3D Printing Technology seminar report by ajaysingh_02

3D Printing Technology 1606203981
A
Seminar Report
On
[3D PRINTING TECHNOLOGY]
Submitted in partial fulfillment of the requirement for the degree of
Bachelor of Technology
DEPARTMENT OF MECHANICAL ENGINEERING
Session 2019-20
Baba Banda Singh Bahadur Engineering College
Fatehgarh Sahib, MRSPTU
SUBMITTED TO: SUBMITTED BY:
Ajay Singh (8M1)
160620398(M.E)

ACKNOWLEDGEMENT
I would like to thank everyone who helped to see this seminar to completion. In
particular, I would like to thank my seminar coordinator, Prof. Dr.APS Sethi for the moral
support and guidance to complete my seminar on time. Also I would like to thank
Mr.Harmesh Kumar (Lecturer in ME) for his valuable help and support.
I express my gratitude to all my friends and classmates for their support and help in this
seminar.
Last, but not the least I wish to express my gratitude to God almighty for his abundant
blessings, without which this seminar would not have been successful

ABSTRACT
The last two decades ended in the midst of revolution caused by a technology that
was barely noticeable at the beginning of the decade. In 1980 few would have guessed that
personal computer along with desktop publishing software would fundamentally change the
way of our industry did business. In 1990 again internet was known and used by a relatively
small set of people. Yet by the end of the decade it was a major force in our industry and in
society and in economy.
Once again we are facing anew decade and we have to wonder what the next dominant
technology likely to change our way of life is. While there is a number of candidates for
the ”next big technology” including perennial favorite, the free energy device, our best is the
technology called 3D printing which as the name implies is a technology that literally prints
real 3D objects. It is used by the marketing industry to create models for marketing focus
groups and pre-production sales demonstration.

CONTENTS
1. Introduction.........................................................................................................................5
1.1 3D PRINTING: MAKING THE DIGITAL REAL............................................................ 6
1.2 3D PRINTING WORKING............................................................................................ 7
1.3 3D PRINTING IS FAST.................................................................................................8
2. Rapid Prototyping Techniques.........................................................................................9
2.1 BLOCK DIAGRAM........................................................................................................ 9
2.2 Stereo lithography.....................................................................................................11
2.3 Laminated Object Manufacturing............................................................................ 12
2.4 Selective Laser Sintering.......................................................................................... 14
2.5 Fused Deposition Modeling......................................................................................14
2.5 Solid Ground Curing..................................................................................................15
2.6 3D Printing.................................................................................................................16
3. The Basic Process of 3D Printing................................................................................... 19
4. 3D printing Vs conventional technologies...................................................................22
5.Application of 3D printers................................................................................................23
5.1 Art...............................................................................................................................23
5.2 Action Figures............................................................................................................24
5.3 Jewelry....................................................................................................................... 25
5.4 Hearing Aids.............................................................................................................. 26
4.5 Prototypes.................................................................................................................. 26
5.6 Home Decor............................................................................................................... 27
5.7 Models........................................................................................................................28
5.8 Components/Manufacturing....................................................................................28
5.9 Medicine.....................................................................................................................29
6. Limitation of 3D Printing...................................................................................................30
7. Advantages of 3D Printing...............................................................................................39
7.1 Flexible Design.......................................................................................................... 39
7.2 Rapid Prototyping.....................................................................................................39
7.3 Print on Demand....................................................................................................... 39
7.4 Strong and Lightweight Parts...................................................................................40
7.5 Fast Design and Production..................................................................................... 40
7.6 Minimising Waste......................................................................................................41
7.7 Cost Effective............................................................................................................. 41
7.8 Ease of Access............................................................................................................42
7.9 Environmentally Friendly........................................................................................ 42
7.10 Advanced Healthcare..............................................................................................42
8. The Future of 3D Printing................................................................................................43
9. SWOT analysis................................................................................................................... 44
10. The Conclusion............................................................................................................... 46
REFERENCE.............................................................................................................................47

1. Introduction
3Dimensions printing is a method of converting a virtual 3D model into a physical
object. 3D printing is a category of rapid prototyping technology. 3D printers typically work
by printing successive layers on top of the previous to build up a three dimensional object.
The past decade has witnessed the emergence of new manufacturing technologies
that build parts on a layer-by-layer basis. Using these technologies, manufacturing time for
parts of virtually any complexity is reduced considerably. In other words, it is rapid. Rapid
Prototyping Technologies and Rapid Manufacturing offer great potential for producing
models and unique parts for manufacturing industry.
A few years ago, to get some prototyping work done for a product or design you are
working on, you are required to spend a lot of man-hours just to come up with the model.
Those hours will be spent creating miniature parts of your design using wood and then
gluing all those parts together painstakingly. Prototyping is, at the very least, time-
consuming and extremely tedious.
These days, however, you can take the tediousness and the time investment out of your
prototyping tasks through rapid prototyping or 3d printing. 3D printing is a revolutionary
method for creating 3D models with the use of inkjet technology. Many engineers have even
dubbed 3D printing as the process of creating something out of nothing. Thus, the reliability
of products can be increased; investment of time and money is less risky. Not everything
that is thinkable today is already workable or available at a reasonable price, but this
technology is fast evolving and the better the challenges, the better for this developing
process.
The term Rapid prototyping (RP) refers to a class of technologies that can
automatically construct physical models from Computer-Aided Design (CAD) data.
It is a free form fabrication technique by which a total object of prescribed shape, dimension
and finish can be directly generated from the CAD based geometrical model stored in a

computer, with little human intervention. Rapid prototyping is an "additive" process,
combining layers of paper, wax, or plastic to create a solid object. In contrast, most
machining processes (milling, drilling, grinding, etc.) are "subtractive" processes that remove
material from a solid block. RP’s additive nature allows it to create objects with complicated
internal features that cannot be manufactured by other means.
In addition to prototypes, RP techniques can also be used to make tooling (referred to as
rapid tooling) and even production-quality parts (rapid manufacturing). For small production
runs and complicated objects, rapid prototyping is often the best manufacturing process
available. Of course, "rapid" is a relative term. Most prototypes require from three to
seventy-two hours to build, depending on the size and complexity of the object. This may
seem slow, but it is much faster than the weeks or months required to make a prototype by
traditional means such as machining. These dramatic time savings allow manufacturers to
bring products to market faster and more cheaply.
1.1 3D PRINTING: MAKING THE DIGITAL REAL
Imagine a future in which a device connected to a computer can print a solid object. A future
in which we can have tangible goods as well as intangible services delivered to our desktops
or highstreet shops over the Internet. And a future in which the everyday "atomization" of
virtual objects into hard reality has turned the mass pre-production and stock-holding of a
wide range of goods and spare parts into no more than an historical legacy.
Such a future may sound like it is being plucked from the worlds of Star Trek. However,
whilst transporter devices that can instantaneously deliver us to remote locations may
remain a fantasy, 3D printers capable of outputting physical objects have been in
development for over two decades. What's more, several 3D printers are already on the
market. Available from companies including Fortus, 3D Systems, Solid Scape, ZCorp, and
Desktop Factory, these amazing devices produce solid, 3D objects from computer data in
roughly the same way that 2D printers take our digital images and output hardcopy photos.

The Desktop Factory currently sells a 3D printer for $4995. This can print models up to a five-
inch cube in size with consumables costing around $1 per cubic inch. However, prices for
most 3D printers tend to start in the ten-to-twenty thousand pound bracket and spiral
upwards. Although some desktop models are on the market, most 3D printers are usually
fairly bulky and often floor-standing.
1.2 3D PRINTING WORKING
3D printers use standard inkjet printing technology to create parts layer-by-layer by
depositing a liquid binder onto thin layers of powder. Instead of feeding paper under the
print heads like a 2D printer, a 3D printer moves the print heads over a bed of powder upon
which it prints the cross-sectional data sent from the ZPrint software. The system requires
powder to be distributed accurately and evenly across the build platform. 3D Printers
accomplish this task by using a feed piston and platform, which rises incrementally for each
layer. A roller mechanism spreads powder fed from the feed piston onto the build platform;
intentionally spreading approximately 30 percent of extra powder per layer to ensure a full
layer of densely packed powder on the build platform. The excess powder falls down an
overflow chute, into a container for reuse in the next build.
Once the layer of powder is spread, the inkjet print heads print the cross-sectional area
for the first, or bottom slice of the part onto the smooth layer of powder, binding the
powder together. A piston then lowers the build platform 0.1016mm (0.004”), and a new
layer of powder is spread on top. The print heads apply the data for the next cross section
onto the new layer, which binds itself to the previous layer. ZPrint repeats this process for all
of the layers of the part. The 3D printing process creates an exact physical model of the
geometry represented by 3D data. Process time depends on the height of the part or parts
being built. Typically, 3D printers build at a vertical rate of 25mm – 50mm (1” – 2”) per hour.

When the 3D printing process completes, loose powder surrounds and supports the part in
the build chamber. Users can remove the part from the build chamber after the materials
have had time to set, and return unprinted, loose powder back to the feed platform for
reuse. Users then use forced air to blow the excess powder off the printed part, a short
process which takes less than 10 minutes. Z Corp. technology does not require the use of
solid or attached supports during the printing process, and all unused material is reusable.
1.3 3D PRINTING IS FAST
3D printing is the fastest additive technology commercially available on the market.
Other companies often refer to their equipment as 3D printers, however these systems rely on
processes using a vector approach or single-jet technology to deposit all build material. Z
Corp. uses inkjet print heads with a resolution of 600 dpi (dots per inch), focuses on a drop-
on-demand approach, and manufactures the only true 3D inkjet printers available. The
technology allows printing of multiple parts simultaneously, while only adding a negligible
amount of time to the print time for one part.
The fundamental inkjet approach is the primary contributor to greater speed, although
there are several other reasons why this system is the fastest. ZPrint software processes data in
parallel with the printing of the part. While the 3D printer deposits the first layer, the software
slices and processes the fifth layer. Some additive technologies process all tool paths before

the job begins. Although the processing time may seem to be fast, it is often only a fraction of
the total time it takes to build the part. It can actually take up to an hour to prepare a job with
multiple parts using some additive technologies.
3D printers enable the stacking of parts vertically because they do not require rigid support
structures. Producing parts with other types of additive technologies requires structural
supports along the vertical axis, limiting the ability to stack or nest parts. With this 3D
printers, users can utilize the entire build area and produce multiple parts with only one set-up
procedure, further reducing the total number of builds and processing time.
2. Rapid Prototyping Techniques
Most commercially available rapid prototyping machines use one of six techniques. At
present, trade restrictions severely limit the import/export of rapid prototyping machines, so
this guide only covers systems available in the U.S.
2.1 BLOCK DIAGRAM
The microcomputer is used to create a 3 Dimensional model of the component to be made using
well-known CAD techniques. A slicing algorithm is used to identify selected successive slices, i.e.,
to provide data with respect to selected 2-D layers, of the 3-D model.
Once a particular 2–D slice has been selected, the slice is then reduced to a series of one
dimensional scan lines. Each of the scan line may comprise of single line segments or two or more
shorter line segments. Each line segment having a defined starting point on a scan line and a
defined line segment length.
The microcomputer actuates the powder distribution operation when a particular 2-D slice of
the 3-D model which has been created has been selected by supplying a powder “START” signal
to a powder distribution controller circuit which is used to actuate a powder distribution system to
permit a layer of powder for the selected slice to be deposited as by a powder head device. The
powder is deposited over the entire confined region within which the selected slice is located.

Once the powder is distributed, the operation of powder distribution controller is stopped when the
microcomputer issues a powder “STOP” signal signifying that powder distribution over such
region has been completed.
Microcomputer then select a scan line i.e., the first scan line of the selected 2-D slice and then
select a line segment, e.g., the first 1-D line segment of the selected scan line and supplies data
defining the starting point thereof and the length thereof to a binder jet nozzle control circuit. For
simplicity in describing the operation it is assumed that a single binder jet nozzle is used and that
such nozzle scans the line segment of a slice in a manner such that the overall 2-D slice is scanned
in a conventional raster scan operation. When the real time position of the nozzle is at starting
point of the selected line segment. Nozzle is turned on at the start of the line segment and turned
off at the end of line segment in accordance with the defined starting point and length data
supplied from the computer for that line segment. Each successive line segment is similarly
scanned for the selected scan line and for each successive scan line of the selected slice in the
same manner. For such purpose nozzle carrier system starts its motion with a scan “BEGIN”
signal from microcomputer. So that it is moved in both x-axis direction and in the Y-axis direction.
Data as to the real time position of the nozzle carrier is supplied to the nozzle control circuit.
When the complete slice has been scanned, a scan “STOP” signal signifies an end of the slice scan
condition.

2.2 Stereo lithography
Patented in 1986, stereolithography started the rapid prototyping revolution. The
technique builds three-dimensional models from liquid photosensitive polymers that solidify
when exposed to ultraviolet light. As shown in the figure below, the model is built upon a
platform situated just below the surface in a vat of liquid epoxy or acrylate resin. A low-
power highly focused UV laser traces out the first layer, solidifying the model’s cross section
while leaving excess areas liquid. Next, an elevator incrementally lowers the platform into
the liquid polymer. A sweeper re-coats the solidified layer with liquid, and the laser traces
the second layer atop the first. This process is repeated until the prototype is complete.
Afterwards, the solid part is removed from the vat and rinsed clean of excess liquid.
Supports are broken off and the model is then placed in an ultraviolet oven for complete
curing. Because it was the first technique, stereolithography is regarded as a benchmark by

which other technologies are judged. Early stereolithography prototypes were fairly brittle
and prone to curing-induced warpage and distortion, but recent modifications have largely
corrected these problems.
Fig 2.2 :Stereo lithography
2.3 Laminated Object Manufacturing
In this technique, developed by Helisys of Torrance, CA, layers of adhesive-coated sheet
material are bonded together to form a prototype.. As shown in the figure below.

Fig2.3: Schematic diagram of laminated object manufacturing.
A feeder/collector mechanism advances the sheet over the build platform, where a base has
been constructed from paper and double-sided foam tape. Next, a heated roller applies
pressure to bond the paper to the base. A focused laser cuts the outline of the first layer into
the paper and then cross-hatches the excess area (the negative space in the prototype).
Cross-hatching breaks up the extra material, making it easier to remove during post-
processing. During the build, the excess material provides excellent support for overhangs
and thin-walled sections. After the first layer is cut, the platform lowers out of the way and
fresh material is advanced. The platform rises to slightly below the previous height, the roller
bonds the second layer to the first, and the laser cuts the second layer. This process is
repeated as needed to build the part, which will have a wood-like texture. Because the
models are made of paper, they must be sealed and finished with paint or varnish to prevent
moisture damage.
Helisys developed several new sheet materials, including plastic, water-repellent paper, and
ceramic and metal powder tapes. The powder tapes produce a "green" part that must be
sintered for maximum strength. As of 2001, Helisys is no longer in business.

2.4 Selective Laser Sintering
Developed by Carl Deckard for his master’s thesis at the University of Texas, selective
laser sintering was patented in 1989. The technique, shown in Fig, uses a laser beam to
selectively fuse powdered materials, such as nylon, elastomer, and metal, into a solid object.
Parts are built upon a platform which sits just below the surface in a bin of the heat-fusable
powder. A laser traces the pattern of the first layer, sintering it together. The platform is
lowered by the height of the next layer and powder is reapplied. This process continues until
the part is complete. Excess powder in each layer helps to support the part during the build.
SLS machines are produced by DTM of Austin, TX.
Fig 2.4: Schematic diagram of selective laser sintering.
2.5 Fused Deposition Modeling
In this technique, filaments of heated thermoplastic are extruded from a tip that moves in
the x-y plane. Like a baker decorating a cake, the controlled extrusion head deposits very
thin beads of material onto the build platform to form the first layer.

Fig2.5: schematic diagram of fused deposition modeling.
The platform is maintained at a lower temperature, so that the thermoplastic quickly
hardens. After the platform lowers, the extrusion head deposits a second layer upon the first.
Supports are built along the way, fastened to the part either with a second, weaker material
or with a perforated junction.
2.5 Solid Ground Curing
Developed by Cubital, solid ground curing (SGC) is somewhat similar to
stereolithography (SLA) in that both use ultraviolet light to selectively harden photosensitive
polymers. Unlike SLA, SGC cures an entire layer at a time. Figure 5 depicts solid ground
curing, which is also known as the solider process. First, photosensitive resin is sprayed on
the build platform. Next, the machine develops a photomask (like a stencil) of the layer to be
built. This photomask is printed on a glass plate above the build platform using an
electrostatic process similar to that found in photocopiers. The mask is then exposed to UV

light, which only passes through the transparent portions of the mask to selectively harden
the shape of the current layer.
Fig 2.6: Schematic diagram of solid ground curing.
After the layer is cured, the machine vacuums up the excess liquid resin and sprays wax in
its place to support the model during the build. The top surface is milled flat, and then the
process repeats to build the next layer. When the part is complete, it must be de-waxed by
immersing it in a solvent bath. SGC machines are distributed in the U.S. by Cubital America
Inc. of Troy, MI. The machines are quite big and can produce large models.
2.6 3D Printing
Ink-Jet Printing refers to an entire class of machines that employ ink-jet technology.
The first was 3D Printing (3DP), developed at MIT and licensed to Soligen Corporation,
Extrude Hone, and others. The ZCorp 3D printer, produced by Z Corporation of Burlington,
MA is an example of this technology. As shown in Figure 6a, parts are built upon a platform

situated in a bin full of powder material. An ink-jet printing head selectively deposits or
"prints" a binder fluid to fuse the powder together in the desired areas. Unbound powder
remains to support the part. The platform is lowered, more powder added and leveled, and
the process repeated. When finished, the green part is then removed from the unbound
powder, and excess unbound powder is blown off. Finished parts can be infiltrated with wax,
CA glue, or other sealants to improve durability and surface finish. Typical layer thicknesses
are on the order of 0.1 mm. This process is very fast, and produces parts with a slightly
grainy surface. ZCorp uses two different materials, a starch based powder (not as strong, but
can be burned out, for investment casting applications) and a ceramic powder. Machines
with 4 color printing capability are available.
3D Systems’ version of the ink-jet based system is called the Thermo-Jet or Multi-Jet
Printer. It uses a linear array of print heads to rapidly produce thermoplastic models (Figure
6d). If the part is narrow enough, the print head can deposit an entire layer in one pass.
Otherwise, the head makes several passes.
Sanders Prototype of Wilton, NH uses a different ink-jet technique in its Model
Maker line of concept modelers. The machines use two ink-jets (see Figure 6c). One
dispenses low-melt thermoplastic to make the model, while the other prints wax to form
supports. After each layer, a cutting tool mills the top surface to uniform height. This yields
extremely good accuracy, allowing the machines to be used in the jewelry industry.
Ballistic particle manufacturing, depicted in Figure 6b, was developed by BPM Inc., which has
since gone out of business.

Fig 2.7: Schematic diagrams of ink-jet techniques.

3. The Basic Process of 3D Printing
Although several rapid prototyping techniques exist, all employ the same basic five-step
process. The steps are:
1. Create a CAD model of the design
2. Convert the CAD model to STL format
3. Slice the STL file into thin cross-sectional layers
4. Construct the model one layer atop another
5. Clean and finish the model
3.1 CAD Model Creation: First, the object to be built is modeled using a Computer-Aided
Design (CAD) software package. Solid modelers, such as Pro/ENGINEER, tend to represent 3-
D objects more accurately than wire-frame modelers such as AutoCAD, and will therefore
yield better results. The designer can use a pre-existing CAD file or may wish to create one
expressly for prototyping purposes. This process is identical for all of the RP build techniques.
3.2 Conversion to STL Format: The various CAD packages use a number of different
algorithms to represent solid objects. To establish consistency, the STL (stereolithography,
the first RP technique) format has been adopted as the standard of the rapid prototyping
industry. The second step, therefore, is to convert the CAD file into STL format. This format
represents a three-dimensional surface as an assembly of planar triangles, "like the facets of
a cut jewel." 6
The file contains the coordinates of the vertices and the direction of the
outward normal of each triangle. Because STL files use planar elements, they cannot
represent curved surfaces exactly. Increasing the number of triangles improves the
approximation, but at the cost of bigger file size. Large, complicated files require more time
to pre-process and build, so the designer must balance accuracy with manageability to
produce a useful STL file. Since the STL format is universal, this process is identical for all of
the RP build techniques.

3.3 Slice the STL File: In the third step, a pre-processing program prepares the STL file to
be built. Several programs are available, and most allow the user to adjust the size, location
and orientation of the model. Build orientation is important for several reasons. First,
properties of rapid prototypes vary from one coordinate direction to another. For example,
prototypes are usually weaker and less accurate in the z (vertical) direction than in the x-y
plane. In addition, part orientation partially determines the amount of time required to build
the model. Placing the shortest dimension in the z direction reduces the number of layers,
thereby shortening build time. The pre-processing software slices the STL model into a
number of layers from 0.01 mm to 0.7 mm thick, depending on the build technique. The
program may also generate an auxiliary structure to support the model during the build.
Supports are useful for delicate features such as overhangs, internal cavities, and thin-walled
sections. Each RP machine manufacturer supplies their own proprietary pre-processing
software.
Fig 3.1

3.4 Layer by Layer Construction: The fourth step is the actual construction of the part.
Using one of several techniques (described in the next section) RP machines build one layer
at a time from polymers, paper, or powdered metal. Most machines are fairly autonomous,
needing little human intervention.
Fig 3.4 Layer by Layer Construction
3.5 Clean and Finish: The final step is post-processing. This involves removing the
prototype from the machine and detaching any supports. Some photosensitive materials
need to be fully cured before use. Prototypes may also require minor cleaning and surface
treatment. Sanding, sealing, and/or painting the model will improve its appearance and
durability.

4. 3D printing Vs conventional technologies
3DP does not—and will not—replace completely conventional technologies such NC and
high-speed milling, or even hand-made parts. Rather, one should regard 3DP as one more option in
the toolkit for manufacturing parts. Figure depicts a rough comparison between 3DP and milling
regarding the costs and time of manufacturing one part as a function of part complexity10. It is
assumed, evidently, that the part can be manufactured by either technology such that the material
and tolerance requirements are met.
Fig5.1: 3DP vs. conventional machining

5.Application of 3D printers
The concept of custom manufacturing is exciting to nearly everyone, but it always
seems to be something that will happen in the “future”. Gibson was right and the following
list of applications for 3D printers show the truth in the saying “The future is here. It’s just
not evenly distributed yet.” The following items are all available for purchase or are being
used in industry now. We are still a long way from Replicators like the ones from Star Trek:
The Next Generation, but we probably won’t have to wait til the 24th century either.
5.1 Art
3D printing allows artists to create objects that would be incredibly difficult, costly, or time
intensive using traditional processes. These sculptures by Bathsheba Grossman are
exquisitely complex and manufactured using a laser sintering process.

5.2 Action Figures
Blood Elves and band mates can both be brought to life using 3D printers. These two were
created using Zcorp. machines which apply glue ink and powder in fine layers slowly creating
a replica of one of your characters. Figure Prints allows you to create characters from
Warcraft, Rock band and Spore printing services are coming soon. A number of other sites
allow you to pull data from Second Life and your own 3D programs.

5.3 Jewelry
Jewelry makers were some of the first to use 3D printing in their manufacturing process,
however they do not use metal printers, but rather ones that use wax. In a process called
“investment casting” a piece of jewelry is sculpted or printed out of wax. Plaster is then
poured on either side. Molten metal is poured onto the wax which melts out leaving a metal
version of your wax sculpt in its place in the plaster. This piece is then finished and polished
by a jeweler. Many independent jewelers have been using high tech printers in their
businesses and an innovative company called Paragon Lake has combined this process with
web based design tools to offer an infinite inventory to the masses of jewelry stores.

5.4 Hearing Aids
3D printers can also make things more functional. In the case of hearing aids a cast of
your ear canal is made. The casting is digitized using a 3D scanner and a perfect replica
of your ear is printed from that ensuring a great fit and improving the quality.
4.5 Prototypes

Prototyping in product development is currently the biggest use of 3D printing technology.
These machines allow designers and engineers to test out ideas for dimensional products
cheaply before committing to expensive tooling and manufacturing processes.
5.6 Home Decor
Home goods are structurally simple but endlessly decorative and are perfect matches for
3D printing. This service, called “Shapeways Creator” allows you to create products like this
lamp with any selection of words that have relevance to you (wedding vows, a favorite poem,
etc.). Another company called JuJups allows you to make a customized picture frame using
intelligent design tools and a zCorp printer.

5.7 Models
Sales folks lives get much easier when you can have models like this of your product printed
up for show and tell.
5.8 Components/Manufacturing

Many of the examples so far are somewhat gimmicky or decorative, However in some
industries 3D printing is displacing traditional manufacturing entirely. In the left hand picture
a surgical knee replacement implant has been designed and manufactured to fit a patient’s
joint perfectly. On the right, high tolerance engine parts were printed using a process called
“Electron Beam Melting” and finished with traditional machining processes. While not the
norm these uses begin to suggest what is possible in medicine and industry.
5.9 Medicine
3D World of Warcraft characters are cool, but these tools have the power to help save
lives. Surgeons are using 3d printers to print body parts for reference before complicated
surgeries. Other 3D printers are used to create bone grafts for patients who have suffered
traumatic injuries. Looking further in the future scientist are working on PRINTING
replacement organs. Personal Fabrication indeed!
10. Crime Scene Reconstruction
3D printing can save lives, bring Orcs to life, and solve crimes. 3D printing/scanning is used in
forensics in real life and as a prop for dramatic effect in this clip from CSI.

6. Limitation of 3D Printing
3D printing has become a trend. The thought of printing anything that you can design into
CAD files is really enthralling. Apart from industrialists and entrepreneurs, a lot of
enthusiasts and hobbyists are also following the trend.
The online communities are surging and the awareness is spreading like a wildfire. However,
there are still a few limitations of 3D printing that make it difficult to reach masses.
With lots of things to 3D print, individuals usually feel intimidated by the way this technology
works. There is a huge number of courses online, but would that knowledge justify the
investment of a few hundred dollars on something that we haven’t tried for real.
6.1 Consumes a Lot of Energy for Operation
You may not have been told about this before. But you would certainly like to know about
the additional cost that 3D printing would put on your shoulders.
We have been witnessing how the electricity cost has turned out against our favor from the
last couple of years. With no sign to slow down, companies keep trying to implement
strategies and measures to reduce the amount spent on electricity bills.
If you have been struggling to bring your expenses down, 3D printing would make your fight
even difficult.
According to the researches made on the technology, it has been found that energy
consumption with 3D printing is 100 times more than the power consumed by traditional
manufacturing.
We may agree to the fact that 3D printing is a step towards a greener planet by facilitating
reusable materials such as plastic.
6.2 The 3D Printer is Costly

If you are thinking of starting a manufacturing firm and have a limited budget to afford
machines, to begin with, you may not like the huge cost associated with 3D printers.
Only one machine can cost you ranging from a hundred to thousands of dollars. Not just that,
the software and material requirement would come as an extra cost.
That is why you may not see many businesses reaping the advantage of 3D printing even
after 40 years of its invention.
There is a simple calculation to do. If you have a large order, your cost would be higher.
However, for small products can be printed at a cheaper cost.
If you are up for buying a consumer 3D printer, you may get it for less money. But, why pay
extra for a few items by investing in material cost and electricity bill, when you can get that
at a lower cost from the market.
6.3 3D Printing Requires Skilled Users for Operation

You may have read that 3D printing is easy as compared to the traditional methods which
are completely true.
However, there are certain skills that must be learned before you go on printing your first 3D
printed object. It may not be as user-friendly as being told or as you perceive it to be.
You must know how to work with CAD files and learn about some hardware settings of 3D
printers before beginning to 3D print.
6.4 Consider it Slow for Mass Production
The new 3D printers are being introduced and this limitation of 3D printer is being worked
upon.
However, the fact is that mass production would eat up time when compared with
traditional manufacturing.
Also, the time will depend on the complexity of the design, the size of the product and a lot
of other parameters. Some 3D printing processes even require a lot of post-processing steps.
If not done properly, it can even destroy the objects 3D printed.
If your 3D printing service center is too busy with orders, you may expect it to deliver yours
after a week or even more

6.5 3D Printing Can be Used for Piracy
We all know that piracy is a huge setback of businesses. Copying one design and selling it
for a lower price can throw the actual manufacturer out of the business. 3D printing is
making it even easier. All you need to copy design is the blueprint of the file.
Once you have the 3D design, you can print as many 3D parts as you please. And, anyone can
do that. Moreover, with technology aggressively reaching more people, the cases of patent
violation could become a huge problem.
The problem is deeper than one can imagine. As the blueprints are accessed through a
shared repository, differentiating between the pirated ones and non-pirated ones wouldn’t
be easy, hence, difficult to fight.

6.6 Harmful Gases Can Cause Health Issues
We all know that plastics when melted emit fumes which is dangerous for humans if inhaled
in large amounts. Aren’t 3D printers are exposing us to the harmful emissions? The 3D
printers used inside the closed doors of our houses are even more dangerous.
There are 3D printing machines that come with HEPA filter but aren’t able to completely
refine 100% of the fumes. Those that aren’t compliant with HEPA filters do not help at all. All
the fumes generated are circulated inside the house or affect those working close to the
machine.
Long term exposure can lead to problems that are still to be realized. It is important to take
precautions and include necessary measures while working with 3D printers.

6.7 The Printing Materials are Limited
The limitation of 3D printing can be directly felt when unable to choose the desired
material for printing. Although the number of material choices is increasing as the demand is
growing, it is still far less than the ones available with traditional manufacturing.
As of now, plastic is the most widely used 3D printing material as it is cheap and easy to
manage given the lower melting point.
Limited material choice makes it difficult to employ the use of 3D printing for a greater
number of applications.

If one is printing with different materials, one may have to buy different 3D printers. As
every printer supports a limited number of materials. A 3D printing process printing with
metal would not print with plastics and vice versa.
6.8 The Textures and Color Printing Limitations
The textures and color options available with traditional manufacturing is still greater than
what we achieve through 3D printing.
Users have to compromise in terms of color and the finished textures with 3D printing.
Or else, it must employ post-processing methods, which sometimes is too hectic and not
even compatible with every 3D printing process to get the desired results.
Talking about the surface finish, one may be disappointed by the results of a few of the
cheaper 3D printers. Even the costlier ones may not be able to provide the quality surface
finish compared to the one achieved through other methods.
Again, printing with wood and ceramics is again a huge challenge.

6.9 The Limited Size of the 3D Printer
If you are working with a certain 3D printer, you are restricted to print objects with no larger
size than allowed by the 3D printer build area.
You must confine your creativity to the size already defined for your 3D printing. These
limitations of 3D Printing is highly felt within the small scale 3D printing service center.
These centers have to define the size of the orders they accept and reject those that are
larger than the defined sizes.
Larger 3D printers are already at work, but not everyone can afford it. Even when able to get
it by investing all the savings and loans, paying for the additional expenses would be
completely impossible with limited budgets.

6.10 3D Printing Leading to Scarcity of Jobs
As we all know that automation has always been the biggest enemy of job security and so
is for the manufacturing industry as well.
Job layoffs are a serious matter and every country’s government is concerned about the
problem as much as the citizens are.
With automated technology, the need for labor force is decreasing exponentially. The
manufacturing industry is one of the major industries that require labor on a larger scale.
Think about a 3D printer that can be operated using 3-4 technicians.
Compare it with the traditional methods and manufacturing technologies that require
dozens and hundreds of workers at the same time.
You would be able to calculate the disruption 3D printing is capable of causing. The
technology is no doubt is helpful in eliminating human error hugely, however, taking away
jobs from labors won’t be justified either
6.11 Limited Materials
While 3D Printing can create items in a selection of plastics and metals the available
selection of raw materials is not exhaustive. This is due to the fact that not all metals or
plastics can be temperature controlled enough to allow 3D printing. In addition, many of
these printable materials cannot be recycled and very few are food safe.

7.Advantages of 3D Printing
7.1 Flexible Design
3D printing allows for the design and print of more complex designs than traditional
manufacturing processes. More traditional processes have design restrictions which no
longer apply with the use of 3D printing.
7.2 Rapid Prototyping
3D printing can manufacture parts within hours, which speeds up the prototyping process.
This allows for each stage to complete faster. When compared to machining prototypes, 3D
printing is inexpensive and quicker at creating parts as the part can be finished in hours,
allowing for each design modification to be completed at a much more efficient rate.
7.3 Print on Demand
Print on demand is another advantage as it doesn’t need a lot of space to stock inventory,
unlike traditional manufacturing processes. This saves space and costs as there is no need to
print in bulk unless required.

The 3D design files are all stored in a virtual library as they are printed using a 3D model as
either a CAD or STL file, this means they can be located and printed when needed. Edits to
designs can be made at very low costs by editing individual files without wastage of out of
date inventory and investing in tools.
7.4 Strong and Lightweight Parts
The main 3D printing material used is plastic, although some metals can also be used for
3D printing. However, plastics offer advantages as they are lighter than their metal
equivalents. This is particularly important in industries such as automotive and aerospace
where light-weighting is an issue and can deliver greater fuel efficiency.
Also, parts can be created from tailored materials to provide specific properties such as heat
resistance, higher strength or water repellency.
7.5 Fast Design and Production
Depending on a part’s design and complexity, 3D printing can print objects within hours,
which is much faster than moulded or machined parts. It is not only the manufacture of the
part that can offer time savings through 3D printing but also the design process can be very
quick by creating STL or CAD files ready to be printed.

7.6 Minimising Waste
The production of parts only requires the materials needed for the part itself, with little or
no wastage as compared to alternative methods which are cut from large chunks of non-
recyclable materials. Not only does the process save on resources but it also reduces the
cost of the materials being used.
7.7 Cost Effective
As a single step manufacturing process, 3D printing saves time and therefore costs
associated with using different machines for manufacture. 3D printers can also be set up and
left to get on with the job, meaning that there is no need for operators to be present the
entire time. As mentioned above, this manufacturing process can also reduce costs on
materials as it only uses the amount of material required for the part itself, with little or no
wastage. While 3D printing equipment can be expensive to buy, you can even avoid this cost
by outsourcing your project to a 3D printing service company.

7.8 Ease of Access
3D printers are becoming more and more accessible with more local service providers
offering outsourcing services for manufacturing work. This saves time and doesn’t require
expensive transport costs compared to more traditional manufacturing processes produced
abroad in countries such as China.
7.9 Environmentally Friendly
As this technology reduces the amount of material wastage used this process is inherently
environmentally friendly. However, the environmental benefits are extended when you
consider factors such as improved fuel efficiency from using lightweight 3D printed parts.
7.10 Advanced Healthcare
3D printing is being used in the medical sector to help save lives by printing organs for the
human body such as livers, kidneys and hearts. Further advances and uses are being
developed in the healthcare sector providing some of the biggest advances from using the
technology.

8.The Future of 3D Printing
 3D printing will become a mainstream technology for serial production
 Design software for additive will become more integrated and easier to use
 Focusing on education will enable more 3D printing applications and adoption
 Dental will adopt 3D printing as a dominant production technology
 3D printing will become smarter
 The 3D printing service bureau market will continue to expand
 .Metal 3D printing will continue to mature
 Composite 3D printing will offer a huge market opportunity
 Automation will become a key focus for the industry
 The additive manufacturing landscape will become more competitive
Trends signal a bright future for AM

9.SWOT analysis
Rapid Prototyping to Additive Manufacturing of Functional materials. 3D printing is a fast
evolving technology. Every day new technologies and production processes are developed
for faster manufacturing with improved performance properties at competitive costs.

3Dresyns offers the widest range of safe functional Stereolithography SLA, DLP, LCD and
Inkjet 3D resins for printing functional and biocompatible materials
3D SWOT analysis (Strengths, Weaknesses, Opportunities & Threats):

10.The Conclusion
As the technology starts getting into people’s ears, the hype tries to hide the problems
related to it. 3D printing is no different.
The major reason why the awareness about 3D printing took so long was because of the
limitation of 3D printing that, more or less, still exists.
3D printing is definitely capable of accomplishing tasks that are not possible through any
other methods.
But that does not make it eligible for making the disruptions that it is capable of. Researches
are heading away to tap the benefit of the technology and control the problems to its best.
We have succeeded too. In terms of reachability, cost, accessibility, awareness, etc. And, we
have to cross a long way too.
However, the way the technology has succeeded in impressing the mass, the results would
be out sooner.
Not just the limitations of material and color options are worked upon, but studies are being
carried to make the technology safe and economical.
Companies are coming up with better and smarter 3D printing machines. Manufacturers of
3D printers are stressing on safety and ease of use.
These can bring a lot of difference in the coming future. Leaving being the limitations of 3D
printing, it will take time for 3D printing to completely eliminate traditional methods of
manufacturing. The clock is already ticking and the change would be seen anytime from now
on.

REFERENCE
1. http://www.emco.co.uk/rapid.htm
2,http://www.hawkridgesis.com/products/p.add.z corps.htm/
3. http://www.sldtech.com/PDFs/3D printers Brochure overviews.pdf
4. www.architecture.mit .edu.
5. www.realizationgroup.com

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