G H Raisoni University, Amravati

School of Science

MCA 2nd Year III Sem

A Semior Report On
3D Printing

Submitted By
Khushbu Gaydhane

Guided By

(Asst. Professor, School of Science, GHRU, Amravati)

G. H. Raisoni University, Amravati

School of Science
Department of Computer Application
2022-23
1. Abstract
2. Introduction
3. History
4. Designing Using CAD
5. Types Of Additive Manufacturing
1. Fused Depostion Modeling
2. Stereolithography
3. Selective Laser Sintering

6. Application
7. Advantage
8. Disadvantage
9. Future Scope
10. Conclusion
 ABSTRACT

Humans have always evolved around technologies which have helped them make their life simple. The
dependence of humans on technology as a part and parcel of their life can be traced back to the time of
Adams and Eves, when the accidental discovery of Fire led to the revolution in the human era. Skipping the
time clock on the major scale, when we think about the 19th Century, the process of Industrial Revolution
becomes a major step which laid the foundation stones for the modern world that we currently live in.
Manufacturing soon become the talk of every household, almost in every corner of the globe. Individuals,
families, communities, states, and even governments started to focus on increasing their mass production to
scale up their growth. Soon, manufacturing also led the way for other industries to develop. The era of
1990s saw the Mobile Revolution, the 2000 saw the Internet boom and the 21st century is said to be heavily
dependent on the Technology of 3D- Printing, which is set to re-invent the manufacturing process.
3D Printing or Additive Manufacturing is a process of making three dimensional solid objects from a
digital file. The creation of a 3D printed object is achieved using Additive Process, where an object is
created by laying down successive layers of materials until the entire object is created. Each of these layers
can be seen as a thinly sliced horizontal cross section of the eventual object. We all use a normal printer at
our home or workplace. Just feed the paper and it prints over. 3D Printing is the next level of innovation,
where the same idea of printing, but one over the other is utilized to bring out an object from the virtual
world to reality.

INTRODUCTION
3D printing or additive manufacturing (AM) is any of various processes for making a three-dimensional
object of almost any shape from a 3D model or other electronic data source primarily through additive
processes in which successive layers of material are laid down under computer control. A 3D printer is a
type of industrial robot.

Early AM equipment and materials were developed in the 1980s. In 1984, Chuck Hull of 3D Systems
Corp, invented a process known as stereo lithography employing UV lasers to cure photopolymers. Hull
also developed the STL file format widely accepted by 3D printing software, as well as the digital slicing
and infill strategies common to many processes today. Also during the 1980s, the metal sintering forms of
AM were being developed (such as selective laser sintering and direct metal laser sintering), although
they were not yet called 3D printing or AM at the time. In 1990, the plastic extrusion technology most
widely associated with the term “3D printing” was commercialized by Stratasys under the name fused
deposition modelling (FDM). In 1995, Z Corporation commercialized an MIT-developed additive process
under the trademark 3D printing (3DP), referring at that time to a proprietary process inkjet deposition of
liquid binder on powder.

AM technologies found applications starting in the 1980s in product development, data visualization,
rapid prototyping, and specialized manufacturing. Their expansion into production (job production, mass
production, and distributed manufacturing) has been under development in the decades since. Industrial
production roles within the metalworking industries achieved significant scale for the first time in the
early 2010s. Since the start of the 21st century there has been a large growth in the sales of AM machines,
and their price has dropped substantially. According to Wohlers Associates, a consultancy, the market for
3D printers and services was worth $2.2 billion worldwide in 2012, up 29% from 2011. Applications are
many, including architecture, construction (AEC), industrial design, automotive, aerospace, military,
engineering, dental and medical industries, biotech (human tissue replacement), fashion, footwear,
jewellery, eyewear, education, geographic information systems, food, and many other fields.

HISTORY
1984: First ever 3D printing technology patented by Charles Hull – Stereolithography Apparatus (SLA).
1987: First commercially available Stereolithography Apparatus (SLA) 3D printer built in 1987. This machine
used laser beams to solidify the photopolymer resins to form the final product
1993: ZCorp invented the Binder Jetting (then known as Zprinting) 3D printing technology
1999: 3D Printed organs are the craze among scientists. Scientists research on the medical applications of this
technology
2002: A fully functional 3D Printed miniature kidney which is able to filter blood
2005:  Dr. Adrian Bowyer’s RepRap Project launched an open-source initiative to manufacture a 3D printer
which could print many basic products
2006: The first commercially viable SLS printer was manufactured and received widespread acceptance and
demand for industries
2008: Darwin, a relaunch of an upgraded version launched in 2005, a self-replicating printer is manufactured
2008: Shapeways, a marketplace where designers could display their designs and receive feedback on the
same. It was an environment of co-creation where artists, animators, architects, etc. joined in the community
2008: For the first time a fully functional 3D printed prosthetic leg is with a socket, foot, knee, etc.
2008: MakerBot releases the first Do-It-Yourself open-source 3D printer kit called Cupcake CNC
2011: World’s first 3D printed Aircraft is created. This unmanned aircraft was flight tested to be successful
2011: i.materialise 3D prints gold and silver for the first time
2012: Doctors and engineers 3D Print a prosthetic lower jaw and implant it in an 83-year old woman
2013:  3D Hubs, an online 3D printing service platform is founded
2014: Amazon, the online retail giant launches their 3D printing store
2015: Desktop Metal was founded with the launch of office-friendly metal 3D printer
2016: Local Motors manufactures OLLIE, a self-driving 3D Printed minibus. The Minibus is controlled by IBM
Watson that talks to the customer.
2017: The world’s first 3D printed bridge developed by BAM Infra opens to cyclists in the Netherlands
2018: World’s first 3D Printed Human Cornea & Researchers at University of Minnesota 3D Print a Bionic Eye
Prototype.
2019: World’s first 3D printed heart with human tissue.
2020: Supporting in the fight against the Covid-19 pandemic by 3D printing face shields, face masks, nasal
swabs, ventilator splitters, etc.

DESIGNING USING CAD

Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification,
analysis, or optimization of a design. CAD software is used to increase the productivity of the designer,
improve the quality of design, improve communications through documentation, and to create a
database for manufacturing. CAD output is often in the form of electronic files for print, machining, or
other manufacturing operations.

CAD software for mechanical design uses either vector-based graphics to depict the objects of
traditional drafting, or may also produce raster graphics showing the overall appearance of designed
objects. However, it involves more than just shapes. As in the manual drafting of technical and
engineering drawings, the output of CAD must convey information, such as materials, processes,
dimensions, and tolerances, according to application-specific conventions.

CAD may be used to design curves and figures in two-dimensional (2D) space; or curves, surfaces, and
solids in three-dimensional (3D) space. CAD is an important industrial art extensively used in many
applications, including automotive, shipbuilding, and aerospace industries, industrial and architectural
design, prosthetics, and many more. CAD is also widely used to produce computer animation for special
effects in movies, advertising and technical manuals, often called DCC digital content creation. The
modern ubiquity and power of computers means that even perfume bottles and shampoo dispensers are
designed using techniques unheard of by engineers of the 1960s. Because of its enormous economic
importance, CAD has been a major driving force for research in computational geometry, computer
graphics (both hardware and software), and discrete differential geometry.

The design of geometric models for object shapes, in particular, is occasionally called computer-aided
geometric design (CAGD). Unexpected capabilities of these associative relationships have led to a new
form of prototyping called digital prototyping. In contrast to physical prototypes, which entail
manufacturing time in the design. That said, CAD models can be generated by a computer after the
physical prototype has been scanned using an industrial CT scanning machine. Depending on the nature of
the business, digital or physical prototypes can be initially chosen according to specific needs.

Today, CAD systems exist for all the major platforms (Windows, Linux, UNIX and Mac OS X); some
packages even support multiple platforms which enhances the capabilities of 3D printing into a new level.
TYPES OF ADDITIVE MANUFACTURING:

Fused Deposition Modeling

Fused Deposition Modeling also known as Fused Filament Fabrication (FFF) is a process by which a
machine deposits a filament of a certain material (normally thermoplastics, wax or similar products) on
top or next to the same material, in order to create a joint by heat and/or adhesion. Thermoplastics are
plastics which become semi-liquid above a specific temperature and return to a solid state when cooling
down.

A FFF printer prints a 3-dimensional object by extruding a stream of heated or melted thermoplastic
material, which is carefully positioned into layer upon layer, working from the bottom up. By adding layer
upon layer, which will almost immediately harden upon leaving the hot print head, the object is created.

Fig: Fused Deposition Modeling

 Stereolithography (SLA)
The main technology in which photo-polymerization is used to produce a solid part from a liquid is SLA,
invented by Charles Hull. This technology employs a vat of liquid ultraviolet curable photopolymer resin
and an ultraviolet laser to build the object’s layers one at a time. For each layer, the laser beam traces a
cross-section of the part pattern on the surface of the liquid resin. Exposure to the ultraviolet laser light
cures and solidifies the pattern traced on the resin and joins it to the layer below.

Fig: SLA Process finished products

After the pattern has been traced, the SLA’s elevator platform descends by a distance equal to the
thickness of a single layer, typically 0.05 mm to 0.15 mm (0.002″ to 0.006″). Then, a resin-filled blade
sweeps across the cross section of the part, re-coating it with fresh material.

On this new liquid surface, the subsequent layer pattern is traced, joining the previous layer. The
complete three dimensional objectsare formed by this project. Stereolithography requires the use of
supporting structures which serve to attach the part to the elevator platform.

Fig: Steriolithography
 Selective Laser Sintering (SLS)

This technology uses a high power laser to fuse small particles of plastic, metal, ceramic or glass
powders into a mass that has the desired three dimensional shape. The laser selectively fuses the
powdered material by scanning the cross-sections (or layers) generated by the 3D modeling program on
the surface of a powder bed. After each cross-section is scanned, the powder bed is lowered by one
layer thickness. Then a new layer of material is applied on top and the process is repeated until the
object is completed.

Fig: SLA Printed Object

All untouched powder remains as it is and becomes a support structure for the object.

Fig: Selective Laser Sintering

Selective laser sintering (SLS) is a 3d printing process (additive manufacturing) that uses high-powered
lasers to sinter, or bind, finely powdered material together into a solid structure. In this process, a printer
lays down an even layer of powder and then precisely sinters that layer, repeating the deposition and
sintering process until the part is complete. The shape of the object is created by aiming a laser at the
powder bed in specific points in space, guided by a digitally produced CAD (computer-aided design) file .
 APPLICATION
1. Automotive Industry:
Nowadays, 3D printing technology have rapidly
changed our industry to design, develop and
manufacture new things. In the automotive
industry, 3D Printing technique have made
phenomena to bring new shines, allowing for
lighter and more complex structures in the fast
time. For instance, Local Motor had printed the
first 3D-printed electric car in 2014. Not only
cars, Local Motors also extended the wide range
application of 3D printing technology by
manufacturer a 3D-printed bus called OLLI. OLLI
is a driverless, electric, recyclable and extremely
smart 3D printed bus. Furthermore, Ford is the
leader in the use of 3D printing technology also
apply 3D printing technology to produce
prototype and engine parts . In addition, BMW
uses 3D printing technology to produce hand-tools for automotive testing and assembly. Meanwhile, in
2017, AUDI was collaborated with SLM Solution Group AG to produce spare parts and prototypes .
Consequently, by using 3D printing technology in automotive industry enable company to try various
alternatives and emphasize right in the improvement stages, prompting ideal and effective automotive
design. At the same time, 3D printing technology can reduce the wastage and consumption of the
materials. Moreover, 3D printing technology can reduce costs and time, therefore, it allows to test new
designs in a very fast time .

2. Food Industry:
3D printing technology open the doors not only for aerospace industry, but also for food industry. At
present, there is a growing demand for the development of customized food for specialized dietary needs,
such as athletes, children, pregnant woman, patient and so on
which requires a different amount of nutrients by reducing the
amount of unnecessary ingredients and enhancing the presence of
healthy ingredients. However, the development of customized
foods must be conducted in a very detailed and inventive way,
which is where the adoption of 3D-food printing appears. Food
layer manufacture also known as 3D-food printing fabricated
through the deposition of successive layers by layer derived
directly from computer-aided design data. By using 3D printing
technology, specific materials can be mixed and processes into
various complicated structures and shape. Sugar, chocolate, pureed food and flat food such as pasta, pizza
and crackers can be used to create new food items with complex and interesting designs and shape.
3D printing technology is a high-energy efficiency technology for food production with environmentally
friendly, good quality control and low cost. 3D-food printing can be healthy and give benefit for human
because it creates new process for food customization and can adjust with individual preferences and
needs. By allowing food preparation and ingredients to be automatically adjusted to the consumer’s
information, it would be possible to have diets which enforce themselves without need to exercise.
 3. Healthcare and medical Industry:
3D printing technology can used to print 3D skin , drug and pharmaceutical research, bone and
cartilage, replacement tissues, organ, printing for cancer research and lastly models for visualization,
education, and communication. There are several advantages of 3D Printing technology for biomedical
products which are:

 3D printing technology can replicate the natural structure of the skin

with the lower cost. 3D printed skin can be used to test pharmaceutical,
cosmetics, and chemical products. Therefore, it is unnecessary to use
the animal skin to test the products. Consequently, it will help the
researcher to get accurate result by using replicate the skin [65].
 By using 3D printing technology to print drug can increase efficiency,
accurate control of dropped size and dose, high reproducibility and able
to produce dosage form with complex drug-release profiles.
 3D printing technology is able to print cartilage and bone to replace
bony voids in the cartilage or bone that caused by trauma or disease
[66]. This treatment is different options from using auto-grafts and
allografts because this treatment focuses on to generate bone,
maintain, or improve its function by using in vivo.
 3D printing technology also can be used to replace, restore, maintain,
or improve the tissues function. The replacement tissues produced by
3D printing technology have the interconnected pore network,
biocompatible, appropriate surface chemistry and has good mechanical
properties.
 3D printing technology also can be used to print out similar organ
failure caused by critical problems such as disease, accidents, and birth
defects.
 3D printing technologies are able to form highly controllable cancer
tissues model and shows great potential to accelerate cancer research.
By using 3D printing technology, the patients can get more reliable and
accurate data.
 3D printout models can use in the learning process to help
neurosurgeons practicing surgical techniques. By using 3D model, it can
improve accuracy, can take the short time to the trainer when
performing clinical procedure, and provides opportunities for training
surgeons hands-on, as the 3D model is a simulation of a real patient’s
pathological condition.

The medical industry is known to be most advanced in the way in which new treatments and methods
have been developed. Not to mention the technologies that drive all of this forward. There has been no
shortage of miracles and that continues to happen. Now 3D printing in healthcare is coming as well. One of
the ways in which the medical industry has been improved and
enhanced is through the use of 3D printers. 3D printing in
healthcare makes it possible for medical professionals to provide
patients with a new form of treatment in a number of ways. 3D
printing is used for the development of new surgical cutting
and drill guides, prosthetics as well as the creation of patient-
specific replicas of bones, organs, and blood vessels.
 4. Architecture, Building, and Construction
Industry:
3D printing technology can be considered as
environmentally friendly derivative and it give
unlimited possibilities for geometric complexity
realization. In the construction industry, 3D printing
technology can be used to print entire building or
can create construction components. The
emergence of the Building Information Modelling
(BIM) will facilitate better use of 3D printing
technology. Building Information Modelling is a digital
representation of functional and physical
characteristics, can share an information and
knowledge about 3D building. It can form a reliable source for decision during its life cycle, from initial
conception to demolition for construct or design the building. This innovative and collaborative
technology will support more efficient method to designing, creating and maintaining the built
environment.
With 3D printing technology, companies can design and create the visual of the building in the fast
time and inexpensively as well as avoid delays and help pinpoint problem areas. At the same time, with 3D
printing technology, construction-engineer and their clients can communicate more efficiently and clearly.
Much of a customer's expectations come from an idea, and 3D printing makes it simple to appear that
idea beyond the dated method of paper and pencil. The examples of 3D printed building are Apis Cor
Printed House in Russia and Canal House in Amsterdam.

5. Fabric and Fashion Industry:

When 3D printing technology enters the retail industry, 3D printed shoes, jewellery, consumer goods
and clothing are emergence into the market. The combination of fashion and 3D printing may not seem
like the most natural fit, but it is starting to become an everyday reality all over the world. For instance,
big companies like Nike, New Balance and Adidas are striving to development the mass production of 3D
printed shoes. Nowadays, 3D printed shoes are produced for athlete's shoes, custom-made shoes and
sneakers.
Besides, 3D printing technology can spread creative possibilities for fashion design. Indeed, it makes it
possible to makes shapes without moulds. In fashion industry, by using 3D printing technology, it can
design and produce garments by using mesh system and also can print ornaments for traditional textile.
Moreover, the application of 3D printing technology not limited to the fashion industry, but also can print
leather goods and accessories. For instances, jewellery, watchmaking, accessories and so on.
The retailers and designers believe the purpose of creating fashion products by using 3D printing
technology is not to duplicate current products, but to improve product design by offering personalised
and unique products to customers. The advantages of the product development by using 3D printing
technology are the product is on- demand custom fit and styling. At the meantime, by using 3D printing
technology, it can reduce the supply chain cost. Lastly, 3D printing technology can create and deliver
products in small quantities in the fast time.

Electric and Electronic Industry

As 3D printing becomes more and more accessible to sciences, technology and manufacturing fields,
the manufacturers are starting to see its potential realized in all sorts of interesting ways. Nowadays,
various 3D printing technologies have already been used broadly for structural electronic devices like
active electronic materials, electrode and devices with mass customization and adaptive design through
embedding the conductors into 3D printed devices.

The production process for the 3D electrode by utilizing the Fused Deposition Modelling of 3D
printing technique provides low-cost and a time efficient approach to mass producing electrode materials.
Compared to commercial electrodes such as aluminium, copper and carbon electrodes, the design and
surface area of the 3D electrode can be easily customized to suit a particular application. Furthermore, 3D
printing process for the 3D electrode is fully automated, with a high degree of precision, made it possible
to complete the printing process for eight 8 electrodes in just 30 minutes.
In addition, active electronic components are any electronic devices or components capable of
amplifying and controlling the flow charges of electric. Besides, active devices also include those that can
generate power. Examples of active electronic components include silicon-controlled rectifiers,
transistors, diodes, operational amplifiers, light-emitting diodes (LEDs), batteries and so on. These
components normally require highly elaborate fabrication processes compared to those used for passive
components due to their complex functionalities. 3D printing technology provides advantages for
processing of product along with its electronics.

ADVANTAGES
 Create anything with great geometrical complexity.
 Ability to personalize every product with individual customer needs.
 Produce products which involve great level of complexity that simply could not be produced
physically in any other way.
 Additive manufacturing can eliminate the need for tool production and therefore reduce the costs,
lead time and labour associated with it.
 3D printing is an energy efficient technology.
 Additive Manufacturing use up to 90% of standard materials and therefore creating less waste.
 Lighter and stronger products can be printed.
 Increased operating life for the products.
 Production has been brought closer to the end user or consumer.
 Spare parts can be printed on site which will eliminate shipping cost.
 Wider adoption of 3D printing would likely cause re-invention of a number of already invented
products.
 3D printing can create new industries and completely new professions.
 Printing 3D organs can revolution arise the medical industry.
 Rapid prototyping causes faster product development.

DISADVANTAGES
 Since the technology is new, limited materials are available for printing.
 Consumes more time for less complicated pats.
 Size of printable object is limited by the movement of extruder.
 In additive manufacturing previous layer has to harden before creating next layer.
 Curved geometry will not be much accurate while printing.
 FUTURESCOPE
NASA engineers are 3-D printing parts, which are structurally stronger and more reliable than
conventionally crafted parts, for its space launch system.
Medicine is perhaps one of the most exciting areas of application. Beyond the use of 3-D printing in
producing prosthetics and hearing aids, it is being deployed to treat challenging medical conditions, and to
advance medical research, including in the area of regenerative medicine.

ROCKET ENGINE
NASA's first attempt at using 3D-printed parts for rocket
engines has passed its biggest, and hottest, test yet. The largest
3D-printed rocket part built to date, a rocket engine injector,
survived a major hot-fire test. The injector generated 10 times
more thrust than any injector made by 3D printing before, the
space agency announced. A NASA video of the 3D-printed rocket
part test shows the engine blazing to life at the agency's Marshall
Space Flight Center (MSFC) in Huntsville Ala.

3D BIO-PRINTING
3D bioprinting is the process of generating
spatially-controlled cell patterns using 3D printing
technologies, where cell function and viability are
preserved within the printed construct. Using 3D
bioprinting for fabricating biological constructs
typically involves dispensing cells onto a
biocompatible scaffold using a successive layer-by-
layer approach to generate tissue-like three-
dimensional structures. Given that every tissue in
the body is naturally compartmentalized of
different cell types, many technologies for printing
these cells vary in their ability to ensure stability
and viability of the cells during the manufacturing
process. Some of the methods that are used for 3D
bioprinting of cells are photolithography, magnetic
bioprinting, stereolithography, and direct cell
extrusion.
3D PRINTING IS SAPCE

In one small step towards space manufacturing, NASA is sending a

3D printer to the International Space Station. Astronauts will be able
to make plastic objects of almost any shape they like inside a box
about the size of a microwave oven enabling them to print new parts
to replace broken ones, and perhaps even to invent useful tools.

The launch, slated for around September 19, will be the first time
that a 3D printer flies in space. The agency has already embraced
ground-based 3D printing as a fast, cheap way to make spacecraft
parts, including rocket engine components that are being tested for its
next generation of heavy-lift launch vehicles. NASA hopes that the new capability will allow future explorers
to make spacecraft parts literally on the fly.

CONCLUSION
As the 3D printer is a device, it should be analysed with the advantages and disadvantages, how the
device can change the society and engineering etc in mind. The very nature of 3D printing, creating a part
layer by layer, instead of subtractive methods of manufacturing lend themselves to lower costs in raw
material. Instead of starting with a big chunk of plastic and carving away (milling or turning) the surface in
order to produce your product. Additive manufacturing only "prints" what you want, where you want it.
Other manufacturing techniques can be just as wasteful. 3D printing is the ultimate just-in-time method of
manufacturing. No longer do you need a warehouse full of inventory waiting for customers. Just have a 3D
printer waiting to print your next order. On top of that, you can also offer almost infinite design options and
custom products. It doesn't cost more to add a company logo to every product you have or let your
customers pick every feature on their next order, the sky is the limit with additive manufacturing.