HISTORY
• TRADITIONALLY, MANUFACTURE OF PARTS HAS BEEN WITH SUBTRACTIVE MACHINING PROCESSES.
• MILLING MACHINES, TURNING LATHES, DRILLS, ROUTERS AND MOST OTHER TRADITIONAL MACHINES OPERATE
BY REMOVING MATERIAL FROM A PIECE OF STOCK.
• MATERIAL IS SUBTRACTED FROM THE STARTING STOCK TO PRODUCE THE FINISHED PART.
• THERE ARE A FEW TRADITIONAL ADDITIVE PROCESSES, SUCH AS INJECTION MOLDING THAT ADD
MATERIAL TO CREATE THE FINISHED PART, BUT THEY STILL RELY ON THE SUBTRACTIVE PROCESS TO
CREATE THE MOLD.
• 3D PRINTERS ARE MACHINES THAT COMPLETELY USE THE ADDITIVE PROCESS.
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THEY START OUT WITH NOTHING AND ADD MATERIAL TO PRODUCE THE FINISHED PART.
HISTORY
• SUBTRACTIVE PRODUCTION CAN BE A TIME CONSUMING AND IMPRECISE METHOD OF CREATING A DESIRED
PART.
• ALTHOUGH IT MAY SEEM LIKE 3D PRINTING IS A NEW TECHNOLOGY, IT HAS BEE AROUND SINCE THE 1980’S.
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ORIGINALLY DEVELOPED FOR RAPID PROTOTYPING
IT WAS MEANT TO REDUCE THE AMOUNT OF TIME FOR A PROTOTYPE PART TO BE PRODUCED.
• 1984: CHARLES HULL DEVELOPED THE TECHNOLOGY FOR PRINTING 3D OBJECTS FROM DIGITAL DATA.
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SHORTLY THEREAFTER, STEREO LITHOGRAPH (STL) FILE TYPE WAS CONCEIVED.
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CREATE DIGITAL SLICES AND INFILL STRATEGIES WHICH ALLOW THE PRINTERS TO CREATE THE OBJECT.
HISTORY
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ORIGINALLY DEVELOPED FOR RAPID PROTOTYPING, PRODUCT DEVELOPMENT AND DATA VISUALIZATION.
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THE OBJECT COULD QUICKLY BE CREATED USING CAD TECHNIQUES, TRANSLATED TO STL FILES AND PRINTED WITH SIGNIFICANTLY
LESS COST AND TIME THEN SENDING A DRAWING TO A TRADITIONAL TOOL AND DIE SHOP.
THIS ALLOWS FOR QUICK AND PRECISE CHANGES AND ONE-OFF PRODUCTION.
FIRST WAVE: WERE EXPENSIVE TO OWN AND OPERATE, AND REQUIRED EXPERTISE TO USE.
1988: SCOTT CRUMP DEVELOPED THE FUSED DEPOSITION MODELING 3D PRINTER, WHICH IS HIGHLY USED TODAY.
1991: HELISYS INC CREATED LAMINATED OBJECT MANUFACTURING (LOM).
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TOOK SHEETS OF ADHESIVE PAPER, CROSS CUT SECTIONS AND THEN THEY WERE MANUALLY STACKED TO CREATE AN OBJECT.
1995: Z CORPORATION RELEASED THE FIRST BINDER JET 3D PRINTER.
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THIS TECHNOLOGY CREATED 3D OBJECTS BY SOLIDIFYING LAYERS OF DEPOSITED POWDER USING A LIQUID BINDER.
HISTORY
• MANY INDUSTRIES BENEFIT FROM THIS RAPID PROTOTYPING SUCH AS AUTOMOTIVE, FIREARMS, FASHION,
MEDICAL AND CONSTRUCTION.
• THE EVOLUTION OF 3D PRINTERS AND THE ACCOMPANYING SOFTWARE HAS MADE THE PRINTERS MORE
AFFORDABLE AND EASIER TO USE.
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THE NUMBER OF COMPANIES MAKING 3D PRINTERS HAS INCREASED GREATLY IN THE PAST 10 YEARS AND THE COST
OF OWNING A 3D PRINTER HAS BEEN GREATLY REDUCED.
ADVANCES IS PRINTING MATERIAL AND MATERIAL COMBINATION HAS MADE THE NUMBER AND TYPE OF PRODUCTS
ALMOST UNLIMITED.
ADVANCES IN SOLUBLE SUPPORT MATERIAL, THE DETAILS IN PROTOTYPING HAS INCREASED.
SMALLER 3D PRINTERS AND NOW EVEN AVAILABLE AND AFFORDABLE FOR HOBBYIST AND HOME USERS.
TYPES OF 3D PRINTERS
LAMINATED OBJECT MANUFACTURING
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A 3D PRINTING SYSTEM WHICH USES THIN SHEETS OF ADHESIVE COATED PAPER WHICH ARE CUT TO SHAPE AND THEN ADHERED
TOGETHER.
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SHEETS OF MATERIAL ARE POSITIONED ON TOP OF ONE ANOTHER AFTER FIRST APPLYING AN ADHESIVE GLUE TO BIND THE NEWLY APPLIED LAYER
TO THE EXISTING STRUCTURE.
THE MOST COMMON MATERIALS USED: METAL, PLASTIC AND OFF-THE-SHELF COPY PAPER.
THE ADHESIVE GLUE CAN BE SELECTIVELY APPLIED, MEANING THAT A HIGHER AMOUNT IS APPLIED IN THE AREA THAT WILL BECOME
PART OF THE OBJECT, AND A LOWER AMOUNT IS APPLIED IN THE SURROUNDING, SUPPORTIVE AREA.
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THIS USES THE GLUE AS EFFICIENTLY AS POSSIBLE, SINCE THE SCARP AREA DOES NOT NEED A STRONG BOND.
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LOM IS ALSO CONSIDERED A COMPARATIVELY INEXPENSIVE 3D PRINTING METHOD TO OPERATE, DUE TO THE WIDELY AVAILABLE AND LOW COST
MATERIALS INVOLVED.
AFTER THE NEW SHEET IS PRECISELY LAYERED ON TOP OF THE EXISTING MODEL, BONDED TOGETHER WITH THE ADHESIVE, HEAT AND PRESSURE
ARE APPLIED, USUALLY USING A COMPRESSIVE PLANT.
• HTTPS://WWW.YOUTUBE.COM/WATCH?V=GUVNZ0BORAI
FUSE DEPOSITION MODELING
• THE MOST COMMON TYPE OF 3D PRINTERS.
• THEY WORK BY PUSHING A PLASTIC FILAMENT THROUGH A HEATED EXTRUSION TIP TO LAY DOWN A
LAYER OF PLASTIC.
• AS AFTER EACH LAYER IS DEPOSITED, THE TABLE LOWERS TO MAKE ROOM FOR THE NEXT LAYER.
• SUPPORT OF OVERHANGING STRUCTURES IS HANDLES BY ADDITIONAL PLASTIC STRUCTURES, NOT PART
OF THE MODEL, BEING CREATED TO SUPPORT THE PART.
• THE SUPPORT PLASTIC MAY BREAK AWAY OR DISSOLVE IN A SOLUTION.
• HTTPS://WWW.YOUTUBE.COM/WATCH?V=WHO6G67GJBM
BINDER JETTING
• BINDER JETTING PRINTERS USE A RESERVOIR GRANULATED BASE MATERIAL THAT IS SOLIDIFIED BY A
SELECTIVE JETTING SYSTEM.
• THE BASE MATERIAL CAN BE ANYTHING FROM POWERED STARCH TO SUGAR TO METAL.
• THE MACHINE SPREADS A LAYER OF POWDER OVER THE BUILD PLATFORM THEN IT JETS BINDER INTO THE
POWDER IN THE SHAPE OF THE LAYER.
• ONCE A LAYER IS PRINTED THE BUILD PLATFORM DROPS DOWN TO RECEIVE ANOTHER LAYER OF POWDER AND
THE NEXT LAYER IS PRINTED ON.
• THIS PROCESS USES THE UNUSED GRANULATED MATERIAL TO SUPPORT OVERHANGS AND THIN WALLS IN THE
PART BEING PRODUCED, WHICH ELIMINATES THE NEEDS FOR AN ADDITIONAL SUPPORT MATERIAL.
• HTTPS://WWW.YOUTUBE.COM/WATCH?V=EJJEBAQWE4S
POLYJET PRINTERS
• SIMILAR TO INKJET PRINTING, BUT INSTEAD OF JETTING DROPS OF INK ONTO PAPER, POLYJET 3D
PRINTERS JET HIGH DENSITY LAYERS OF CURABLE LIQUID PHOTOPOLYMER ONTO A BUILD TRAY.
• THE 3D PRINTER JETS AND INSTANTLY UV-CURES TINY DROPLETS OF LIQUID PHOTOPOLYMER.
• FINE LAYERS ACCUMULATE ON THE BUILD TRAY TO CREATE A PRECISE 3D MODEL OR PART.
• WHERE OVERHANGS OR COMPLEX SHAPES REQUIRE SUPPORT, THE 3D PRINTER JETS A REMOVABLE GELLIKE SUPPORT MATERIAL.
• HTTPS://WWW.YOUTUBE.COM/WATCH?V=SOM3CDDHFZE
WAX DEPOSITION MODELING
• BUILD SMOOTH, DETAILED CASTING WAX-UPS BY JETTING TINY DROPLETS OF A WAX-LIKE MATERIAL
CALLED TRUEWAX ONTO A BUILD TRAY.
• WHERE OVERHANGING SHAPES AND COMPLEX GEOMETRIES REQUIRE SUPPORT DURING PRODUCTION,
THE 3D PRINTER DEPOSITS A REMOVABLE WAX-BLEND MATERIAL CALLED TRUESUPPORT.
• USED TO CREATE WAX-UPS FOR CROWNS, BRIDGES AND PARTIAL DENTURES.
• HTTPS://WWW.YOUTUBE.COM/WATCH?V=9RUJ_EJC4WQ
WHY 3D PRINT
WHY?
• PROTOTYPING
• JIGS & FIXTURES
• ONE OF A KIND/SHORT RUN
• MOLD MAKING
• FINISHED PARTS
• FOR PROFIT
• REMOTE LOCATION
PROTOTYPING
• PROTOTYPING IS THE PRODUCTION OF AN EARLY SAMPLE OF A PROPOSED PRODUCT FOR THE PURPOSE
OF TESTING FIT, FORM, OR FUNCTION.
• IS DONE TO SAVE TIME, MATERIAL AND COST.
• A PROTOTYPE OF A PRODUCT MIGHT BE PRODUCED TO JUDGE CUSTOMER REACTION TO SIZE, FEEL,
APPEARANCE OR FUNCTIONALITY.
• GETTING A PRODUCT JUST RIGHT BEFORE INVESTING IN THE MANUFACTURING PROCESS SAVES A GREAT
DEAL OF MONEY AS IT CAN PREVENT THE MANUFACTURE OF PRODUCTS THAT THE CUSTOMER WILL NOT
LIKE OR DO NOT WORK AS INTENDED.
JIGS & FIXTURES
• JIGS AND FIXTURES ARE USED IN EVERY STAGE OF THE MANUFACTURING PROCESS TO HOLD PARTS
DURING MACHINING AND/OR ASSEMBLY, AND ARE USED TO ENDURE ACCURATE, REPEATABLE ALIGNMENT
OF INDIVIDUAL PARTS.
ONE OF A KIND/SHORT RUN
• IF ONLY ONE OR A FEW COPIES OF A PART ARE NEEDED, IT MAY NOT BE COST EFFECTIVE TO HAVE THEM
MANUFACTURE BY TRADITIONAL MEANS
• 3D PRINTERS ALLOW FOR THE PRODUCTION OF ONE OF A KIND PARTS THAT ARE INTENDED FOR A VERY
SPECIFIC PURPOSE.
MOLD MAKING
• CAN MAKE THE MOLD FOR INJECTION MOLDING OR CAN BE USED TO CREATE THE MASTER BLANKS FOR
THE CASTING PROCESSES.
• THE NEGATIVE RELIEF OF AN OBJECT IS CREATED PRODUCING A CAVITY IN WHICH THE PRODUCTION
MATERIAL CON BE INJECTED.
FINISHED PARTS
• ALTHOUGH 3D PRINTERS ARE NOT WIDELY USED FOR THE PRODUCTION OF END USE SALEABLE PARTS YET,
THIS IS ONE OF THE FASTEST GROWING AREAS OF APPLICATION.
• THIS IS A GROWING PART OF THE INDUSTRY.
• EXAMPLE: SOMEDAY YOU WILL NEED A GEAR FOR A GARAGE DOOR OPENER, YOU WILL SIMPLY BUY THE STL
FILE ONLINE AND PRINT IT YOURSELF.
FOR PROFIT
• THERE IS SUCH A DEMAND FOR 3D PRINTED PARTS FOR ALL OF THESE APPLICATIONS, THAT COMPANIES
HAVE COME INTO EXISTENCE THAT WILL DO 3D PRINTING FOR CUSTOMERS FOR A FEE.
REMOTE LOCATION
• AS THE QUALITY AND DURABILITY OF 3D PRINTED PARTS CONTINUES TO GROW, THE USE OF THESE
PRINTERS IN REMOTE LOCATIONS WHERE SECURING PARTS IS DIFFICULT, WILL BECOME MORE COMMON.
DESIGN TO PRODUCTION PROCESS
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DESIGN TO PRODUCTION PROCESS
1. A PART IS PROPOSED:
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AT THIS STAGE, IT MUST BE DETERMINED IF IT IS POSSIBLE TO PRINT THE PART BASED ON SIZE, SHAPE, AND STRUCTURE.
2. GEOMETRY IS PROPOSED:
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AT THIS STAGE, THE DESIGNER PRODUCES THE 2-DIMENSIONAL GEOMETRY THAT WILL BE USED TO GENERATE THE 3D SHAPES.
3. THE 3-DIMENSIONAL SHAPES ARE GENERATED
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THIS STAGE IS COMPLETED IN THE 3D DESIGN SOFTWARE. (SOLIDWORKS)
4. THE PRODUCTION FILE IS PRODUCED
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STL FILES
5. THE STL FILE IS PROCESSED FOR PRODUCTION
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PREPARES THE STL FILE FOR PRODUCTION AND ESTIMATE TIME AND MATERIAL.
6. THE PART IS PRODUCED
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WHERE THE ACTUAL PRINTING OCCURS
7. POST PRODUCTION PROCESS
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PICKING AWAY NONSOLUABLE SUPPORT MATERIAL, SOAKING AWAY SOLUBLE SUPPORT MATERIAL. FINISHING WORK.