODELLING

(Fig.1 CAD model used for 3D printing booth.)

3D printable models may be created with a computer-aided

design (CAD) package, via a 3D scanner, or by a plain digital
camera and photogrammetry software. 3D printed models created with CAD
result in reduced errors and can be corrected before printing, allowing
verification in the design of the object before it is printed. [31] The manual
modeling process of preparing geometric data for 3D computer graphics is
similar to plastic arts such as sculpting. 3D scanning is a process of
collecting digital data on the shape and appearance of a real object, creating
a digital model based on it.

CAD models can be saved in the stereolithography file format (STL),

a de facto CAD file format for additive manufacturing that stores data based
on triangulations of the surface of CAD models. STL is not tailored for
additive manufacturing because it generates large file sizes of topology
optimized parts and lattice structures due to the large number of surfaces
involved. A newer CAD file format, the Additive Manufacturing File format

DYPSOEA (Mechanical Engineering) Page 6

 3D Metal printing

(AMF) was introduced in 2011 to solve this problem. It stores information

using curved triangulations.

(Fig.2 3D models can be generated from 2D pictures taken at a 3D photo

PRINTING
Before printing a 3D model from an STL file, it must first be
examined for errors. Most CAD applications produce errors in output STL
files, of the following types:

holes;

faces normal;

self-intersections;

noise shells;

manifold errors.

A step in the STL generation known as "repair" fixes such

problems in the original model. Generally STLs that have been produced

DYPSOEA (Mechanical Engineering) Page 7

 3D Metal printing

from a model obtained through 3D scanning often have more of these

errors. This is due to how 3D scanning works-as it is often by point to point
acquisition, 3D reconstruction will include errors in most cases.

Once completed, the STL file needs to be processed by a piece of

software called a "slicer," which converts the model into a series of thin
layers and produces a G-code file containing instructions tailored to a
specific type of 3D printer (FDM printers).] This G-code file can then be
printed with 3D printing client software (which loads the G-code, and uses it
to instruct the 3D printer during the 3D printing process).

Printer resolution describes layer thickness and X–Y resolution

in dots per inch (dpi) or micrometers (µm). Typical layer thickness is around
100 μm (250 DPI), although some machines can print layers as thin as 16
μm (1,600 DPI). X–Y resolution is comparable to that of laser printers. The
particles (3D dots) are around 50 to 100 μm (510 to 250 DPI) in
diameter. For that printer resolution, specifying a mesh resolution of 0.01–
0.03 mm and a chord length ≤ 0.016 mm generate an optimal STL output
file for a given model input file. Specifying higher resolution results in
larger files without increase in print quality.

(Fig. 3 Molten Polymer Deposition)

Time-lapse of an 80 minute video of an object being made out
of PLA using molten polymer deposition.
DYPSOEA (Mechanical Engineering) Page 8
 3D Metal printing

WORKING
In the current scenario, 3D printing or Additive Manufacturing has
been used in manufacturing, medical, industry and sociocultural sectors
which facilitate 3D printing or Additive Manufacturing to become
successful commercial technology. More recently, 3D printing has also been
used in the humanitarian and development sector to produce a range of
medical items, prosthetics, spares and repairs. The earliest application of
additive manufacturing was on the toolroom end of the manufacturing
spectrum. For example, rapid prototyping was one of the earliest additive
variants, and its mission was to reduce the lead time and cost of developing
prototypes of new parts and devices, which was earlier only done with
subtractive tool room methods such as CNC milling, turning, and precision
grinding. In the 2010s, additive manufacturing entered production to a much
greater extent.

(Fig. 7 The Audi RSQ was made with rapid prototyping

industrial KUKA robots.)

DYPSOEA (Mechanical Engineering) Page 9

 3D Metal printing

(Fig. 8 A 3D printed jet engine turbine model)

(Fig.9 3D printed sculpture of an Egyptian Pharaoh shown at Threeding)

DYPSOEA (Mechanical Engineering) Page 10

 3D Metal printing

ADVANTAGES OF 3D METAL PRINTING

1.Reduction in lead times

2.Cost advantages through the reduction of material waste

3.New approach to design

4.Ease of access

5.Subtractive manufacturing methods, such as CNC milling or turning,

remove a significant amount of material from an initial block, resulting in
high volumes of waste material.

DYPSOEA (Mechanical Engineering) Page 11

 LIMITATION OF 3D METAL PRINTING

1. High Energy Consumption

2. 3D Printing Technology is Expensive

3. Limited Materials

4. 3D Printers Aren’t that User-friendly

5. Harmful Emissions

6. Too Much Reliance on Plastic

7. Copyright Infringements

8. Production of Dangerous Weaponry

 FUTURE SCOPE FOR 3D METAL PRINTING

3-D printing is an unstoppable force. Not too long ago, the printing
speed and limited output of 3-D printers made them suitable only for rapid
prototyping. But in the coming years, 3-D printers will be at the heart of full-
scale production capabilities in several industries, from aerospace to
automotive to health care to fashion. Manufacturing as we know it will
never be the same.

The stage for this change wasn’t set overnight. Decades of

innovation have led us to the precipice of the 3-D printing industrial
revolution. But recent advancements in speed, printing technology and
material capabilities are now aligned, and together they will push the entire
industry forward.

Along with growing competition and investment in the 3-D printing

industry, these new capabilities will reshape custom manufacturing. The 3-D
printing industry is on the verge of another tipping point, and here are the
reasons why.
 CONCLUSION

In a lot of industries, 3D printing provides countless benefits.

However, it is not going to replace traditional manufacturing. It is still an

emerging technology with some disadvantages that need to be considered

when selecting a product development method. Manufacturers and product

designers therefore need to see it as a process to complement traditional

manufacturing. They can exploit its unique capabilities to improve product

design and manufacture entirely new products that could not be otherwise

produced.
 REFERANCE

1.https://www.scribd.com/document/190054253/Abstract-on-3d-printing

2.https://www.sciencedirect.com/science/article/pii/S2405896316325496

3.https://www.forbes.com/sites/forbestechcouncil/2018/01/23/the-future-of-3-d-

printing/#bdbc88f65f65

4.Wikipidia.com

**THANK YOU**