3D Printing
Guide

  • 1. Introduction
  • 2. 3D printing processes
  • 3. softwares for 3d designing
  • 4. how to reduce cost for 3d printing

INTRODUCTION TO 3D
PRINTING

3D printing is an assembling procedure where progressive layers of material are set down over one another in an added substance process.Although 3D printing is frequently discussed as another technology,it has really been around forover 30 years.

History

AM forms for metal sintering or liquefying, (for example, particular laser sintering, direct metal laser sintering, and specific laser dissolving) as a rule passed by their very own individual names during the 1990s. At the time, all metalworking was finished by procedures that we presently call non-added substance (throwing, creation, stepping, and machining); albeit a lot of robotization was connected to those advancements, (for example, by robot welding and CNC), the possibility of an apparatus or head traveling through a 3D work envelope changing a mass of crude material into an ideal shape with a toolpath was related in metalworking just with procedures that evacuated metal (as opposed to including it, for example, CNC processing, CNC EDM, and numerous others.

In any case, the robotized strategies that additional metal, which would later be called added substance producing, were starting to challenge that supposition. By the mid-1990s, new strategies for material testimony were created at Stanford and Carnegie Mellon University, including microcasting and splashed materials. Conciliatory and bolster materials had likewise turned out to be increasingly normal, empowering new item geometries.

About 3d Printing

3D printing is any of different procedures in which material is joined or cemented under PC control to make a three-dimensional article, with material being included, (for example, fluid particles or powder grains being combined), commonly layer by layer. During the 1990s, 3D printing systems were viewed as reasonable just for the creation of utilitarian or aesthetical models and an increasingly suitable term was quick prototyping.

Today, the exactness, repeatability and material range have expanded to the point that 3D printing is considered as a modern generation innovation, with the name of added substance producing. 3D printed articles can have an exceptionally mind boggling shape or geometry and are constantly created beginning from an advanced 3D display or a CAD document. There are a wide range of 3D printing procedures, that can be assembled into seven classifications.

APPLICATIONS TO 3D
PRINTING

ENGINEERING

Typically,engineers can invest days making physical models to clarify their plans to clients.Using current innovation, they can utilize their current CAD illustrations to quickly make a 3D model and print it in 3D.Not just do they spare time yet complex geometries that can't be displayed by hand can be delivered productively and requiring little to no effort.

MEDICAL

Typically,engineers can invest days making physical models to clarify their plans to clients.Using current innovation, they can utilize their current CAD illustrations to quickly make a 3D model and print it in 3D.Not just do they spare time yet complex geometries that can't be displayed by hand can be delivered productively and requiring little to no effort.


BENEFITS TO 3D
PRINTING

Efficient technology

Compress time cycle by 3d printing multiple prototypes on demand.

Reduce Development cost

Cut traditional prototypes an cutting tools.

Geometric complexity

Product differentiation,design freedom , texture and structure.

Fuels Innovation

Print prototypes in hours,obtain feedback and reconsider until designs are perfect.

Customised Products

Customised merchandise and other products which enhances innovation.

Win Bussiness

Bring realisitic models to prospective accounts, sponsors.

3D PRINTING
PROCESS

1. Stereolithography

Stereolithography is an added substance fabricating process that, in its most basic structure, works by centering a bright (UV) laser on to a tank of photopolymer resin.

With the assistance of PC supported assembling or PC helped plan (CAM/CAD) software, the UV laser is utilized to draw a pre-modified structure or shape on to the outside of the photopolymer tank.

Photopolymers are touchy to bright light, so the tar is photochemically hardened and shapes a solitary layer of the ideal 3D object. Then, the manufacture stage brings down one layer and an edge recoats the highest point of the tank with resin. This procedure is rehashed for each layer of the structure until the 3D object is finished. Finished parts must be washed with a dissolvable to wipe wet pitch off their surfaces.

WORKING

The UV laser is used to draw a design or shape according to the design uploaded on to the surface of the material.

The photopolymers are sensitive to UV light, so the resin is photochemically solidified and forms a single later of the desired 3D object.

In this way, first a base is made on the platform and it goes on till the top of the layer of the product.

Completed parts are washed with a solvent to clean wet resin off their surfaces

APPLICATIONS

  • Medical industry has preferred SLA 3D printing for creating anatomical regions of a patient.
  • Models made from this are used as an aid to diagnosis, preoperative planning etc.
  • Surgeons use models to plan surgeries.
  • Protoyping parts are often made from this technique. For a relatively low price, SLA can produce prototypes even of odd shapes.

ADVANTAGES

  • Speed Many parts can be made within a day
  • Prototypes and designs can be made quickly
  • The material used can be machined
  • It can also be used to make master patterns for casting or other processes

2. Fused Deposition Modeling (FDM)

Fused Deposition Modeling (FDM) is a 3D printing procedure that utilizes a constant fiber of a thermoplastic material. Filament is encouraged from an expansive curl through a moving, warmed printer extruder head, and is stored on the developing work. The print head is moved under PC control to characterize the printed shape. Normally the head moves in two measurements to store one even plane, or layer, at once; the work or the print head is then moved vertically just barely to start another layer. The speed of the extruder head may likewise be controlled to stop and begin affidavit and structure an intruded on plane without hanging or spilling between segments .

WORKING

The raw material is first extruded as a thin filament through a heated nozzle.

It is first deposited at the bottom of the printer platform

The next layer fuses with the layer below. This keeps on going from bottom to the top till the product has been made

APPLICATIONS

  • Automotive
  • Manufacturing
  • Consumer goods
  • Medical industry

ADVANTAGES

  • Raw material is relatively inexpensive, durable.
  • Wide choice of raw material
  • Affordable
  • Low turnaround time

3.Specific laser sintering (SLS)

Specific laser sintering is an added substance fabricating (AM) method that utilizes a laser as the power source to sinter powdered material (normally nylon/polyamide), pointing the laser consequently at focuses in space characterized by a 3D show, restricting the material together to make a strong structure. It is like direct metal laser sintering (DMLS); the two are instantiations of a similar idea yet vary in specialized subtleties. Specific laser dissolving (SLM) utilizes a practically identical idea, however in SLM the material is completely softened as opposed to sintered, permitting distinctive properties (gem structure, porosity, etc).

An added substance producing layer innovation, SLS includes the utilization of a powerful laser (for instance, a carbon dioxide laser) to intertwine little particles of plastic, metal, clay, or glass powders into a mass that has an ideal three-dimensional shape. The laser specifically melds powdered material by examining cross-areas produced from a 3-D advanced depiction of the part (for instance from a CAD document or sweep information) on the outside of a powder bed. After each cross-segment is examined, the powder bed is brought down by one layer thickness, another layer of material is connected on top, and the procedure is rehashed until the part is completed.

Since completed part thickness relies upon pinnacle laser control, as opposed to laser span, a SLS machine ordinarily utilizes a beat laser. The SLS machine preheats the mass powder material in the powder bed to some degree underneath its liquefying point, to make it simpler for the laser to raise the temperature of the chose districts the remainder of the route to the softening point.

WORKING

After uploading the CAD file, the selected material will be heated up by a high powered laser just below its melting point.

Due to heating, the material fuses together to form a solid 3D object.

Once the initial layer is formed, the platform of the SLS machine drops exposing a new layer of powder.

The new layer is again heated and the same process is repeated till the entire object has been printed.

When the object is fully formed, it is left to cool in the machine before being removed.

APPLICATIONS

  • Aerospace parts
  • Military hardware
  • Functional Prototypes
  • Jigs and Fixtures
  • Investment Casting Patterns
  • Medical and Healthcare

ADVANTAGES

  • Speed Many parts can be made within a day
  • Prototypes and designs can be made quickly
  • The material used can be machined
  • It can also be used to make master patterns for casting or other processes

4. DIGITAL LIGHT PROCESSING (DLP)

DIGITAL LIGHT PROCESSING is a process similar to SLA because it works with photopolymers. The difference stands in the power source i.e. the laser. DLP uses arch lamp filled with a liquid crystal display panel. This is generally faster than SL Printing since the light is applied to the entire photopolymer resin in a single pass. This produces highly accurate parts with excellent resolution.

WORKING

Initially the file with the CAD/CAM design is uploaded and sent to the printer.

A vat of 3D polymer is exposed to light from a DLP projector.

The DLP projector displays the image of the 3D model as uploaded onto the liquid polymer.

The part which is exposed hardens and the build plate moves down.

The liquid polymer is once more exposed to the light.

The process is repeated till the 3D model is complete.

APPLICATIONS

  • Patterns for casting.
  • Prototypes.
  • Visual prototypes for photo shoots and market testing.
  • Low volume products with high complexities.

ADVANTAGES

  • Only a shallow vat of resin is required to facilitate this process which generally results in less waste and lower running cost.

Some platforms where you can design 3D models.

Solid Works

SolidWorks is a solid modeling computer-aided design and computer-aided engineering computer program that runs on Microsoft Windows. SolidWorks is published by Dassault Systèmes. According to the publisher, over two million engineers and designers at more than 165,000 companies were using SolidWorks as of 2013.

Plateform

Window

Recommended for

intermediate / Professionals

Price

Paid

Fusion 360

Fusion 360 helps students and educators prepare for the future of design. It's the first 3D CAD, CAM, and CAE tool of its kind, connecting your entire product development process into one cloud-based platform. Download the software today, then turn your ideas into reality.

Plateform

Mac, Window

Recommended for

intermediate / Professionals

Price

Paid/Free

TinkerCad

Tinkercad is the largest community of 3D design and 3D printing enthusiasts of its kind! And its uniquness has so far attracted over seven million Tinkerers, with more users joining every minute!

Plateform

Online

Recommended for

Beginners

Price

Free

Cura

Add your Cura is an open source 3D printer slicing application. It was created by David Braam who was later employed by Ultimaker, a 3D printer manufacturing company, to maintain the software. Cura is available under LGPLv3 licenseor connect to a database.

Plateform

Window

Recommended for

Intermediate

Price

Free

Simplify 3D

It translates 3D models into instructions your printer understands. Better instructions mean better prints, so a simple software upgrade makes all the difference in the world. In fact, more than 90% of experts agree that 3D printing software has the greatest impact on print quality, even more so than the 3D printer itself! 1

Plateform

Windows , Mac , Linux

Recommended for

Intermediates , Professional

Price

Paid

On Shape

Onshape’s modern CAD system frees engineers to focus on doing their best work. Unlike old CAD systems, Onshape unites modeling tools and design data management in a secure cloud workspace that is accessible on any device, never loses data, and eliminates design gridlock.

Plateform

Online

Recommended for

Professionals

Price

Free

How to Reduce 3d Printing cost

1. Choose your Printing Material Wisely

Some of the materials we use in 3d printing are more expensive as compared to the other materials available . If the model can be work out with the material of less cost then it is preferable to opt out for the low cost material.

2. Reduce the Size of your Model

If you are printing a material which and its size does not have functional importance then it is recommended that the size of the model can be reduced . This results in the decrease of overall requirement of the material for the model and also the cost.

3. Choose your Printing Material Wisely

Some of the materials we use in 3d printing are more expensive as compared to the other materials available . If the model can be work out with the material of less cost then it is preferable to opt out for the low cost material .

4. Eliminate the Use of Support structures (if possible)

Most 3D printing processes require support structures to act as “scaffolding” for features that can’t be built above open air, such as overhangs, undercuts, holes, cavities, etc. But in some cases it is not required the use of supports in that case the cost of your 3d printing model can be effectively reduce by avoiding the use of support structures if possible in your model. Eliminating the support structures also improves the surface finish of the model.

5. Choose the surface finish that suits your model well

Sometimes the surface finish of the model is a achieved by the manual post processes which results in the increase of the cost of the model . This cost can be reduced by the consider each finish on the upload page, and choose a finish which takes less time . For example, dyeing is a less expensive way to color your objects than painting the complete model , because it's a faster technique. However, the color will last longer and be of higher quality with painting. It's up to you to choose which finish is best depending on your priorities.