What is the printer? Maybe you all know, but do you know what 3D Printer is and how do they work? If you do not know anything about this and like everything else, then you should read this article carefully.
Where a normal printer is able to print only in 2d, a 3D Printer is advanced from it and it can print things like three dimensional like a real object. With this you can design the object as you would imagine. This simplicity and accessibility makes 3D printer available to you.
If you do not know about 2D or 3D then these are 2 dimensional and 3-dimensional. If any object is placed in a plane surface then its position can be seen in x axis, y axis and z axis. With that, you can see the depth of that object, the 3d object is completely visible as real objects.
Where 2d models can be seen only in front of you, you can see the 3d models from all sides back and forth. As we look at things in our real life.
Read the article till the end to get all the information related to what the 3D printing machine is and how it works. In the same way, the entire process of doing this work has been explained in a simple language too. Hope this article is what 3D printer you like. So let's go ahead without delay.
3D printing or additive manufacturing is a process where three-dimensional solid objects are created from a digital file.
Additive processes are used to create 3D printed object. In order to create an object in this additive process, the material is placed on one of the successive layers until it becomes an object. You can see each layer in it, at the end of a thinly sliced horizontal cross-section, that eventual object that you want to create at the end.
3D printing is completely opposite subtractive manufacturing where an object is slowly cut into small pieces by using a milling machine.
3D printing enables you to make very complex (functional) shapes that can be very difficult to do with traditional manufacturing methods. There is very little need for this.
3D printer history
If you open the history of manufacturinf itself, then the subtractive methods have been brought to the first instance. Subtractive methods have been given more importance in the entire machining empire (in which the exact shapes are made with high precision), in which filing and turning are main by milling and grinding.
Applications of Additive manufacturing have been provided the last place in the entire manufacturing spectrum.
For example, rapid prototyping was one of the earliest additive variants and its mission was how to reduce lead time and cost when the prototypes of new parts and devices are being developed, to do this first subtractive toolroom methods were usually slow and expensive).
But as techonology started to advance, additive methods were used to get more productivity in manufacturing. At a time in which only subtractive methods were used, the benefits are now being achieved by using additive methods.
If we talk about real integration of new additive technologies, in commercial production, then subtractive methods should be used on a complementing tone, not with subtractive methods but they should be eradicated completely.
If talked about future of Commercial Manufacturing, manufacturing companies need all the available technologies of flexible, ever-improving users, if they want to be competitive.
How does 3D printing work?
3D printing begins with your computer when you create a 3D model in your system. In this, this digital design is a CAD (Computer Aided Design) file.
A 3D model is either made up of ground up with 3D modeling software which is based on data generated by a 3D Scanner. With the help of a 3D scanner, you can create a digital copy of an object.
3D Scanning
This is a process in which a real-world object or environment is analyzed to collect data concerning their shape and appearance. These collected data is then made from digital 3D models.
3D Modeling and 3D Modeling Software
In 3D Computer Graphics, 3D modeling is called the process by which the mathematical representation of the surface of an object is made, in 3 dimensions, by those special softwares. The product that is created in it is called 3D Model and the person who works on these 3D Models is called 3D Artists.
3D Modelling Softwares is a class of 3D Computer Graphics Software used to make a 3D model. The individual programs of this class are called modeling applications or modelers.
3D modeling software is always built with the needs of the user industry. Such as Aerospace, Transportation, furniture designs, fabrics etc.
Now that we have a 3D model, now the next step is to prepare it so that it can be made 3D printable.
Slicing: 3D Model to 3D Printer
You have to slice a 3D model to make it 3D printable ready. Slicing means to divide a 3D model into hundreds and thousands of horizontal layers. To do this, slicing software is used.
Sometimes it is possible to slice a 3D file into a 3D modelling software or in a 3D printer only. It is also possible that you have to use a certain slicing tool for a specific 3D printer.
When your 3D model is sliced, you are ready to feed it in your 3D printer. It is used via USB, SD or Wi-Fi. It depends on which brand of 3D printer you are using. When you upload a file into a 3D printer, then the object is ready to be 3D printed by layer by layer.
Types of 3D Printing Technology
There are several ways to print 3D. All of these technologies are additive, they also differ, so primarily in ways that layers are constructed to create an object.
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Some methods are used in the melting and softening material to extrude the layers. They use a UV laser (or some other similar light source) to cure another photo-reactive resin. Layer by layer
To make this thing even more precise: From 2010, the American Society for Testing and Materials (ASTM) group "ASTM F42 - Additive Manufacturing" has developed a set of standards which classify Additive Manufacturing processes. In categories.
Under Standard Terminology for Additive Manufacturing Technologies, 7 processes are used.
1. Vat Photopolymerization
1.1 Stereolithography (SLA)
1.2 Digital Light Processing (DLP)
1.3 Continuous Liquid Interface Production (CLIP)
2. Material Jetting
3. Binder Jetting
4. Material Extrusion
4.1 Fused Deposition Modeling (FDM)
4.2 Fused Filament Fabrication (FFF)
5. Powder Bed Fusion
5.1 Selective Laser Sintering (SLS)
5.2 Direct Metal Laser Sintering (DMLS)
6. Sheet Lamination
7. Directed Energy Deposition
Here we will learn about all these seven 3D Printing Processes.
Vat Photopolymerization
A 3D printer is based on the Vat Photopolymerization method, in which a container is filled from photopolymer resin and it is then hardened by a UV light source.
Stereolithography (SLA)
The most commonly used technology in this is Stereolithography (SLA).
In this technology, a vat of liquid ultraviolet curable photopolymer resin is used and an ultraviolet laser is used to make the layers of the object one at a time.
For each layer, the laser beam traces one cross section that part pattern also on the surface of the liquid resin. By coming in the exposure of the ultraviolet laser light, it cures and solidifies the pattern, which is traced to resin, and then joins it with the bottom layer.
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 that part, which then re-coates it with fresh material. On this new liquid surface, the subsequent layer pattern is trace, in which it is associated with the previous layer. Now this three-dimensional object is completely complete and is ready by the end of the project.
Stereolithography requires support structures which are attached with the part of the elevator platform that they have to serve and hold the object as it floats in the basin that is complete with the liquid resin. They have to manually remove when the object finally gets finished.
This technique was invented by Charles Hull in 1986, at that time he also found a company called 3D Systems.
Digital Light Processing (DLP)
DLP is Digital Light Processing, one of the methods of printing which uses light and photosensitive polymers. Where this is very similar, like the stereolithography, the key difference between them is that they are light-source. DLP utilizes traditional light-sources such as arc lamps
In most forms of DLP, each layer is the desired structure, it is projected in the vat in the form of liquid resin which is then solidified layer by layer, in which the buildplate moves up or down. As this process succeeds every layer, so that this is the most happening process, in most forms of 3D printing.
Envision Tec Ultra, MiiCraft High Resolution 3D printer, and Lunavast XG2 are examples of DLP printers.
Continuous Liquid Interface Production (CLIP)
The most recent and fastest process that Vat uses for Photopolymerization is CLIP, which is full form, Continuous Liquid Interface Production. It was invented by a company whose name is Carbon.
Carbon launched three industrial 3D printers:
1. Carbon M1
2. Carbon M2 3D Printer
3. Carbon L1
Digital Light Synthesis
The CLIP process has the heart of Digital Light Synthesis technology. In this technology, light projects from a custom high performance LED light engine to a sequence of UV images, in which it exposes a cross-section, 3D printed part, to which UV curable resin is partially cured, in a precisely controlled way.
Oxygen is passed from the oxygen permeable window to which a thin liquid interface is formed between the uncured resin window and the printed part called the dead zone.
These dead zones are very thin, about ten of microns Inside the dead zone, oxygen prohibits the curing of light that resin that is closest to the window, because it allows continuous flow fluid below the printed part. UV projected light upwards just above the dead zone causes a cascade such as curing the part.
Printing does not allow the Carbon hardware to end end properties in real world applications. Once light has shaped part, a second programmable curing process achieves that desired mechanical properties by baking only 3d printed part, in a thermal bath or oven.
Programmed thermal curing sets the mechanical properties for which he triggers a secondary chemical reaction which causes the material to be strengthened and finally the desired final properties.
Parts that are printed with Digital Light Synthesis ™ are mostly those of injection-molded parts. Digital Light Synthesis ™ produces consistent and predictable mechanical properties, making parts that are solid from inside.
Material Jetting
In this process, the material is applied in droplets by a small diameter nozzle, which is similar to the work of a common inkjet paper printer, but it is applied layer-by-layer, so that a platform can be made, to create a 3D object and then be hardened with the help of UV light.
Binder Jetting
Binder jetting is used in two materials: powder base material and a liquid binder.
In the build chamber, the powder is first spread in equal layers and then the binder is applied. By jet nozzles, which "glue" makes the powder particles in the shape of a programmed 3D object.
Now the finished object is glued together by using binder remains in the container, using the powder base material. Once the print is finished, the remaining powder is cleaned and used in 3D printing in the next object.
This technology was first developed in Massachusetts Institute of Technology in 1993 and in 1995. Z Corporation has acquired its exclusive license.
Material Extrusion
The most commonly used technology in this process is its name Fused Deposition Modeling (FDM).
Fused Deposition Modeling (FDM)
This FDM technology works by using a plastic filament or metal wire, which is made to be unwound and material is supplied by a coil, which is an extrusion nozzle which turns on or off the flow.
In this, the nozzle is heated to melt the material and which can be moved in both horizontal and vertical directions through a numerically controlled mechanism, which is directly controlled by a computer-aided manufacturing (CAM) software package through.
In this, the object is produced in the extrude form layer of melted material, such as the material becomes hardens, as if it is extruded from the nozzle.
The most used of this technology is in two plastic 3D printer filament types:
ABS (Acrylonitrile Butadiene Styrene) and PLA (Polylactic acid)
There are many more materials available, including properties ranging from wood fill to flexible and even conductive materials.
FDM was invented by Scott Crump in the late 80's. After making this technology a patent, he started a company named Stratasys in 1988. The term Fused Deposition Modeling and its abbreviation FDM are both trademarked by Stratasys Inc.
Fused Filament Fabrication (FFF)
Its exact equivalent term, Fused Filament Fabrication (FFF), was nominated by members of the RepRap project, who wanted to provide it with a phrase that would later be legally unconstrained. That is, there was no problem in using it.
Well there are many different types of FFF 3D Printer configurations. The most popular arrangements are:
Cartesian-XY-Head
Cartesian-XZ-Head
Delta
Core XY
Powder Bed Fusion
The most commonly used technology in this is the Selective Laser Sintering (SLS).
Selective Laser Sintering (SLS)
SLS uses very high power laser to fuse small, plastic, ceramic and glass powders of particles together in a mass, which has a desired three-dimensional shape.
In this, the laser selectively fuses the powdered material for which it scans the cross-sections (or layers) that are generated in the surface of the powder bed through the 3D modeling program.
Once each cross-section is scanned, then the powder bed is reduced to a layer thickness. Then the material of a new layer is applied in the top and this process is repeat until the object is complete.
Direct Metal Laser Sintering (DMLS)
DMLS is basically similar to SLS, but it uses metal, plastic, ceramic or glass instead.
All untouched powders remain the same way and become a support structure for that object. Therefore no support structure is needed in it, which provides it with advantage above the SLS and SLA.
All unused powder can be used in the next print. SLS was developed and patented. They were searched by Carl Deckard, who were from University of Texas, in the mid-1980s, under the sponsorship of DARPA.
Sheet Lamination
The process of Sheet lamination is that the contents of the sheets are tied together with the help of external force. Sheets can be anything, whether they are metal, paper or a form of polymer.
Metal sheets are welded together in the layers with ultrasonic welding and then the CNC is made to a proper shape.
Paper sheets can also be used, but they stick with each other due to adhesive glue and they are cut later by the precise blades in shape. This field is a leading company of Mcor Technologies.
Directed Energy Deposition
This process is mostly used in the high-tech metal industry, as well as in rapid manufacturing applications. In this 3D printing apparatus is often attached with a multi-axis robotic arm and contains a nozzle which deposits metal powder or wire above a surface and an energy source (laser, electron beam or plasma arc). ) Which melt it, as well as finally becomes a solid object.
What materials are used in 3D Printer and Printing?
Mainly six types of materials are used to additive manufacturing:
Polymers, metals, concrete, ceramics, paper and some edibles (e.g., chocolate).
The material is often produced by wire feedstock a.k.a. In 3D printer filament, powder form or liquid resin.
All these materials are used in all the previously mentioned 3D printing techniques. Although polymers are more commonly used, some additive techniques emphasize the use of certain materials themselves.
How to choose the right 3D printing process?
Choosing the right optimal 3D printing process can be difficult for a particular application. Often there are more than one process that are suitable for each process, each process offers different benefits, such as greater dimensional accuracy, superior material properties and better surface finish.
For this reason, I have made a decision making tools and generalized guidelines that will help you choose the right 3D printing process.
Generally speaking, then there are three main things that you should first consider:
Material properties needed: strength, hardness, impact strength etc.
Functional and visual design requirements: smooth surface, strength, heat resistance etc.
The capabilities of 3D printing process: accuracy, available print volume, layer height etc.
What is the industry of 3D printing? How does it work?
The expected growth of the 3D printing industry worldwide was around $ 3.07b, from 2013 to $ 12.8B in 2018. According to sources, it is also going to cross the $ 21B figure by 2020.
As it is evolve, 3D printing technology is going to transform all major industries in the future, but it is going to change how we live, work, and play in the future.
This 3D printing industry encompass the technologies and materials of many forms with you. Where people think about 3D printing, they vizualize about the desktop 3D Printer. I told about this very little thing.
3D printing is divided into metals, fabrics, bio and other industries. That is why it is important that it be seen as a cluster of diverse industries which have different applications.
3D printing is now more complicated with our day-to-day business operations. CEO of many companies are seeing 3D printing as a benefit. In most of the time, most companies are primarily focusing on research, development and prototyping. Everyone knows about their potential.
Advantages of 3D Printing
Now let us know about the important benefits of 3D printing.
Geometric Complexity That too no Extra Cost
3D printing allows easy fabrication, too, of complex shapes, most of the things can not be prepared with any other manufacturing method.
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Due to the additive nature of this technology, their geometric complexity is not worth the high price. The cost of performance of such complex things and organic geometry optimized is just as much as the 3D print. Which is much less than the cost of traditional manufacturing.
Very little Start-up Costs
In the earlier formative manufacturing (such as Injection Molding and Metal Casting), each part requires an unique mold. The cost of these custom tools is very high. Thousands of items were manufactured in the same parts to reduce their cost.
Since there is no special tooling required in 3D printing, so it is equal to start-up cost. The cost of the 3D printed part depends on the amount of materials used only, as long as the machine is figured out in print and in post-processing, if found, get the final output.
Customizing Every Part
Have you ever thought that our clothes are standardized sizes? The reason I have already told that in traditional manufacturing it is easy to sell identical types of products to consumers and also cheaper.
3D printing allows easy customization Since its start-up cost is very low, it just needs to change the digital 3D model to create a new custom part. So what is the result?
Therefore, according to the specific needs of the user, easily, each item can be customized, which has no effect on manufacturing costs.
Low-cost prototyping, too soon
There is a great use of 3D printing that can be easily prototyping - both for form and function. All these things can be done in very short time and there is no harm in other processes. Also, no other manufacturing process is capable of doing this.
Parts that are printed in a desktop 3D printer can usually be prepared overnight, and a large amount of order can also be prepared in 2-5 days.
There is also a considerable improvement in design cycle (design, test, improvement, re-design) with the preparation of prototyping. Products that took 8+ months before development took place, they now only take 8-10 weeks to develop them.
Being Large Range For Specialty Materials
The most common and common 3D printing materials used in the present time are plastics. Metal 3D printing is also used in many industrial applications.
3D printing pallet has specialty materials whose properties can be changed according to specific applications. The 3D printed parts we are using nowadays are also high heat resistance, high strength or stiffness and also biocompatible.
Composites are also very common in 3D printing. The materials used in this are mixed with metal, ceramic, wood or carbon particles, or reinforced carbon fibers. In the results we find parts that have unique properties that are suitable for specific applications.
What are the limitations of 3D printings?
Where 3D Printings have so many advantages, some of these limitations are also limited. So let's know about their limitations.
Having low strength and anisotropic material properties
Physical properties of these 3D printed parts are not as good as the bulk material. Since they were made layer-by-layer, hence they are weaker and more brittle, in a direction they also approx 10% to 50%.
For this reason, plastic 3D printed parts are used mostly in non-critical functional applications.
Low cost-competitive even those in higher volumes
3D printing can never compete with traditional production processes when it comes to big production runs.
With no custom tool or mold in 3D printing, start-up costs are low, so the prototypes and identical parts of a small quantity (up to about 10) can be easily manufactured economically. When it comes to large quantities of matter, then in the case of the cost that technology fails there.
Limited precision and tolerances
The accuracy of a 3D printed part depends on the process and calibration of that machine. Typically, parts that are printed in a desktop FDM 3D printer have very little accuracy and tolerances too little.
For example, if you create the design of a hole whose diameter is 10mm then its true diameter will be after printing from 9.5 mm to 10.5 mm.
Post-processing and support removal
Printed parts are used in very few places immediately. Because they are not ready at that time, but they have to go through one or more post-processsing steps to get ready.
For example, when an item is printed with 3D printer, as if separated from the printer, then there are some marks and blemishes in the surface which is in contact with the other device. These areas require extra operations (sanding, smoothing, painting) to achieve a high quallity surface finish.
What is the main use of 3D printing
3D printer
Now let us know about the different applications of 3D printing.
Aerospace
Aerospace and Space engineers use 3D printing to produce high-performance parts. They have the ability to create topology optimized structures that have high strength-to-weight ratio and such a possibility that the multiple components can be consoled in a single part and which are very appealing.
Automotive
This automotive industry has also got a lot of money from 3D printings because of which it can easily make its customization and that too in a very short time.
For example, Volkswagen traditionally uses CNC machining to create custom jigs and fixtures. CNC typically has longer production times and higher costs. These same jigs and fixtures can be 3D-printed, overnight and test can also be done in the assembly line the same second day. the next day
Robotics
In the world of robotics & automation, custom one-off parts are always needed to develop new robotic mechanisms. 3D printing has evolve very soon, according to a major manufacturing technology, in this industry, because of their speed, great design freedom and ease of customization.
Its large range of material options, along with unique properties, allows you to create unique structures, such as "soft" robots.
Industrial tooling
In the development of new 3D printing materials which provide high heat resistance and stiffness, which are combined, by their ability to create custom parts quickly, too, at very low cost, it promotes 3D printing. In industrial tooling to use them in multiple applications.
Healthcare
You may be surprised to know that hearing aids are manufactured in the US exclusively with the help of 3D printing. Those companies who do not adopt new technology quickly have to face much competition later.
Healthcare and prosthetics field have received considerable benefits when they adopt 3D printing. There is no need to make custom shapes, such as hearing aids, from now on and maunal labor. They can be easily created from a digital file immediately. This can be prepared in very small amounts and in a big way.
Product design
With the help of 3D printing, product designers can easily customize their products without any extra cost. They can easily create high-quality functional prototypes for those new product concepts. There is also a lot of increase in the design cycle.
Entertainment
3D printing has become a very favorite tool for movie makers, because it has the ability to create believable props. With its high design flexibillity, it helps the entertainment professionals to make things according to their thinking. It can be made very easily and quickly, besides its price is also very low.
Education
3D printing technology has a lot of potential in educational environments. With its help, course subjects can be made alive by making their scaled replicas. It equips students with practical (and much more valuable) real-life experience.
Makers
For those makers who constantly explore new ideas, 3D printing is a perfect tool for them. One key benefit of this is that its ability to make unlimited spare parts and new designs can be made without any external vendors.
They can easily develop and customize their designs so that they get more time to think new and better concepts and to provide the correct form.
What is the Future of 3D Printing?
Experts believe that this will change the nature of the technological development commerce of additive manufacturing as end users can manufacture themselves very much without having to depend on them. For this, they will not have to buy anything from other people and corporations.
3D printers which are now capable of producing the output of color and in multiple materials, or further progress is going to improve, in which even the functional (electronic) products can also be found in the output.
Also 3D printing is also going to be affected by the use of energy, waste reduction, customization, product availability, medicine, art, construction and science, 3D printing will further change the attitude of manufacturing world and this is going to be necessary.
