3D Printing

06 BHAVYA THARAKAN – ET24BTEL003

07 REVATHY NAIR – ET24BTEL025
10 KHANDWALA KAVYA DHARIT – ET24BTEL013
11 PARMAR PRAKASH CHANDUBHAI – ET24BTEL019
12 DURVA PATEL – ET24BTEL007
 Table of contents

01 02 03
Introduction Components Working

04 05 06 07
Types Applicati Pros & Future
ons 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 Stereo lithography (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 components on the 3D printer
 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
Deposition Stereo lithography Laser
Modelling (SLA) Sintering
(FDM) (SLS)
 Fused deposition modelling
(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
design.
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.
 Stereo lithography (SLA)
What is SLA?

Stereo lithography (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 photo initiators, 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 moulds 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 jewellery, 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 labour costs.
 Pros & Cons
Pros Cons
1. Flexible Design: Enables the creation of intricate and 1. Limited Material Choices: The selection of materials,
complex designs that are otherwise difficult to achieve especially metals and plastics, is still not exhaustive.
with traditional methods.
2. Restricted Build Size: Print chambers are small,
2. Rapid Prototyping: Allows parts or prototypes to be requiring larger parts to be printed in sections and
manufactured within hours, speeding up the design joined later.
process.
3. Post-Processing Requirements: Many 3D-printed parts
3. Print on Demand: Reduces the need for large stock require additional cleaning and finishing processes.
inventories, saving storage space and costs, thus
minimise waste 4. High Cost for Large Volumes: The cost per unit remains
high when scaled for mass production, limiting
4. Strong and Lightweight Parts: Essential for industries economic feasibility.
such as automotive and aerospace, where these
properties are critical. 5. Layered Part Structure: The layer-by-layer
manufacturing process can cause delamination under
5. Fast Design and Production: Accelerates the stress.
manufacturing process, especially for complex objects.
 Future Trends in 3D Printing
Multi-Material Bioprinting for Sustainability
Printing Healthcare Focus
Advancements in 3D printing technology 3D bio printing of tissues and Innovations in large-scale 3D
will allow for the simultaneous use of organs is expected to revolutionize printers will expand applications
different materials, including metals, healthcare, with potential in industries like construction,
polymers, and ceramics, enabling the applications in personalized where entire buildings and
creation of complex and functional medicine, prosthetics, and infrastructure can be 3D-
products. regenerative treatments printed.

Large-Scale Mass Integration

Printing Customization with AI and IoT
Innovations in large-scale 3D 3D printing will enable the AI-driven designs and IoT-
printers will expand applications production of customized enabled monitoring will
in industries like construction, products on a large scale, enhance 3D printing efficiency,
where entire buildings and particularly in fashion, quality control, and predictive
infrastructure can be 3D- consumer electronics, and maintenance.
printed. automotive industries.
 Conclusion
3D printing is revolutionizing modern manufacturing with its ability to create
complex designs, reduce waste, and enable rapid prototyping. Despite
challenges such as limited materials and scalability, the technology continues
to evolve, finding applications in diverse fields like healthcare, aerospace, and
automotive.
With advancements in materials, printer technologies, and integration with AI
and IoT, 3D printing holds immense potential to shape the future of
sustainable and customized manufacturing. It is not just a tool for innovation
but a driver of transformative change across industries.
THANK YOU!!