3D printing research

3-D printing (Additive manufacturing)
서지우, Jiwoo Seo
Ateam Ventures
St. George’s School

General idea
 CAD (computer aid design),(can be achieved by 3D scanning/ download)
 Readable file format (STL, OBJ, 3Ds, 3MF)
 Files’ errors fixed (netfabb, Meshmixer, Cura, Slic3r)
 G-code file (layer by layer) (Skeinforge, Slic3r, and Cura)
 3d printing
 Finishing touch. (Sanding, removing extra material, painting colors)

7 Standard Terminology for Additive
Manufacturing Technologies
1. Material Extrusion
2. Vat Photopolymerisation
3. Material Jetting
4. Binder Jetting
5. Powder Bed Fusion
6. Sheet Lamination
7. Directed Energy Deposition
Chosen by ASTM (American Society for Testing and Materials )

1. Material Extrusion
Most common method: Fused Filament Fabrication (FDM)
(FFF)
plastic filament/ metal wire unwound from a coil, supply
nozzle. Can turn the flow on/off
Nozzle is heated to melt the material and controlled by a
CAM (computer-aided manufacturing) software package
Material immediately hardens after extrusion from nozzle.

1. Material Extrusion
 Material extrusion is the most common method of 3D printing
 Most common materials:
ABS (Acrylonitrile Butadiene Styrene)
PLA (Polylactic acid)
 It is the method used by the 3D printer Creatable D2
 Often, the products’ layers can be seen, and material extrusion
produce rougher surfaces compared to other methods.

FFF problems
 FFF can’t print “overhangs” and “bridges”
 Overhangs are parts that extrude out in a way that there is nothing
underneath it to print on, and therefore the printer has problems printing.
 Makers follow the “45° rule”, which says overhangs with overhang angles
under 45 degrees will be successfully printed without any support.
 Each printer has different maximum overhang angles it can print. One way
to find your printer’s overhang angle is to print the “Overhang Test Model”
45°
Overhang
angle

Overhangs solutions
 Change orientation
 Attach a fan by the nozzle to harden material faster, making it easier to
print overhangs
 Add support material and remove them after printing. (more time and work
needed. Can leave marks/ otherwise damage the product)
Removing the support
material caused marks

PVA, HIPS – support material
 PVA (polyvinyl alcohol) - water-soluble thermoplastic
 PVA has a special characteristic of dissolving in water, so it is becoming
popular as a support material. Using PVA gets rid of the long, hard process
of removing support material, and instead lets people just drop it in water
for the post-printing process.
 HIPS (High Impact Polystyrene) – similar material that dissolves in Limonene
instead of water.
 Hygroscopic PVA attracts lots of water from the air, so it must be stored in
an air-tight container with a dehumidifier. Compared to the difficult
storage of PVA, HIPS is easier to store.
http://3dprintingforbeginners.com/3d-printing-technology/
A product of PLA with
PVA as support. It is
dissolved in water
and the post-printing
work is done.

2. Vat photopolymerisation
Most common method: Stereolithography (SLA)
The printing bed is inside a pool of resin, just under the surface.
An UV laser moves and shoots down in the desired shape on a
layer of resin.
Layer of resin solidifies into a desired shape on to the bed
Platform moves down
The UV laser solidifies the next layer
Repeat
Video of SLA printing:
https://youtu.be/yYGycgnYlBM

 New, innovative method: CLIP (Continuous Liquid Interface Production)
O2 permeable window; oxygen inhibits the solidification process. The
window can control the amount of oxygen entering, making a “dead
zone”: a thin layer (30microns) of liquid.
The platform starts from the bottom of the resin pool, and moves up,
lifting the product up from the liquid.
Instead printing in layers, UV light is shone continuously in different
shapes like a movie, printing extremely fast.
An interesting TED talk of
CLIP
http://www.ted.com/talks
/joe_desimone_what_if_3d
_printing_was_25x_faster?l
anguage=en#t-2881
https://youtu.be/8uD0d1IP
sF4

CLIP
 Introduced by Carbon 3D in March, and had quietly
raised $41 million of funding from Sequoia Capital and
Silver Lake.
 Claims that CLIP prints 25~100 times faster than
average 3D printing
 Very Smooth surfaces, no visible layers.
 “It was immediately clear to us that 3D printing would
never be the same.” - Jim Goetz
 Variety of materials, elastic, flexible, rigid.
Joseph DeSimone

 Accurate, detailed shape.
 CLIP- very fast! With one of the biggest problem of
3D printing being its slow printing speed, CLIP will
have significant impact in the 3D printing field.
 SLA – very slow.
 Need lots of post-print work to clean/make stronger.
 Expensive, limited material. (resin)

3. Material Jetting
 Like a 2D ink-jet printer
 Material laid down, hardened and cured
by UV light.
 Platform moves down, repeat

3. Material Jetting
 Pros:
 Very accurate, good surface finishes
 Can print multiple materials colors
 Cons:
 Only polymers and wax materials can be used for
jetting.
 Parts are rather fragile
 Building process is slow.
 Support material needed.
Material:
Polypropylene,
HDPE, PS, PMMA,
PC, ABS, HIPS, EDP

4. Binder Jetting
 Layer of powder is set on a platform
 Liquid adhesive (binder) is applied in desired shape with
a nozzle
 Next layer of powder is laid down
Metals: Stainless steel
Polymers: ABS, PA, PC
Ceramics: Glass

4. Binder Jetting
 Pros:
 Wide range of materials: metal, polymers and ceramics
 Parts can be printed with range of different colors.
 Generally faster.
 No need for support structure.
 Cons:
 Weak because of the use of binder. Not for structural purposes.
 Lots of post-print process needed to remove the un-binded
material.

5. Powder Bed Fusion
 Most common method: Selective laser sintering (SLS)
 powder of material is laid down on a layer
 Laser heats powder, fuses them together. Unheated powder remains
there as the support material.
 Another layer of powder is laid down, and repeats.
 The chamber is heated to few degrees below the material melting
point, to make the powder easier to fuse.
 EBM (electron beam melting) has the same concept, but uses an electron
beam instead of a laser.
SHS: Nylon DMLS, SLS,
SLM: Stainless Steel,
Titainium, Aluminium,
Cobalt Chrome, Steel
EBM: titanum, Cobalt
Chrome, ss, al and copper

5. Powder Bed Fusion
 Pros:
 Doesn’t require support material. (Unheated powder
acts as support)
 So faster than most other methods.
 Variety of materials like: glass, ceramics, and even metal.
 Useful in aerospace engineering
 Cons:
 High power usage
 Lots of post-printing work
 Size limitation
http://www.livescience.com/38862-selective-laser-sintering.html

6. Sheet Lamination
 Most common methods: UAM (ultrasonic additive manufacturing), LOM
(laminated object manufacturing)
 A sheet of material is placed on cutting bed.
 The sheet is cut in a desired shape
 The sheets are attached by adhesive for paper and ultrasonic-welding
for metal
 Next layer is added, and the process is repeated.
http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing

6. Sheet Lamination
 Sheet lamination is generally used to make visual models and
not for structural use
 Materials: Paper, plastic, sheet metals.
 A4 paper is the most common material because it’s cheap and
easy to get.
 Pros:
 Cheap and fast printing
 Cons:
 Requires lots of material and produces lots of waste
 Printed products have bad strength/integrity
 Detailed colors can be added to create incredible effects and
achieve artistic visuals (like a human head).

7. Directed Energy Deposition
 Material(powder, wire) is deposited from a nozzle onto
an object.
 Material is melted by laser/electron beam/plasma
 EMB (Electron beam melting) – uses metals
Metals: Cobalt Chrome, Titanium
 SLM (Selective laser melting)

Material: 3 major plastic filaments
ABS (Acrylonitrile Butadiene Styrene)
PLA (polyactic acid)
PVA (polyvinyl alcohol)
From 3D Hubs database

Materials: 3 plastic filaments
 ABS (FFF) (Acrylonitrile Butadiene Styrene) filament
 Durable, strong, slightly flexible. Resistant to heat.
 Variety of applications, including: pipes, automobile parts, protective
headgear, kitchen appliances, toys. (also the material of LEGOs).
 Nozzle must be heated to (210~250)°C. Print bed should be heated to
prevent cracks/ warping.
 Cheapest of the plastic filaments. Can be easily sanded, painted
 Can be glued by “ABS glue”
 Recyclable but is non-biodegradable because it’s petroleum- based
 Many colors, including transparent.
 Attracts water from air when not in use for a long time.
 Creates fumes, which might irritate sensitive people.
http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/materials/

PLA (FFF) – (polyactic acid) filament
 PLA: bio-degradable thermoplastic (resin-SLA) (filament-FFF)
 Most environmentally friendly material in 3D printing because it’s bio-degradable.
 Degrades into inoffensive lactic acid in the body. Used in medical suturing as well as
surgical implants. Surgically implanted screws, pins, rods or mesh simply break down in
the body within 6 months to 2 years.
 Extruded at 160°C-220 °C. Unlike ABS, it doesn’t create fumes, but lets off a slight odor
that apparently smells like pancakes and corn. It’s slow to cool, so a fan is
recommended.
 After printing, it can be sanded and painted with acrylic paint, but it unlike ABS, it can’t
be not easily glued
 PLA is increasing for its low toxicity and environmental friendliness. It has a low resistance
to heat and becomes soft at 50 °C. This could be a flaw but also a benefit, letting the
user easily correct and bend the product.
 Many say that PLA will soon beat ABS to become the most popular material
 Easy to work with, many colors including transparent and “glow in the dark”.
 More water-absorbing than ABS. Water saturated PLA is very hard to print.

PVA (FFF) – (polyvinyl alcohol) filament
 Water-soluble plastic.
 White, odorless
 Most commonly used as support structure to help with overhang issues.
It’s a very convenient support structure because all the user has to do is
drop the product into water, instead of the long, hard process of
removing the support structure.
 Has an extremely strong water attraction, so hard to store.
 Extruded at 190°C. If it absorbed water, the printing quality goes very
bad, so it is sometimes dried before printing.
 High price, difficult sourcing.

Material: other plastics
Nylon 12 (powder, filament)
 Popular in traditional manufacturing for its superb price-performance.
 High fatigue-resistance, chemical resistance.
 Highest impact-resistance of any FFF thermoplastic.
 You can create advanced prototypes and custom tooling for
applications that demand high fatigue resistance
 Naturally white, but can be colored pre/post-painting
 When combined with aluminum powder, it can create Alumide,
another common material in 3D printing

Laywood (FFF) - filament
 Laywood- specially for FFF. Filament form. Wood/polymer composite
 The prints actually look and smell like wood and post-processing
presents various options, as the prints can be sanded, grinded and
painted like standard wooden products.
 It’s very popular to those who are interested in art and design and who
are bored of printing just plastic.
 Manufacturer recommends to print at 175°C and 250°C. Interestingly,
different printing temperatures cause different texture and color, so
interesting and artistic textures that change by layers
 The filament is fragile so it must be carefully handled. If the user wants,
laywood can be printed in smooth surfaces with layers unnoticeable.

Materials
 Ceramics:
 Silica/Glass
 Porcelain
 Silicon-Carbide
 Strong, but after printing, need to go under firing, glazing.
 Paper:
 Easily obtainable, cost effective
 Safe, Environmentally friendly, recyclable
 Requires no post-processing

Materials
Metals:
Aluminum, cobalt
Stainless Steel-most common. powder
(sintering, melting, EBM)
Gold, silver-powder. Very strong
Titanium-powder (sintering, melting,
EBM) the strongest metal.

Materials
 Bio Materials:
 Being researched.
 Living tissues, can make human body parts
 Food:
 Chocolate,
 Pasta and meat.
 Pizza!

Physical computing
 How humans interact/
communicate through computers.
 Interactive physical systems by
the use of software and hardware
that can sense and respond to
the analog world.
https://en.wikipedia.org/wiki/Physical_computing
Digital Fabrication
 Process that joins design
with
construction/production
 3D printing is a major part
of digital fabrication

Community sharing
 Shape Engine: A 3D printing sharing platform that
connects 3D printer owners and 3D printer users
without a printer.
 Makerspace: Areas people gather to create, share
skills, supplies, ideas, work on project.
 Fablab: originated at MIT’s Center for Bits and Atoms
(CBA) by Professor Neil Gershenfeld
 Fab Labs provide access to digital fabrication.
 “Give ordinary people the right tools, and they will
design and build the most extraordinary things.”
 Thingiverse: Webite sharing of user-created digital
design files. Providing primarily open source hardware
designs

Shape Engine
 3D printing sharing platform where 3D printer owners can take
advantage of the printer’s idle time by sharing the printers to
customers and making profit.
 People who want to 3D print but don’t own a 3D printer can use
Shape Engine to connect to a local 3D printer owner and
become a customer by ordering the owner to print a product,
then picking it up with a payment.
 Shape Engine also provides help with 3D modeling to anyone who
needs help so people who aren’t skilled with 3D modeling can use
Shape Engine to receive help and successfully print their desired
products.

Makerbot Thingiverse
 Biggest website for sharing 3D files.
 People share open source hardware designs licensed under the GNU
General Public License or Creative Commons licenses. (The license
allows anyone to share, change, and save the files, as long as it is in the
boundary set by the owner
 Numerous projects and maker communities
use Thingiverse, with a big one being the
RepRap project.
Number of items on Thingiverse:

3D Hubs
 Uses the same concept as Shape Engine.
 People can upload 3D designs, choose a printer location, and print
their desired products
 Largest network for 3D printers.
 100 new printers per week.
 15,000 locations in 140 countries, providing over 1 billion people
access to a 3D printer within 10 miles of their home

3d printed guns
 Defense Distributed – open-source organization that designs
weapons that can be downloaded and 3D printed.
 Liberator – first fully 3d printable gun, available for download on the
internet. May 6, 2013
 It was downloaded 100,000 times in just 2 days after its upload.
 US Department of State demanded it the Liberator to be taken
down from the internet 3 days later in May 9, 2013. However, it was
too late: there were already 100,000 downloads that people
downloaded world wide.
 It was a big issue in the sensitive field of Unite States’
gun control, and attracted lots of attention to
3D printing.

3d printed food
 Mechanical engineer Anjan Contractor won a $125,000
grant last year to build a prototype 3D printer designed
to print food for astronauts on long missions.
 He printed a pizza with his open-source RepRap Mendel
3D printer

Anti-gravity 3d printing
 Made in Space has made the “Zero-G Printer”
 Launched into orbit on September 21, 2014.
 Mataerial makes 3d printers that print without gravity, and freely
prints without the need for a flat printing surface.
 Plastic extruded from the printer solidifies instantly, allowing to
draw freeform shapes in the air from any surface, (a wall or a
ceiling)
Zero-G Printer

3D printing in the medical field
 South Korean doctors of Yonsei University Severance hospital
successfully implanted 3D printed pelvis in teenage patient, March
2015. Customized implant significantly shortened the surgery time
and allowed patient to heal faster.
 Kyoto University successfully transplanted 3D-printed spines (with
titanium powder) in 4 patients.

RepRap project
 Invented by 아드리언 Adrian Bowyer, RepRap (Replicating Rapid-prototype) is a (as in
“free” software)free desktop 3d printer that is capable of printing many of its own
parts.
 The goal of RepRap is to create an affordable, self-replicating machine that will spread
around the world to let people create not only various goods, but also the machines
themselves so that they could “give one to a friend”. But the current reality is far from
the goal, the machines being extremely expensive and only able to print about half of
its parts. The RepRap team is working to make the machines accessible to communities
in the developing world and individuals in the developed world.
 RepRap was the first of the low-cost 3D printers, and the RepRap Project started the
open-source 3D printer revolution. It has become the most widely-used 3D printer
among the global members of the Maker Community.
Source: Moilanen, J. & Vadén, T.: Manufacturing in motion: first survey on the 3D printing
community, Statistical Studies of Peer Production.

The impact of 3D printing.
 3Dprinting revolutionized the prototype manufacturing industry. 3d printing
shortened the time of prototype production by 1/7 and the cost by 1/8.
Through 3D printing, we are able to manufacture faster and cheaper than
ever. With the recent uses of 3D printing, its demand is increasing in the
manufacturing field, where 3D printing has various applications, like
producing tools needed in medical apparatus manufacturing such as jig
and fixture.
Source:
MEDICAL DEVICE & DIAGNOSTIC INDUSTRY, January 2009

Cost of 3D printing.
 According to a survey, one of the biggest obstacle in using 3D printers was the
high price of the printers. (31.5% of the response)
 Also, producing goods like prototypes and models takes at least 200$, making it is
hard for ordinary people to use.
Domestic mockup/prototype manufacturing prices
NC manufacturing
(design mockup)
At least 200$
CNC manufacturing
(working mockup)
At least 500$
3D planning/
business planning
At least 1000$
Product Development At least 3000$

Growing market of 3d printing
 Allied Market Research (AMR) projects that the 3D
printing market will grow from $2.3B in 2013 to $8.6B in
2020
 3D printing will impact all major industries.
Siemens prediction of future 3D printing:
Market by industries
Market growth

3D printing in manufacturers
 67% of manufacturers surveyed are currently implementing 3D printing either in
full production or pilot and 25% intend to adopt 3D printing in the future.
 92% of manufacturers using/ going to use 3D printers

Distribution
 Hardware/software:
 Ateam Ventures
 Stratasys
 Makerbot
 Autodesk
 3Ds Systems
 WYNIT
 Retailer:
 Lulzbot
 Amazon, ebay
 Internet/software:
 HP, microsoft
 Google, intel

http://www.forbes.com/sites/louiscolumbus/2015/08/11/mobile-driving-more-dollars-in-tech-84-of-execs-say-they-will-meet-or-beat-
revenue-targets/

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