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Additive Technologies in Metallurgy & Mechanical Engineering

The 3D model in STL format is transferred to the 3D printer software. The program automatically (or operator manually) places the model in the virtual space of the working camera. Then the program automatically generates elements of auxiliary structures (from a special support material) and calculates the number of consumables and the time for growth of the prototype. Before starting the printing process, the model is automatically divided into horizontal layers and the printhead paths are calcu

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Sandip Patel
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67 views4 pages

Additive Technologies in Metallurgy & Mechanical Engineering

The 3D model in STL format is transferred to the 3D printer software. The program automatically (or operator manually) places the model in the virtual space of the working camera. Then the program automatically generates elements of auxiliary structures (from a special support material) and calculates the number of consumables and the time for growth of the prototype. Before starting the printing process, the model is automatically divided into horizontal layers and the printhead paths are calcu

Uploaded by

Sandip Patel
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Сourse

«Additive Technologies in Metallurgy &


Mechanical Engineering»
Liudmila Radionova

Lecture notes
Topic 4. FDM (Fused Deposition Modeling) and MJM (Multi-jet
Modeling) technology
FDM is the most common 3D printing technology in the world. It is used to grow
products not only in the cheap home printers, but also in industrial systems of high-
precision 3D printing. The principle of construction with FDM technology is to grow
products in layers of pre-melted plastic thread.
The 3D model in STL format is transferred to the 3D printer software. The program
automatically (or operator manually) places the model in the virtual space of the working
camera. Then the program automatically generates elements of auxiliary structures (from
a special support material) and calculates the number of consumables and the time for
growth of the prototype. Before starting the printing process, the model is automatically
divided into horizontal layers and the printhead paths are calculated. The process of the
model preparation for printing is called "slicing", which generates a G-code. It contains all
the parameters of printing, movements of the extruder, and if it is necessary, generates
supporting structures needed to print the overhang elements.
Then the process of direct 3D printing is started: the heating head with dies
(extruder) melts a thin plastic thread and layers it according to the data of the
mathematical 3D model. Some devices allow using different materials during the same
production cycle. For example, it is possible to print a model from one material with
supports printed from another, easily soluble material, which enables to remove the
supporting structures easily after the printing process. Alternatively, it is possible to print
in different colors of the same type of plastic while creating a single model.
The product, or "model", is produced by extrusion and application of microdrops of
molten thermoplastic with the formation of successive layers that solidify immediately
after extrusion. After completion of the product construction process, auxiliary structures
are removed (manually or by dissolution using a special solution). The finished product
can be used in printed form or subjected to any post-processing method.
All kinds of thermoplastics and composites including ABS, PLA, polycarbonates,
polyamides, polystyrene, lignin and many others are available as consumables. As a rule,
different materials provide a choice of balance between certain strength and temperature
characteristics. One of the most popular materials is polylactide, or "PLA-plastic". This
material is made of corn or sugar cane, which makes it non-toxic and environmentally
friendly, but it is relatively short-lived. Contrary, ABS-plastic, is very durable and resistant
to wear, although it is susceptible to direct sunlight and can emit small amounts of harmful
fumes when heated. FDM is one of the cheapest printing methods, which ensures the
growing popularity of home printers based on this technology. In the home, 3D printers
based on FDM technology can be used to create a variety of target objects. Layer-by-
layer deposition modeling (FDM) is also used for rapid prototyping.
Multi Jet modeling - 3D printing technology based on multijet modeling with
photopolymer or wax material.
The principle of printing is similar to inkjet. At the heart of the technology is a
printing head with a whole battery of tiny nozzles, arranged linearly in several rows. The
number of nozzles starts from 96 for younger models of printers and reaches 448 for top
models. One nozzle is one smallest drop of model material for building a product.
The printing unit moves along the working surface and applies layers of liquid
polymer. After the printing block a UV lamp follows, which illuminates the newly applied

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particles of material, resulting in the hardening and formation of a given product. In
addition to the base material, auxiliary (or support) material is used in the printing process.
This is a wax structure, which serves as a support for the hinged elements of the future
model. When printing is finished, the wax support is melted in a special furnace.
3D printers using MJM technology can work with wax and photopolymer materials.
Wax printing is carried out by two heads: one head applies harder wax of the main
part, the second head applies softer or fusible wax for printing supports. The obtained
details can be easily used to create moulds when the wax blank is easily melted from the
mould at 60°C. The MJM technology produces objects with incredibly smooth surfaces
and high quality precision. Construction of prototypes from the tiniest drops of liquid
photopolymer enables to achieve accuracy, which, for example, is not available to plastic
3D printers. The accuracy of MJM technology products manufacturing is 0.016-0.050 mm,
printing resolution - up to 750×750×1600 DPI (in the highest definition mode), layer
thickness - from 16 microns.
The main advantage of the technology is a smooth surface of finished products,
excellent physical and mechanical properties of prototypes (including the stability of
geometric dimensions), as well as the ability to process the surface (gluing, painting, etc.).

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This course was developed with the support of the "Open
Polytech" educational project

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