3D Printing and Design (Advance)

3D Printing and Design (Advance) By:- Er. Shivam Choudhary( M. Tech) UNIT-1.0 3D Printing Materials UNIT-2.0 Solid based 3D Printing Processes UNIT-3.0 Liquid based 3D Printing Processes UNIT-4.0 Powder based 3D Printing Processes UNIT-5.0 Post Processing and Quality Unit-1.0 3D Printing Materials 1.1 Various forms of 3D printing raw material-Liquid, Solid, Wire, Powder. 1.2 Popular FDM, SLA, SLS, Binder Jetting, Material Jetting and Direct Energy deposition 3D printing materials. 1.3 Polymers, Metals, Non-Metals, Ceramics. 1.4 Polymers and their properties. 1.5 Powder Preparation and their desired properties. 1.6 Choosing the Right 3D Printing Material on the basis of Performance Requirements and Material Properties Unit-2.0 Solid based 3D Printing Processes 2.1 Basic principle and working of fused deposition modeling (FDM) process. 2.2 Liquefaction, solidification and bonding. 2.3 Laminated Object Manufacturing process. 2.4 Cost estimation of FDM 3D printed component. Unit-3.0 Liquid based 3D Printing Processes 3.1 Photo polymerization. 3.2 Principle and working of stereo lithography apparatus. 3.3 SLA based 3D printing processes. 3.4 SLA based 3D printing process materials. 3.5 Scanning techniques. 3.6 Curing processes. 3.7 Cost estimation of SLA 3D printed component. Unit-4.0 Powder based 3D Printing Processes 4.1 Powder fusion mechanism. 4.2 Principle and working of Selective Laser Sintering (SLS) process. 4.3 SLS based 3D printers. 4.4 Laser Engineering Net Shaping process. 4.5 Electron Beam Melting. 4.6 Binder Jet 3D Printing. 4.7 Materials and Process parameters for SLS based 3D printing processes. 4.8 Cost estimation of SLS based 3D printed component. Unit-5.0 Post Processing and Quality 5.1 Need of post processing: Functional and Aesthetic reasons. 5.2 Steps of Post Processing: Cleaning/Support removal, Fixing, Curing or hardening, Surface finishing, Colouring. 5.3 Cleaning: Support Removal (FDM and Material Jetting); Powder Removal (SLS and Powder Bed Fusion); Washing (SLA and Photo polymerisation). 5.4 Fixing: Filling, Gluing, Welding. 5.5 Surface finishing: Sanding, Polishing, Tumbling, Hydro dipping, Epoxy coating, Electro Plating, Vapour smoothing-Acetone treatment. 5.6 Colouring, Coating, Priming and Painting. 5.7 Inspection and testing: Digital, Visual, Physical. 5.8 Defects and their causes. 3D Printing  3D printing is a method of creating three-dimensional objects, through the use of computer models.  3D printers analyze a design or model given to them by a computer and print it out in real life by depositing some material, like wood filament or polymer resin layer by layer to create a 3D model.  3D printing, also known as additive manufacturing, is the process of making a physical object from a three-dimensional digital model, typically by laying down many thin layers of a material in succession.  The creation of a 3D printed object is achieved using additive processes, where an object is created by laying down successive layers of material until the object is created.  Each of these layers can be seen as a thinly sliced cross-section of the object.  3D printing enables you to produce complex shapes using less material than traditional manufacturing methods. Various forms of 3D printing raw material  3D printing technology can be divided into solid, liquid, and powderbased, depending on the form of input materials used.  For solid-based 3D printing, plastic wire material and layers of adhesivecoated paper, plastic, or metal laminates can be processed to fabricate 3D parts in FDM (Fused Deposition Modeling) and LOM (Laminated Object Manufacturing) respectively.  Polymer materials are usually provided as solid filament, pellets, liquid resin or powders.  Powder-based 3D printing is an additive manufacturing method that uses raw material in powder form.  This is in contrast to the filament materials used in other, more common 3D printing techniques.  The powder material, in this case, can be either metal or plastic. Fused Deposition Modeling(FDM)  FDM stands for Fused Deposition Modeling.  It is an additive manufacturing process where the material is fused together layer by layer in a specified pattern to create a 3D object.  FDM became popular starting in the 1980s and is now widely used for cheap and easily customizable rapid prototyping.  FDM uses polymers as raw material (or filaments), including PLA (Polylactic Acid), ABS (Acrylonitrile Butadiene Styrene), PET (Polyethylene Terephthalate), PEEK (Polyether Ether Ketone), TPU (Thermoplastic Polyurethane), PPSU (Polyphenylsulfone), HIPS (High Impact Polystyrene), ASA (Acrylonitrile Styrene Acrylate), and reinforced polymers.  Some of the most common filament materials for FDM include ABS, PETG, TPU, PLA, PEEK and PC SLA (Stereolithography)  SLA stands for Stereolithography.  It is a widely-used 3D printing process and the most popular of the resin printing technologies.  SLA creates objects by selectively curing a polymer resin, layer by layer, using an ultraviolet (UV) laser beam.  The materials used in SLA are photosensitive thermoset polymers that come in a liquid form.  It is used in businesses across a wide range of industries including engineering, product design, dental, manufacturing, jewelry, healthcare, audiology, and more. Selective Laser Sintering(SLS )  SLS stands for Selective Laser Sintering and is a type of powder bed fusion (PBF) 3D printing technology.  In SLS, a high-power laser draws each layer into a bed of powder, usually Nylon.  The laser sinters the powder particles together to form solid structures.  SLS 3D printing has been a popular choice for engineers and manufacturers for decades.  Low cost per part, high productivity, and established materials make the technology ideal for a range of applications from rapid prototyping to small-batch, bridge, or custom manufacturing  SLS is also the method of choice for practical applications requiring mechanical joints such as snap fits, live hinges, and others. Binder Jetting  Binder jetting is a 3D printing process that involves depositing a thin layer of a powdered component into the build chamber, followed by the application of adhesive droplets by a print head to bind the particles together.  This creates the part layer by layer, and post processing may be required to complete the work.  Binder jetting is used in two main areas: metal 3D printing and in the printing of sand models and casts. Material Jetting  Material jetting is an inkjet printing process where inkjet-type print heads apply droplets of material to print a model slice.  These “inks” can be pure photopolymer or pure waxes, or they can contain ceramic or metal particles.  Some machines have heads for applying color to the model.  Material jetting falls into three categories, by the nature of the materials they use: PolyJet, Nanoparticles Jetting (NPJ), and Drop on Demand (DOD). Directed Energy Deposition (DED)  Directed Energy Deposition (DED) is an additive manufacturing process in which focused thermal energy is used to fuse materials by melting as they are being deposited .  It allows for the creation of objects by melting the material (most frequently used for metals such as titanium, aluminum, stainless steel or copper) in powder or as a wire with a focused energy source as it is deposited by a nozzle on a surface.  DED can be used to manufacture everything from small brackets and fixtures to the skeleton and exterior panels of aircraft  DED methods can be used to construct products from scratch, one very popular area of use is coating or cladding other items in metal, or for repairing damaged metal products. 3D printing material  3D printing material refers to the raw material used in the 3D printing process to create a physical object.  There are many materials that can be used for 3D printing, including plastic, metal, carbon fiber, and even wood .  Different types of 3D printers use different materials (such as polymer, ceramic, metal, and composites)  Some of the most popular plastic materials for 3D printing include ABS (Acrylonitrile Butadiene Styrene) and PLA (Polylactic Acid).  Some of the most popular metal materials for 3D printing include steel, stainless steels, tool steels, specialty alloys (such as Inconel and Cobalt Chromium), titanium, and aluminum.  Steel is the most common metal used in 3D printing due to its strength, ability to be turned into 3D printing metal powder, relatively low cost, and post-processability. Polymer  A polymer is a large molecule or a macromolecule, which essentially is a combination of many subunits.  The term polymer in Greek means ‘many parts’. Polymers can be found all around us, from the strand of our DNA, which is a naturally occurring biopolymer, to polypropylene which is used throughout the world as plastic.  Polymers can be naturally found in plants and animals (natural polymers) or can be human-made (synthetic polymers).  Different polymers have a number of unique physical and chemical properties, due to which they find usage in everyday life. Classification of Polymers Natural Polymers They occur naturally and are found in plants and animals. For example, proteins, starch, cellulose and rubber. To add up, we also have biodegradable polymers called biopolymers. Semi-synthetic Polymers They are derived from naturally occurring polymers and undergo further chemical modification. For example, cellulose nitrate and cellulose acetate. Synthetic Polymers These are human-made polymers. Plastic is the most common and widely used synthetic polymer. It is used in industries and various dairy products. For example, nylon-6, 6, polyether, etc. Properties of Polymers  The properties of a polymer are affected by its structure, the type of monomer units from which it is formed, and other factors.  Some physical properties of polymers include tensile strength, melting point, boiling point, hardness, density, heat capacity, thermal expansion, and crystallinity.  The chemical properties of a polymer depend on its molecular structure and the functional groups present in its monomer units. Metals  Metals are substances that form naturally below the surface of the Earth.  Most metals are lustrous or shiny. Metals are inorganic, which means they are made of substances that were never alive.  Metal is very strong and durable and therefore is used to make many things.  These are used for making automobiles, satellites, cooking utensils, etc.  Most metals are hard but some are not.  Sodium and potassium are such metals that can be cut by knife whereas mercury is a liquid metal at room temperature.  Iron is solid in nature. Non-Metals  Non-metals are elements that generally lack metallic properties.  They are usually poor conductors of heat and electricity and are brittle.  Non-metals are the elements which form negative ions by accepting or gaining electrons.  Non-metals usually have 4, 5, 6 or 7 electrons in their outermost shell. Ceramics  Ceramics are materials that are neither metallic nor organic.  They may be crystalline, glassy or both crystalline and glassy.  A ceramic is any of the various hard, brittle, heat-resistant, and corrosion-resistant materials made by shaping and then firing an inorganic, nonmetallic material, such as clay, at a high temperature.  Common examples are earthenware, porcelain, and brick. Powder preparation  Powder preparation is the process of reducing the particle size of powder ingredients.  This can be done through various methods such as atomization, comminution, and chemical methods.  The choice of method depends on the type of powder being prepared and its intended use. Atomization  Atomization is one of the most effective industrial powder preparation methods.  This method involves the disintegration (atomizing) of liquid metal by means of highspeed medium (air, inert gas, water) striking the melt streaming through a nozzle.  The molten alloy is prepared in a furnace and then it is transferred to the tundish.  The melt is poured from the tundish through the nozzle into the chamber.  The water (air, gas) jets break the melt stream into fine droplets.  The droplets solidify when they fall in the chamber. The powder is collected at the bottom of the chamber. The powder is removed from the chamber and dried (if necessary). Comminution  Comminution is a mechanical method of powder preparation involving breaking solid particles in mills (ball, vibratory, hummer).  This method is generally applied for the preparation of powders of brittle materials.  The most widely used comminution machine is a ball mill, utilizing the energy of steel balls, which move in a rotating drum and crush the metal pieces into fine particles. Chemical methods  Chemical methods of powder preparation involve the use of chemical reactions to produce powders.  Metal powders may be prepared by reduction of the metal oxides (carbides) followed by mechanical crushing or precipitation of metals from solution (hydrometallurgical method).  Powder may also be prepared by electrolytic deposition of a metal at the cathode followed by mechanical crushing of the deposited material. Properties of Powder Preparation  Some properties that may be desired in a powder include a specific particle shape, particle size distribution, apparent density, compressibility, flowability, and chemical composition.  The method used for powder preparation can affect these properties. For example, atomization can produce spherical particles while comminution can produce irregularly shaped particles.  The choice of method for powder preparation should be based on the desired properties of the resulting powder. Choosing the right 3D printing material based on performance requirements and material properties. To choose the right 3D printing material based on performance requirements and material properties, you should consider the following steps:  Identify the performance requirements: Determine the specific performance requirements for the object being printed, such as strength, flexibility, durability, heat resistance, and chemical resistance.  Research available materials: Research the available 3D printing materials and their properties to determine which materials meet the performance requirements.  Evaluate material properties: Evaluate the properties of the available materials to determine which ones are best suited to meet the performance requirements. Consider factors such as strength, flexibility, durability, heat resistance, and chemical resistance.