2. General idea
CAD (computer aid design),(can be achieved by 3D scanning/ download)
Readable file format (STL, OBJ, 3Ds, 3MF)
Files’ errors fixed (netfabb, Meshmixer, Cura, Slic3r)
G-code file (layer by layer) (Skeinforge, Slic3r, and Cura)
3d printing
Finishing touch. (Sanding, removing extra material, painting colors)
3. 7 Standard Terminology for Additive
Manufacturing Technologies
1. Material Extrusion
2. Vat Photopolymerisation
3. Material Jetting
4. Binder Jetting
5. Powder Bed Fusion
6. Sheet Lamination
7. Directed Energy Deposition
Chosen by ASTM (American Society for Testing and Materials )
4. 1. Material Extrusion
Most common method: Fused Filament Fabrication (FDM)
(FFF)
plastic filament/ metal wire unwound from a coil, supply
nozzle. Can turn the flow on/off
Nozzle is heated to melt the material and controlled by a
CAM (computer-aided manufacturing) software package
Material immediately hardens after extrusion from nozzle.
5. 1. Material Extrusion
Material extrusion is the most common method of 3D printing
Most common materials:
ABS (Acrylonitrile Butadiene Styrene)
PLA (Polylactic acid)
It is the method used by the 3D printer Creatable D2
Often, the products’ layers can be seen, and material extrusion
produce rougher surfaces compared to other methods.
6. FFF problems
FFF can’t print “overhangs” and “bridges”
Overhangs are parts that extrude out in a way that there is nothing
underneath it to print on, and therefore the printer has problems printing.
Makers follow the “45° rule”, which says overhangs with overhang angles
under 45 degrees will be successfully printed without any support.
Each printer has different maximum overhang angles it can print. One way
to find your printer’s overhang angle is to print the “Overhang Test Model”
45°
Overhang
angle
7. Overhangs solutions
Change orientation
Attach a fan by the nozzle to harden material faster, making it easier to
print overhangs
Add support material and remove them after printing. (more time and work
needed. Can leave marks/ otherwise damage the product)
Removing the support
material caused marks
8. PVA, HIPS – support material
PVA (polyvinyl alcohol) - water-soluble thermoplastic
PVA has a special characteristic of dissolving in water, so it is becoming
popular as a support material. Using PVA gets rid of the long, hard process
of removing support material, and instead lets people just drop it in water
for the post-printing process.
HIPS (High Impact Polystyrene) – similar material that dissolves in Limonene
instead of water.
Hygroscopic PVA attracts lots of water from the air, so it must be stored in
an air-tight container with a dehumidifier. Compared to the difficult
storage of PVA, HIPS is easier to store.
http://3dprintingforbeginners.com/3d-printing-technology/
A product of PLA with
PVA as support. It is
dissolved in water
and the post-printing
work is done.
9. 2. Vat photopolymerisation
Most common method: Stereolithography (SLA)
The printing bed is inside a pool of resin, just under the surface.
An UV laser moves and shoots down in the desired shape on a
layer of resin.
Layer of resin solidifies into a desired shape on to the bed
Platform moves down
The UV laser solidifies the next layer
Repeat
Video of SLA printing:
https://youtu.be/yYGycgnYlBM
10. 2. Vat photopolymerisation
New, innovative method: CLIP (Continuous Liquid Interface Production)
O2 permeable window; oxygen inhibits the solidification process. The
window can control the amount of oxygen entering, making a “dead
zone”: a thin layer (30microns) of liquid.
The platform starts from the bottom of the resin pool, and moves up,
lifting the product up from the liquid.
Instead printing in layers, UV light is shone continuously in different
shapes like a movie, printing extremely fast.
An interesting TED talk of
CLIP
http://www.ted.com/talks
/joe_desimone_what_if_3d
_printing_was_25x_faster?l
anguage=en#t-2881
https://youtu.be/8uD0d1IP
sF4
11. CLIP
Introduced by Carbon 3D in March, and had quietly
raised $41 million of funding from Sequoia Capital and
Silver Lake.
Claims that CLIP prints 25~100 times faster than
average 3D printing
Very Smooth surfaces, no visible layers.
“It was immediately clear to us that 3D printing would
never be the same.” - Jim Goetz
Variety of materials, elastic, flexible, rigid.
Joseph DeSimone
12. 2. Vat photopolymerisation
Accurate, detailed shape.
CLIP- very fast! With one of the biggest problem of
3D printing being its slow printing speed, CLIP will
have significant impact in the 3D printing field.
SLA – very slow.
Need lots of post-print work to clean/make stronger.
Expensive, limited material. (resin)
13. 3. Material Jetting
Like a 2D ink-jet printer
Material laid down, hardened and cured
by UV light.
Platform moves down, repeat
14. 3. Material Jetting
Pros:
Very accurate, good surface finishes
Can print multiple materials colors
Cons:
Only polymers and wax materials can be used for
jetting.
Parts are rather fragile
Building process is slow.
Support material needed.
Material:
Polypropylene,
HDPE, PS, PMMA,
PC, ABS, HIPS, EDP
15. 4. Binder Jetting
Layer of powder is set on a platform
Liquid adhesive (binder) is applied in desired shape with
a nozzle
Next layer of powder is laid down
Metals: Stainless steel
Polymers: ABS, PA, PC
Ceramics: Glass
16. 4. Binder Jetting
Pros:
Wide range of materials: metal, polymers and ceramics
Parts can be printed with range of different colors.
Generally faster.
No need for support structure.
Cons:
Weak because of the use of binder. Not for structural purposes.
Lots of post-print process needed to remove the un-binded
material.
17. 5. Powder Bed Fusion
Most common method: Selective laser sintering (SLS)
powder of material is laid down on a layer
Laser heats powder, fuses them together. Unheated powder remains
there as the support material.
Another layer of powder is laid down, and repeats.
The chamber is heated to few degrees below the material melting
point, to make the powder easier to fuse.
EBM (electron beam melting) has the same concept, but uses an electron
beam instead of a laser.
SHS: Nylon DMLS, SLS,
SLM: Stainless Steel,
Titainium, Aluminium,
Cobalt Chrome, Steel
EBM: titanum, Cobalt
Chrome, ss, al and copper
18. 5. Powder Bed Fusion
Pros:
Doesn’t require support material. (Unheated powder
acts as support)
So faster than most other methods.
Variety of materials like: glass, ceramics, and even metal.
Useful in aerospace engineering
Cons:
High power usage
Lots of post-printing work
Size limitation
http://www.livescience.com/38862-selective-laser-sintering.html
19. 6. Sheet Lamination
Most common methods: UAM (ultrasonic additive manufacturing), LOM
(laminated object manufacturing)
A sheet of material is placed on cutting bed.
The sheet is cut in a desired shape
The sheets are attached by adhesive for paper and ultrasonic-welding
for metal
Next layer is added, and the process is repeated.
http://www.lboro.ac.uk/research/amrg/about/the7categoriesofadditivemanufacturing
20. 6. Sheet Lamination
Sheet lamination is generally used to make visual models and
not for structural use
Materials: Paper, plastic, sheet metals.
A4 paper is the most common material because it’s cheap and
easy to get.
Pros:
Cheap and fast printing
Cons:
Requires lots of material and produces lots of waste
Printed products have bad strength/integrity
Detailed colors can be added to create incredible effects and
achieve artistic visuals (like a human head).
21. 7. Directed Energy Deposition
Material(powder, wire) is deposited from a nozzle onto
an object.
Material is melted by laser/electron beam/plasma
EMB (Electron beam melting) – uses metals
Metals: Cobalt Chrome, Titanium
SLM (Selective laser melting)
22. Material: 3 major plastic filaments
ABS (Acrylonitrile Butadiene Styrene)
PLA (polyactic acid)
PVA (polyvinyl alcohol)
From 3D Hubs database
23. Materials: 3 plastic filaments
ABS (FFF) (Acrylonitrile Butadiene Styrene) filament
Durable, strong, slightly flexible. Resistant to heat.
Variety of applications, including: pipes, automobile parts, protective
headgear, kitchen appliances, toys. (also the material of LEGOs).
Nozzle must be heated to (210~250)°C. Print bed should be heated to
prevent cracks/ warping.
Cheapest of the plastic filaments. Can be easily sanded, painted
Can be glued by “ABS glue”
Recyclable but is non-biodegradable because it’s petroleum- based
Many colors, including transparent.
Attracts water from air when not in use for a long time.
Creates fumes, which might irritate sensitive people.
http://3dprintingindustry.com/3d-printing-basics-free-beginners-guide/materials/
24. PLA (FFF) – (polyactic acid) filament
PLA: bio-degradable thermoplastic (resin-SLA) (filament-FFF)
Most environmentally friendly material in 3D printing because it’s bio-degradable.
Degrades into inoffensive lactic acid in the body. Used in medical suturing as well as
surgical implants. Surgically implanted screws, pins, rods or mesh simply break down in
the body within 6 months to 2 years.
Extruded at 160°C-220 °C. Unlike ABS, it doesn’t create fumes, but lets off a slight odor
that apparently smells like pancakes and corn. It’s slow to cool, so a fan is
recommended.
After printing, it can be sanded and painted with acrylic paint, but it unlike ABS, it can’t
be not easily glued
PLA is increasing for its low toxicity and environmental friendliness. It has a low resistance
to heat and becomes soft at 50 °C. This could be a flaw but also a benefit, letting the
user easily correct and bend the product.
Many say that PLA will soon beat ABS to become the most popular material
Easy to work with, many colors including transparent and “glow in the dark”.
More water-absorbing than ABS. Water saturated PLA is very hard to print.
25. PVA (FFF) – (polyvinyl alcohol) filament
Water-soluble plastic.
White, odorless
Most commonly used as support structure to help with overhang issues.
It’s a very convenient support structure because all the user has to do is
drop the product into water, instead of the long, hard process of
removing the support structure.
Has an extremely strong water attraction, so hard to store.
Extruded at 190°C. If it absorbed water, the printing quality goes very
bad, so it is sometimes dried before printing.
High price, difficult sourcing.
26. Material: other plastics
Nylon 12 (powder, filament)
Popular in traditional manufacturing for its superb price-performance.
High fatigue-resistance, chemical resistance.
Highest impact-resistance of any FFF thermoplastic.
You can create advanced prototypes and custom tooling for
applications that demand high fatigue resistance
Naturally white, but can be colored pre/post-painting
When combined with aluminum powder, it can create Alumide,
another common material in 3D printing
27. Laywood (FFF) - filament
Laywood- specially for FFF. Filament form. Wood/polymer composite
The prints actually look and smell like wood and post-processing
presents various options, as the prints can be sanded, grinded and
painted like standard wooden products.
It’s very popular to those who are interested in art and design and who
are bored of printing just plastic.
Manufacturer recommends to print at 175°C and 250°C. Interestingly,
different printing temperatures cause different texture and color, so
interesting and artistic textures that change by layers
The filament is fragile so it must be carefully handled. If the user wants,
laywood can be printed in smooth surfaces with layers unnoticeable.
28. Materials
Ceramics:
Silica/Glass
Porcelain
Silicon-Carbide
Strong, but after printing, need to go under firing, glazing.
Paper:
Easily obtainable, cost effective
Safe, Environmentally friendly, recyclable
Requires no post-processing
30. Materials
Bio Materials:
Being researched.
Living tissues, can make human body parts
Food:
Chocolate,
Pasta and meat.
Pizza!
31. Physical computing
How humans interact/
communicate through computers.
Interactive physical systems by
the use of software and hardware
that can sense and respond to
the analog world.
https://en.wikipedia.org/wiki/Physical_computing
Digital Fabrication
Process that joins design
with
construction/production
3D printing is a major part
of digital fabrication
32. Community sharing
Shape Engine: A 3D printing sharing platform that
connects 3D printer owners and 3D printer users
without a printer.
Makerspace: Areas people gather to create, share
skills, supplies, ideas, work on project.
Fablab: originated at MIT’s Center for Bits and Atoms
(CBA) by Professor Neil Gershenfeld
Fab Labs provide access to digital fabrication.
“Give ordinary people the right tools, and they will
design and build the most extraordinary things.”
Thingiverse: Webite sharing of user-created digital
design files. Providing primarily open source hardware
designs
33. Shape Engine
3D printing sharing platform where 3D printer owners can take
advantage of the printer’s idle time by sharing the printers to
customers and making profit.
People who want to 3D print but don’t own a 3D printer can use
Shape Engine to connect to a local 3D printer owner and
become a customer by ordering the owner to print a product,
then picking it up with a payment.
Shape Engine also provides help with 3D modeling to anyone who
needs help so people who aren’t skilled with 3D modeling can use
Shape Engine to receive help and successfully print their desired
products.
34. Makerbot Thingiverse
Biggest website for sharing 3D files.
People share open source hardware designs licensed under the GNU
General Public License or Creative Commons licenses. (The license
allows anyone to share, change, and save the files, as long as it is in the
boundary set by the owner
Numerous projects and maker communities
use Thingiverse, with a big one being the
RepRap project.
Number of items on Thingiverse:
35. 3D Hubs
Uses the same concept as Shape Engine.
People can upload 3D designs, choose a printer location, and print
their desired products
Largest network for 3D printers.
100 new printers per week.
15,000 locations in 140 countries, providing over 1 billion people
access to a 3D printer within 10 miles of their home
36. 3d printed guns
Defense Distributed – open-source organization that designs
weapons that can be downloaded and 3D printed.
Liberator – first fully 3d printable gun, available for download on the
internet. May 6, 2013
It was downloaded 100,000 times in just 2 days after its upload.
US Department of State demanded it the Liberator to be taken
down from the internet 3 days later in May 9, 2013. However, it was
too late: there were already 100,000 downloads that people
downloaded world wide.
It was a big issue in the sensitive field of Unite States’
gun control, and attracted lots of attention to
3D printing.
37. 3d printed food
Mechanical engineer Anjan Contractor won a $125,000
grant last year to build a prototype 3D printer designed
to print food for astronauts on long missions.
He printed a pizza with his open-source RepRap Mendel
3D printer
38. Anti-gravity 3d printing
Made in Space has made the “Zero-G Printer”
Launched into orbit on September 21, 2014.
Mataerial makes 3d printers that print without gravity, and freely
prints without the need for a flat printing surface.
Plastic extruded from the printer solidifies instantly, allowing to
draw freeform shapes in the air from any surface, (a wall or a
ceiling)
Zero-G Printer
39. 3D printing in the medical field
South Korean doctors of Yonsei University Severance hospital
successfully implanted 3D printed pelvis in teenage patient, March
2015. Customized implant significantly shortened the surgery time
and allowed patient to heal faster.
Kyoto University successfully transplanted 3D-printed spines (with
titanium powder) in 4 patients.
40. RepRap project
Invented by 아드리언 Adrian Bowyer, RepRap (Replicating Rapid-prototype) is a (as in
“free” software)free desktop 3d printer that is capable of printing many of its own
parts.
The goal of RepRap is to create an affordable, self-replicating machine that will spread
around the world to let people create not only various goods, but also the machines
themselves so that they could “give one to a friend”. But the current reality is far from
the goal, the machines being extremely expensive and only able to print about half of
its parts. The RepRap team is working to make the machines accessible to communities
in the developing world and individuals in the developed world.
RepRap was the first of the low-cost 3D printers, and the RepRap Project started the
open-source 3D printer revolution. It has become the most widely-used 3D printer
among the global members of the Maker Community.
Source: Moilanen, J. & Vadén, T.: Manufacturing in motion: first survey on the 3D printing
community, Statistical Studies of Peer Production.
41. The impact of 3D printing.
3Dprinting revolutionized the prototype manufacturing industry. 3d printing
shortened the time of prototype production by 1/7 and the cost by 1/8.
Through 3D printing, we are able to manufacture faster and cheaper than
ever. With the recent uses of 3D printing, its demand is increasing in the
manufacturing field, where 3D printing has various applications, like
producing tools needed in medical apparatus manufacturing such as jig
and fixture.
Source:
MEDICAL DEVICE & DIAGNOSTIC INDUSTRY, January 2009
42. Cost of 3D printing.
According to a survey, one of the biggest obstacle in using 3D printers was the
high price of the printers. (31.5% of the response)
Also, producing goods like prototypes and models takes at least 200$, making it is
hard for ordinary people to use.
Domestic mockup/prototype manufacturing prices
NC manufacturing
(design mockup)
At least 200$
CNC manufacturing
(working mockup)
At least 500$
3D planning/
business planning
At least 1000$
Product Development At least 3000$
43. Growing market of 3d printing
Allied Market Research (AMR) projects that the 3D
printing market will grow from $2.3B in 2013 to $8.6B in
2020
3D printing will impact all major industries.
Siemens prediction of future 3D printing:
Market by industries
Market growth
44. 3D printing in manufacturers
67% of manufacturers surveyed are currently implementing 3D printing either in
full production or pilot and 25% intend to adopt 3D printing in the future.
92% of manufacturers using/ going to use 3D printers
재료.
플라스틱에서 대표적으로 3개의 필라민트가 있습니다.
ABS- 굉장히 다양한 응용. 파이프, 차 부품, 안정장치 (충격흡수를 잘함). 부엌, 악기, 장난감, LEGO.
강하고 오래 가면서, 약간 구부르는기가 잇고, 열기 에 강함. ABS 를 프린트 하는 기계는 210-150 도 사이에 녹임. ABS 를 사용하면 프린트 베드 를 가열해서 제품이 금가거나 휘는걸 방지할수 있다.
제일싼 플라스틱, 나중에 샌딩 과 페인팅 할수 있고, ABS glue 를 사용해 풀로 쉽게 붙일수고 있다.
재활용 됄수 있지만 생물분해가 안됌.
색깔이 많고 투명 까지 잇고.
ABS 를 오랫동안 사용안하게 돼면 공기에서 물을 먹기때매 밀폐됀 공간에 보관 하는게 좋다
프린트 하면서 가스를 내뿜는데, 민감한 사람들한테 해가 됄수 있고 환기가 잘돼는곳에 프린팅을 하는게 좋다.
PVA 는 특별하게 물에 녹는 플라스틱이다.
지금도 많은 곳에 사용돼고있으며 (종이 패키징, 낚시 (물에 넣으면 안에있는 미끼를 풀어주는 방식), 애들 장난감)
다른 플라스틱들 보다 훨씬 쌔게 물을 빨아드리는 성향이 있어 보관하기가 어렵다. 밀폐됀 컨테이너에 건조제와 같이 넣어야됀다.
190도에 가열돼서 프린팅 돼고, 프린팅 하기 전에 말려야됄수도 있다.
PVA 는 비싸고 구하기가 어려운 점도 있다.
Nylon 12 파우더 와 필라민트 로 가능하다.
가격에 비해 우수한 성과를 보여서 옛날부터 인기가 많다.
약화 저항력, 화학 저항력, 과 FFF 플라스틱 중에 제일 뛰어난 충격 저항력을 자랑하고 있다.
약화 저항력이 필요한 모델, 프로토타입에 좋다.
원래는 하얀색이지만 프린트 전/후 색깔을 입힐수도 있다
알류미늄 파우더와 석으면 alumide 이란 또다른 흔한 재료를 만들수 있다.
Laywood 는 필라민트 형태로 나무와 폴리머 를 섞어서 만든 재료다.
쉽게 프린트 하기 쉽고 재밋다.
프린트됀 재품들은 나무의 냄새와 형태를 가지고 재품들은 진짜 나무 재품들처럼 샌딩, 그라인딩, 페인팅을 할수있다.
그래서 예술과 디자인쪽에 관심있거나 플라스틱만 프린트하기 지루한 사람들중에서 인기가 많다.
제조업자는 프린팅할때 175~250도 로 가열하는것을 권한다. 여기서 재밌는거는 Laywood 를 다른 온도로 프린트할때 다른 형태로 나오는것이다. 높은 온도로 프린팅 하면 어둡고 까칠한 텍스쳐가돼고 낮은 온도로 할때에는 더 밝고 매끄러운 텍스처가 완성됀다. 이것을 이용해서 층에따라 다른 색깔이 있는 재밌는 텍스쳐를 만들수도 있다.
필라민트가 약하고 쉽게 부러지기때문에 조심해서 다뤄야됀다
하나의 장점은 Laywood 가 프린트 됄때 원한다면, 프린트하는 층들이 거의 안보이게 매끄럽게 만들수 있다.
Ceramics: 강하지만 프린트한다음 불에 굽고 코팅 같은 많은 작업들을 해야한다.
Paper: 쉽게 구할수 있고 싸다. 안전하고 환경에좋고 재활용 가능. 프린트한다음 더이상 작업이 안필요함.
Stainless steel- 강하고 나중에 금/은색으로 칠할수 있다.
Gold silver : 요새 인기를 끄는 쇠들. 강함을 자랑하지만 비싼다는점이 있다.
Titanium – 당연히 엄청나게 강하고 쇠들중에 제일 강하다.
평범한사람에게 맞는도구를 준다면, 그들은 대단한것들을 만들것이다.
많이 아시다시피 Thingiverse 는 엄청나게큰 오픈소스 아드웨어 디자인들을 공유하는 웹사이트다.
디자인들은 GNU 라이센스, CC 라이센스 밑에 공유 돼며, 이 라이센스가 말하는건 제작가 허용하는선 안에서 아무나 디자인들을 공유, 수정, 저장할수 있는것이다.
수많은 프로젝트, 메이거 공동체, RepRap 같은 큰 프로젝트들 까지 Thingiverse 를 이용하고 있다.
3D Hubs.
이 회사의 원리는 간단하다:
아무나 어떤 3D 디자인을 업로드 한다.
프린트 할 장소를 정하고 연락을해서 거기서 프린트를 예약 한다.
프린트됀 재품을 가지러가서 거기서 있는 프린터와 사람들을 만난다.
3D Hubs 는 현재 제일 큰 3디 프린팅 네트워크중 하나이다. 아무나 3d 프린터가 있으면 3D Hubs 에 등록하여 프린트 장소로 할수있고 돈도 벌수 있다.
제가 연결했을땐 19327 프린트 장소가 있엇고 아마도 얼마 없어 이 숫자는 훨씬 커져잇을것이다.
3D Hubs 에 따르면 2013년 에 매주 100개의 3디 프린터 들이 네트워크에 등록 하고 있다고 했다. 2015인 지금은 그 숫자가 훨씬 커졋을것이다.
요새는 거의 20,000 프린터 장소가 140 나라에 퍼져있으며, 무려 10억 명에게 자기 집에서 16km 반경에 3d 프린터 가 있는것이다.
프린트를 하고싶은 고객과 프린트를 갖고 있는 주인들을 연결해줌으로서 거대한 3d 프린팅 사회를 만들고 연결해서
Defense distributed 은 공유, 다운로드, 프린트 할수 있는 무기들을 디자인 하는 곳.
2013, 5월 6일 Liberator 이란 이름으로 처음으로 완전히 3d 프린팅으로 만들수 있는 총 을 개발해서 엄청나게 큰 화제를 일으켯다.
2일만에 십만 번 다운로드 됏다.
3일만에 미국 정부에서 Liberator 을 인터넷에서 내리라는 명령을 했지만 벌써 너무 늦고 이미 10만 명이 다운로드 한 다음이엿다.
미국에서는 총에대한 사건들과 법들에 대해 엄청나게 민감하기 때문에 이 사건은 화제가 됌으로서 3d printing 을 민감한 총에 대한 논쟁에 넣어버린것이다.
엔지니어 anjan Contractor 은 우주에 나가는 우주인들을위해 음식을 프린트 할수 있는 3d 프린터를 만들라는 계기에 돈을 얻엇다.
그는 성공적으로 RepRap 프린터로 피자를 만들엇다.
Made in Space 는 3d 프린터들이 우주에서 큰 영항을 끼칠꺼라고 믿고 무중력 상태에서 작동하는 3d 프린터를 만들엇다.
2014 9월 21일 에 우주에 발사 돼엇다.
Mataerial (오타 아님) 은 중력과 프린트베드에 상관없이 자유자재로 프린트 할수 있는 3디 프린터를 만들고 싶엇다.
그래서 특별하게 바로 고체가돼는 특별한 재료로 프린트를 했다. 프린트
랩랩, RepRap, 은 “Replicating Rapid-prototype” 의 줄임말으로서, FFF (Fused Filament Fabrication) 을 사용해서 자기자신의 부품들을 프린트를 할수있는 3d 프린터 이다. 모든 랩랩의 디자인은 GNU 일반 공중 사용 허가서 아래 누구나 마음대로 변형하거나 배포할수있다. 랩랩의 팀 은 랩랩의 자기자신을 복사할수있는 능력으로 싸게 랩랩들을 사람들에게 배포하면서 사람들이 비싼 산업용 기계들 없이 물품들을 싸게 생산하는 것을 기획한다.